HDPE- PROFILED PIPES...Minimum Required Strength ISO 4427 N/mm2 8 10 Indentation hardness Impact...

HDPE- PROFILED PIPES _________________________________________________________________________

1

SEWERAGE AND STORM WATER PIPING SYSTEMS

TECHNICAL MANUAL


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Polykun Piping Systems

Sewerage and drainage structured pipe

Dr.-Ing. Fathalla QASEM


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CONTENTS

1. General Specifications of HDPE- pipes

1.1. Material Properties

1.2. Resistance to Chemical

1.3. Flexibility and Strength

1.4. Electrical Insulation

1.5. Ease of Application, Minimum Wastage

2. HDPE- Piping System

2.1. Series PF Pipes and Field of Applications

2.1.1. Wall Structure for Profile Types of Series PF- HDPE Pipes

2.1.2. Applications of PF –pipes

2.2. Series DW pipes and field of application

2.2.1. Wall Structure of Series DW1-Pipes

2.2.2. Wall Structure of Series DW-pipes with two layers and more

2.2.3. Connection Details of Series DW-pipes

2.2.4. Applications of DW Series Pipes

2.3. Series SW solid Pipes and Field of Applications

2.3.1. Wall Structure of Series SW solid pipes

2.3.2. Connection Details of Series SW - solid pipes

3. HDPE-FITTINGS

3.1. Bends

3.2. Branches

3.3. Reductions

3.4. Puddle flange

3.5. House connection

3.5.1. House connection fitting components

3.5.2. House connection procedure

3.6. Manholes and Tanks

3.6.1. Manholes

3.6.1.1. Straight passage manholes

3.6.1.2. Tangential manholes

3.6.2 Tanks

4. PIPING DESIGN CALCULATIONS 4.1. Hydraulic Calculation

4.1.1 Wall Roughness

4.1.2 Calculation of Flow rate

4.1.2.1 Pranddlt-Coledroook Formula

4.1.2.2 Manning Formula

4.1.2.3 Hazen-Willams Formula

4.1.3. Calculation of Flow Rate for Partially filled

4.1.4 Gradient

4.2. Static Calculations

4.2.1 Deformation of a HDPE-buried pipe


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4.2.2. Strain in the pipe wall

4.3. Pipe Class/ Ring Stiffness

4.4. External Load

4.4.1 Soil Load

4.4.2 Traffic Load

4.5. Stability (Buckling) Calculations

4.6. Thermal Longitudinal Elongation Calculation

5. HDPE PIPE CONNECTION METHODS

5.1 Welded Connection

5.1.1. Electro-fusion Welding Method

5.1.2. Butt Welding Method

5.1.3. Extrusion Welding

5.2. Mechanical Connection

5.2.1. Rubber Sealing Connection

5.2.2. Flange Connection

6. Installation and Application of HDPE/PP Pipes

6.1 Pipe in Trenches and Installation

6.1.1 Choice of Pipe Stiffness

6.1.2 Compaction Degree and Methods

6.1.3. Material of Pipe Zone and Remaining Backfill

6.1.4. Type of Installation

6.1.5. Parallel Piping Systems

6.2 Application of HDPE-Profiled Pipes

6.2.1. Sewer and Storm Water Lines

6.2.2. Sea Outfall and Intake Pipes

6.2.3. Relining

6.2.4. Landfill Drainage Systems

6.2.6. Lined Pipes

7. HDPE- PIPE STORAGE AND TRANSPORTATION 7.1. Storage Methods

7.2. Transportation Methods

8. HDPE- PIPE MANUFACTURING AND QUALITY WARRANTY 8.1. Standards and Test Methods

8.2. Quality Certificates

8.3. Official Position Numbers

9. HDPE Pipe Sample Purchase Tender

10. HDPE- PIPES AND MANHOLE QUESTIONNAIRE

10.1. Pipe Questionnaire

10.2. Manhole Questionnaire


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1. Specification of HDPE- Profiled PIPES

Figure 1: HDPE-profiled pipe

1) HDPE- profiled pipes are available in diameters up to inside diameter 4000 mm.

They are produced from HDPE or PP in accordance with the field of applications and

load conditions. The pipes fulfils the required ring stiffness according to EN 13476 and

DIN 16961.

2) HDPE- pipes can be delivered with different joint systems. The pipes can be

connected with electro-fusion joint for all pipe sizes. In addition to welded

connections, socket and spigot can be also incorporated with gasket connections. The

pipes with butt-weld or flange joints are also available upon request.

3) Any kind of tanks, manholes or other special applications having ID up to 4000

mm can be produced by HDPE piping system.

4) Transportation and the storage of any kind of foodstuff can be made by HDPE

piping system, thanks to HDPE (High Density polyethylene) used in manufacturing of

the pipes, which is completely hygienic.

5) The internal wall surfaces of HDPE- pipes are manufactured by co-extrusion

technology, if requested all pipes can be delivered either with a bright, inspection

friendly color, or an electro-conductive inner surface.

6) No wastage is generated during the transportation and storage of HDPE pipes due

to their high impact strength and great deal storage area can be saved by telescopic or

stockpiling one onto another.

7) The possibility of using the electro-fusion welding within confined area makes it

possible to excavate narrower pipe trenches with less labor and shorter installation

times and thus the investment cost can be reduced.


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8) Lifetime over 100 years.

9) High mechanical resistance ( abrasion, impact resistant and secure against fracture).

10) The outer surface of the pipes is back. Black HDPE-pipes are permanently

resistance to atmospheric corrosion and UV radiation. UV stabilizers, antioxidants and

pigments shall be included pre-compounded by material supplier.

11) Very good hydraulic properties due to inner smooth surface.

12) Good chemical resistance.

13) The absolute tightness and high degree of safety are obtained by HDPE- pipes that

are connected with electro-fusion welding.

14) Large range of accessories.

15) Non-polluting, recyclable.

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


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1.1 Material properties

Sewer piping system (SPS-pipes) are manufactured from high-density

polyethylene (HDPE). Polypropylene (PP) pipes are recommended for fluids at

elevated temperatures.

Properties of HDPE and PP used in manufacturing of SPS- pipes;

Ease of transportation due to their low density,

High degree of resistance to chemicals,

Flexibility that ensures excellent resistance to impact loads,

Durability of HDPE against UV,

Easily and reliable welding in pipe connection,

Resistant to abrasion,

Smooth surface preventing precipitation,

High degree of fluidity with minimum pressure loss,

Suitable for cold weather without effected from frost,

Heat resistively up to 60ºC for HDPE and 95ºC for PP,

No corrosion is ever formed,

Resistant to rodents and roots penetration.

Table 1: Materials specifications:

Properties Standard Unit PE 80 PE 100 PP-R

P

H

Y

S

I

C

A

L

Color - - Black/

yellow

Black/

yellow

Black

Density DIN 53479

ISO 1183

g/cm3 0,95 0,96 0,91

Melt Flow Index

MFR 190/5

MFR 190/21, 6

MFR 230/5

ISO 1133 g/10 min

0,40

10

-

0,45

6,6

-

0,50

-

1,25-1,5

M

E

C

H

A

N

I

I

C

A

L

Modulus of elasticity

Short term

Long term (50 years)

ISO 178

DIN 53456

N/mm2

1.000

150

1.200

150

750

160

Yield strength DIN 53495 N/mm2 23 25 26

Tensile strength DIN 53495 N/mm2 32 38 15

Elongation at Break DIN 53495 % >350 >350 >50

Minimum Required Strength ISO 4427 N/mm2 8 10

Indentation hardness

Impact strength at 23ºC

(by Charpy method)

ISO 2039 - 42 46 45

T

H

Coefficient of linear thermal

Expansion

DIN 53752 1/oC 1,8x10

-4 1,8x10

-4 1,6x10

-4

E Thermal Conductivity DIN 52612 W/m. oC 0,4 0,38 0,42

R

M

VICAT Softening Point ISO 306 oC - 127 -

A

L

Flammability DIN 4120 - B2 B2 B2


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1.2 Resistance to Chemical

The Polyethylene (PE) and the polypropylene (PP) to chemical aggression are

well-know. The characteristic is considered in EN 13476-1, in which it is stated that

the PE and PP materials are resistant to water with a large range of values of pH, as

waste water, rain water and ground waters. If the pipes are used for waters

contaminated by chemical products originated from industrial discharges, the chemical

and thermal resistance has to be considered, as per ISO 10358.

Table 2 : CHEMICAL RESISTANCE FACTORS, PE-HD,

PE-HD = Pyethylene; high density Symbols: 1 = resistant

PP = pypropylene 2 = limited resistance

3 = non-resistant

s.s.=saturated solution

The following data is derived from DIN and ISO codes.

Chemicals Formula Conc.

(%)

Temp (0C) PE-HD

PP

Acetaldehyde CH3CHO 100 20

60

1

2

Acetic acid CH3COOH 10 20

60

1

1

1

1

Acetic acid glacial CH3COOH 96 20

60

1

2

1

2

Acetic anhydride CH3CO-O-COOH3 100 20

60

1

2

1

Acetone CH3CO-CH3 100 20

60

2

2

1

1

Acetic acid COOH(CH2)4COOH S.S. 20

60

1

1

Acetic alcohol CH2=CH-CH2OH 96 20

60

1

1

Alum Al2(SO4)3K2SO4

4H2O

≤10 20

60

1

1

1

Aluminium Chloride AlCl3 S.S. 20

60

1

1

Aluminium fluoride AlF3 S.S. 20

60

1

1

Aluminum Sulphate Al2(SO4)3 S.S. 20

60

1

1

Ammonia (aqueous solution) NH3 ≤10 20

60

1

1

1

Ammonia (gas) NH3 100 20

60

1

1

1

Ammonia (liquid) NH3 100 20

60

1

1

1

Ammonia chloride NH4CL S.S. 20

60

1

1

Ammonium fluoride NH4F >10 20

60

1

1

1

Ammonium nitrate NH4NO3 S.S. 20

60

1

1

1

1

Ammonium sulphate (NH4)2SO4 S.S. 20

60

1

1

1

1


9

Ammonium sulphide (NH4)2S >10 20

60

1

1

Amyl acetate CH3COOH(CH2)4CH3 100 20

60

2

3

2

Aniline C6H5NH2 100 20

60

1

2

1

1

Antimony trichloride SbCl3 90 20

60

1

1

Aqua regia HCl+HNO3 3/1 20

60

3

3

3

3


(%)

Temp (0C) PE-HD

PP

Arsenic acid H3As04 20

60

1

1

Barium carbonate BaCO3 20

60

1

1

1

1

Barium chloride BaCl2 20

60

1

1

1

1

Barium hydroxide Ba(OH)2 20

60

1

1

1

1

Barium sulphate BaSO4 20

60

1

1

1

Barium sulphide BaS >10 20

60

1

1

Beer 20

60

1

1

Benzaldehyde C6H5CHO 100 20

60

2

3

Benzine 20

60

1

2

3

3

Benzoic acid C6H5CHO 20

60

1

1

1

Benzene C6H6 100 20

60

2

3

2

3

Borax Na2B4O7 20

60

1

1

1

1

Boric acid H3BO3 20

60

1

1

1

Bromine (dry gas) Br2 100 20

60

3

3

3

3

Bromine (liquid) Br2 100 20

60

3

3

3

3

Butane C4H10 100 20

60

2

2

1

Butanol C4H9OH 100 20

60

1

1

1

2

Butyric acid C3H7COOH 100 20

60

1

Calcium carbonate CaCO3 20

60

1

1

1

1

Calcium chlorate Ca(C103)2 20

60

1

1

1

1

Calcium chloride CaCl2 20

60

1

1

Calcium hydroxide Ca(OH)2 20

60

1

1

1

1

Calcium hypochlorite Ca(C10)2, 4H20 >10 20 1


10

60 1

Calcium nitrate Ca(NO3)2 20

60

1

1

1

1

Calcium sulphate CaSO4 20

60

1

1

Calcium suphide CaS >10 20

60

2

2

Carbon disulphide CS2 100 20

60

2

3

1

3

Chemicals Formula Conc. (%) Temp (0C) PE-HD

PP

Carbon monoxide Co 100 20

60

1

1

Carbon letrachloride CCl4 100 20

60

2

3

3

3

Caustic soda NaOH >10 20

60

1

1

1

1

Caustic soda (sodium hydroxide) NaOH 40 20

60

1

1

1

1

Chlorine (aqueous solution) Cl2 20

60

2

3

1

2

Chlorine dioxide (dry gas) ClO2 100 20

60

1

1

1

1

Chlorine (dry gas) Cl2 100 20

60

2

3

3

3

Chlorine methane CH3Cl 100 20

60

2

Chloroacetic acid ClCH2-COOH >10 20

60

1

1

1

Chloroform Cl3CH 100 20

60

3

3

2

3

Chromic acid CrO3+H20 >10 20

60

1

2

1

1

Citric acid HOO.CH2-C(H)

(COOH)-CH2COOH

20

60

1

1

1

1

Cresylic acid C6H3COOH 20

60

2

Cupric chloride CuCl2 20

60

1

1

1

1

Cupric nitrate Cu(NO3)2 20

60

1

1

1

1

Cupric sulphate CuSO4 20

60

1

1

1

1

Cyclohexanol C6H11OH 100 20

60

1

2

1

3

Cyclohexanone C6H10O 100 20

60

2

2

2

3

Dekalin C10H18 100 20

60

1

2

3

3

Developer (photographic) norm.

conc

20

60

1

1

Dextrine (C6H10O5)n >10 20

60

1

1

1

1

Diethyl ether C2H5-O-C2H5 100 20

60

2

3

1

2

Dioktyl phthalate C6H4(COOC8H17)2 100 20 1 2


11

60 2 2

Dioxane C4H3O2 100 20

60

1

1

2

2

Ethanole C2H5OH 40 20

60

1

2

1

1

Ethyl acetate CH3COOC2H5 100 20

60

1

3

2

3

Ethylene glycol OHCH2CH2OH 100 20

60

1

1

1

1

Ferrous chloride FeCl3 20

60

1

1

Ferrous sulphate Fe2(SO4)3 20

60

1

1

Fluorine F2 100 20

60

3

3

Formaldehyde HCHO 40 20

60

1

1

1

Formic acid HCOOH 50 20

60

1

1

1

1

Formic acid HCOOH 98-100 20

60

1

1

1

3

Furturyl alcohol

CH – CH

║ ║

OHC CH2OH

100

20

60

1

2

Gluconic acid OHCH2COOH >10 20

60

1

1

1

Glucose C6H12O6

CH2OH

CHOH

OH2OH

20

60

1

1

1

1

Glycerol

100 20

60

1

1

1

1

Heptane C7H16 100 20

60

1

3

3

3

Hydrobromic acid HBr 10 20

60

1

1

1

2

Hydrochloric acid HCl 10 20

60

1

1

1

1

Hydrochloric acid HCl concentr 20

60

1

1

1

2

Hydrocyanic acid HCN 10 20

60

1

1

Hydrofluoric acid HF 4 20

60

1

1

1

Hydrofluoric acid HF 60 20

60

1

2

2


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(%)

Temp (0C) PE-HD

PP

Hydrogen H2 100 20

60

1

1

1

Hydrogen sulphide (gas) H2S 100 20

60

1

1

1

Hydroquinon C6H4(OH)2 20

60

1

1

Iron nitrate Fe(NO3)3 >10 20

60

1

1

Lactic acid CH3CH(OH)OOOH 100 20

60

1

1

1

1

Magnesium carbonate MgCO3 20

60

1

1

1

1

Magnesium chloride MgCl2 20

60

1

1

1

1

Magnesium hydroxide Mg(OH)2 20

60

1

1

Magnesium nitrate Mg(NO3)2 20

60

1

1

Maleic acid HOOC. CH=CH. COOH 20

60

1

1

1

1

Mercury chloride Hg(Cl)2 20

60

1

1

1

1

Mercuric nitrate Hg(NO3)2 >10 20

60

1

1

1

1

Mercury Hg 100 20

60

1

1

1

1

Mercury cyanide Hg(CN)2 20

60

1

1

1

1

Methanol CH3OH 100 20

60

1

1

1

2

Milk (From cow or goat) 100 20

60

1

1

1

1

Mineral Oils 20

60

1

2

Molasses Using

conc.

20

60

1

1

Nickel Chloride NiCl2 20

60

1

1

1

Nickel nitrate Ni(NO3)2 20

60

1

1

1

1


13


PP

Nickel sulphate NiSo4 20

60

1

1

1

1

Nicotinic acid ≤10 20

60

1

Nitric acid HNO3 25 20

60

1

1

1


60

2

3

2

3


60

3

3

3

3


60

3

3

3

3

Oils and greases 20

60

1

2

Oleic acid C8H17CH=CH-

(CH2)7COOH

100 20

60

1

2

2

3

Oleum H4SO4 fuming 20

60

3

3

OrthOphosphoric acid H3PO4 50 20

60

1

1

Orthophosporic H2PO4 95 20

60

1

2

Oxalic acid (COOH)2 20

60

1

1

1

2

Oxygen O2 100 20

60

1

2

1

Ozone O3 100 20

60

2

3

Peroxide H2O2 30 20

60

1

1

1

2

Peroxide H2O2 90 20

60

1

3

Phenol C6H5OH ≥10 20

60

2

2

1

1

Phosphorous trichloride PC13 100 20

60

1

2

Picric acid (NO2)3C6H2OH 20

60

1 1

Potassium bicarbonate KHCO3 20

60

1

1


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PP

Potassium bromate KBrO3 20

60

1

1

1

1

Potassium bromide KBr 20

60

1

1

1

1

Potassium carbonate K2CO3 20

60

1

1

1

Potassium chlorate KClO3 20

60

1

1

1

1

Potassium chloride KCl 20

60

1

1

1

Potassium chromate K2CrO4 20

60

1

1

1

1

Potassium cyanide KCN >10 20

60

1

1

1

Potassium dichromate K2Cr2O7 20

60

1

1

Potassium ferri cyanide K3Fe(CN)6 20

60

1

1

Potassium ferrocyanice K4Fe(CN)6 20

60

1

1

Potassium fluoride KF 20

60

1

1

1

1

Potassium hydrogen sulphate KHSO4 20

60

1

1

Potassium hydrogen sulphide KHSO3 >10 20

60

1

1

Potassium hydroxide KOH 10 20

60

1

2

1

Potassium hydroxide KOH >10 20

60

1

1

Potassium hypochlorite KClO >10 20

60

1

2

Potassium nitrate KNO3 20

60

1

1

1

1

Potassium orthophosphate K3PO4 20

60

1

1

Potassium perchlorate KClO4 20

60

1

1

1

1

Potassium permanganate KMnO4 20 20

60

1

1

1


15


PP

Potassium peroxydisulfate K2S2O8 20 20

60

1

1

1

Potassium sulphate K2SO4 20

60

1

1

1

Potassium sulphide K2S >10 20

60

1

1

Propionic acid CH3CH2COOH 50 20

60

1

1

1

Propionic acid CH3CH2COOH 100 20

60

1

2

1

Pyridine C5H5N 100 20

60

1

2

2

Salicylic acid C6H4OHCOOH 20

60

1

1

Silver acetate CH3COOAg 20

60

1

1

1

1

Silver cyanide AgON 20

60

1

1

Silver nitrate AgNO3 20

60

1

1

1

1

Sodium benzoate C6H5OOONa 20

60

1

1

1

Sodium bromide NaBr 20

60

1

1

Sodium carbonate Na2CO3 20

60

1

1

1

1

Sodium chlorate NaClO3 20

60

1

1

1

Sodium chloride NaCl 20

60

1

1

1

1

Sodium cyanide NaCN 20

60

1

1

Sodium ferricyanide N3Fe(CN)6 20

60

1

1

Sodium ferrocyanide N4Fe(Cn)6 20

60

1

1

Sodium fluoride NaF 20

60

1

1

Sodium hydrogen Carbonate NaHCO3 20

60

1

1

1

1


16


(%)

Temp (0C) PE-HD

PP

Sodium hydrogen phosphate Na2HPO4 20

60

1

1

Sodium hydrogen sulphide NaHSO3 >10 20

60

1

1

1

Sodium hypochlorite NaClO 5 20

60

1

1

1

1

Sodium nitrate NaNO3 20

60

1

1

1

1

Sodium nitrite NaNO2 20

60

1

1

Sodium orthophosphate Na3PO4 20

60

1

1

Sodium sulphate Na2SO4 20

60

1

1

1

1

Sodium sulhpite Na2SO3 20

60

1

1

1

Sodium sulphate Na2SO4 20

60

1

1

1

1

Sodium sulhpite Na2SO3 20

60

1

1

1

Stannic chloride SnCl2 20

60

1

1

1

1

Sulphuric acid H2SO4 10 20

60

1

1

1

1


60

1

1

1

1


60

1

3

2

3

Sulphuric subacidity H2SO3 30 20

60

60

1

1

2

1

Sulphur dioxide (dry) SO3 100 20

60

1

1

1

Sulphurtrioxide SO3 100 20

60

3

3

Tannic acid C14H10O9 >10 20

60

1

1

Tartaric (dihydroxisuccinic) acid COOH(CHOH)2COOH >10 20

60

1

1

1

1

Thionyl chloride SOCl2 100 20

60

3

3


17


(%)

Temp (0C) PE-HD

PP

Toluene C6H5CH3 100 20

60

2

3

2

3

Trichlorethylene Cl2C=CHCl 100 20

60

3

3

Triethanolamine N(CH2CH2OH)3 >10 20

60

1

2

1

Urea (NH2)2CH >10 20

60

1

1

1

Urine H20 60 1

Water 20

60

1 1

1

Wines and alcohols

(commercial grades)

20

60

1

1

1

1

Wine vinegar See vinegar 20

60

1

1

1

1

Xylene C6H4(CH3)2 100 20 2 3

Yeast >10 20

60

1

1

Zinc carbonate ZnCO3 20

60

1

1

Zinc chloride ZnCl2 20

60

1

1

1

1

Zinc oxide ZnO 20

60

1

1

Zinc sulphate ZnSO4 20

60

1

1

1

1


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1.3 Flexibility and Strength

The flexibility of the materials used for manufacturing of HDPE profiled pipes

is very high. Therefore, HDPE pipes are not influenced from the earthquake

movements, thanks to their flexibility and impact absorbing properties.

Underground piping system is subject to many variable loads and, impact

forces in their service life. The pipelines installed by making use of conventional

piping materials are worn out eventually under ever-increasing loads induced from

road traffic.

Especially the pipes that are made from rigid pipe material are in a condition to

resist the load induced via concentrated supporting point on their bases. Such pipes are

vulnerable to fracture, when they are squeezed by instantaneous impact loads acting

along two opposite directions, since their flexibility is inferior.

Consequently, the conventional pipes are frequently damaged under such

influences and fractured, dented, broken and subjected to the adverse effects of roots

penetration and overload.

On the other hand, the loads induced on HDPE pipes are uniformly distributed

to the sides of the pipe by compacted soil.

Upon cushioning in response to the load imposed, HDPE pipes restore their

initial shape after the loads imposed are released.

Figure 3: Pipe flexibility


19

Among the properties of HDPE pipes, it is worth to mention their superiority of

longitudinal elongation in comparison with conventional pipes. The elongation figures

of shaped HDPE pipes are as high as four times of their initial pipe lengths. Due to

their tremendous elongation property, they maintain their service, even in case of an

earth slide. HDPE pipes are resistant to any kind of impacts, loads and soil

movements.

The service life of HDPE pipes are much longer than any other pipe systems,

since their design is based on the consideration of ample safety factors and many

potential risk factors in order to ensure comprehensive material strength that might be

utilized under severe conditions to be encountered in future due to rapid technological

development.

The excellent performance of HDPE pipes and especially their resistance to soil

movement in comparison with conventional piping materials can be best understood

in the light of the result of the damage experienced during the earthquake of

Kobe/Japan in 1995 and the earthquake of Armenia/Columbia in 1999.

Kobe, Japan in 1995

Piping Material Steel Cast Iron HDPE

Length of pipeline tested, meter

Number of damages determined

Number of damages per km of pipeline

21.338 m

25.821 no.

1,21 no

12.204 m

630 no

52 no

1.458 m

0

0

Armenia/Columbia in 1999

Piping Material Asbestos Steel Cast

Iron

HDPE

Length of pipeline tested, meter

Percentage of damages determined

The number of damages per km of

pipeline

221.957 m

71,70%

1,43 no

3.810 m

0,70 %

0,82

1.030 m

0,03 %

1,29

115.182 m

0,00 %

0

As it is seen, no damage has ever induced on HDPE pipes during

aforementioned earthquakes. The new pipelines that have been installing in these

regions are made from HDPE pipes. Taking into consideration of the fact that Turkey

is situated within earthquake zone, HDPE is indispensable material to be selected for

underground piping.

1.4. Electrical Insulation

For the purpose of safety, the electrical insulation and grounding are requested

for the critical and important pipelines like methane disposal, methane flues, effluent

water from waste disposal areas, transportation of light flammable gases and

flammable powders, where HDPE pipes are used. For HDPE pipes that are

implemented in such critical investment project, the anticipated insulation is ensured

by coating the internal surface of HDPE pipes that are manufactured by co-extrusion

technology by PE-EL material to comply the specifications stipulated by GUV 17,4


20

and DIN / IEC 60093-60167 standards, in addition to grounding of piping system

against static electricity.

For such projects, it is recommended to contact to our technical department

during the application phase.

1.5. Ease of Application, Minimum Wastage

HDPE profiled pipes are manufactured in standard 6-meter lengths. Down to 1-

meter pipe, as well as any kind of auxiliary pipe fittings, are also available upon

request to meet the design requirements. Raw material utilized in manufacturing has

very low density compared with others and thus, the transportation and the storage of

all components comprising the piping system are very convenient. The materials used

in manufacturing of HDPE pipes are not broken, cracked and the maximum utilization

of the pipe material is possible in shop fabrication or site installation of the piping,

since the impact resistance is very high.

The connection of HDPE profiled pipes and pipe fittings is performed by

electro-fusion welding that ensures absolute tightness and saves labor cost, since the

welding operation for one pipe connection can be performed in 30 minutes maximum.

This welding method ensures the installation of piping several times longer than the

conventional piping within the given installation period.

On the other hand, great deal of excavation and backfilling operation can be

saved in the projects where HDPE profiled pipes are utilized, since the trenches can

be made narrower and the inclination of gravity piping to be made by using HDPE

profiled pipes that are installed with minimum inclinations.

Figure 4: Handling of large HDPE- Profiled Pipes


21

2. HDPE-Profiled Piping System

There are several types of thermoplastics that are used in the manufacture in

pipe. There are three principal thermoplastics used to make pipe: polyvinyl chloride

(PVC), polypropylene (PP) and high density polyethylene (HDPE).

Due to the good flexibility of polyethylene is the polyethylene pipes mostly

used. Polyethylene pipes are available in various sizes and wall configurations for

varied applications, some of them are listed below:

Table 3: Application of Polyethylene Pipes

Application Type

Industrial (includes gas) Solid wall

Water (new service) Solid wall

Gravity sewer (lining) Solid wall/ Profile wall

Gravity sewer Profile wall

The Polykun Co. has benefited from the properties and advantage of the thermoplastics

for the pipe production (especially polyethylene and polypropylene) and enhanced

existing production procedures. The result of these developments is the profile types

PF, DPF, CPF, DW and SW.

The practical experience showed us, that it is necessary to be in the position to offer

pipes, which are applicable for all kind of conditions. Therefore different kinds of pipe

wall profiles have been developed.

Besides the high flexibility of the Polykun piping system, these profiled pipes have

succeeded to meet the German standards DIN 16961 as well as the standards of other

countries like European norm EN 13476, the US norm ASTM F894, the Brazilian

norm NBR 7373 and Japanese norm JIS K 6780.

By using profiled pipes we can

safe weight up to 65%

compared to equivalent solid

wall pipes with the same ring

stiffness.

Another important point is the design of the pipe wall. In former times very big wall

thickness for pipes had to be used in order to maintain loads, which influence the pipe.

The results were heavy and very expensive pipes although wall thickness stipulated in

the norms would be sufficient for the actual application of the pipe. In order to solve

this problem the profile pipe has been developed. A profile is added to the minimum

required basic wall. The profile is connected to this wall. This profile which is

calculated by special software produces a significantly higher moment of inertia and

thus the loads can be carried. For comparison, a solid wall pipe of the same material

with the respective moment of inertia would weight three times more.


22

Figure 5: Ring flexibility test of HDPE-profiled pipe

HHDPE pipes are manufactured in three different shapes according to the field

Of application and the purpose of use:

Series PF : external profiled, internal smooth surface.

Series DW : profiled pipe with external and internal smooth surface.

Series SW : solid pipe with external and internal smooth surface.

Series PFand SW can be produced from HDPE and PF Series DW1, DW2 and

DW3 pipes are produced from HDPE only.

2.1 Series PF Pipes and Field of Applications


23

Figure 6: View of HDPE-profiled pipe

PF Pipes series in HDPE piping system are the pipes with smooth internal

Surface, having spiral profiled exterior surfaces. Such pipes are generally used

For sanitary sewer systems and the gravity piping systems. Their major

Properties are as follows:

Smooth internal wall surface ensures desirable hydraulic flow

characteristics. Produced in light colors, their internal surfaces ensure ease of

maintenance and inspection, if with PE-EL coating is provided.

Series PF pipes exhibit high ring strength due to their shape exteriors, in

addition to excellent underground anchorage provided by grooved spiral profile

of the outside of the pipe, thus they feature considerable resistance to impact

loads induced by heavy traffic loads.

Manufactured in sizes between 300 mm ID up to 4000 mm ID, absolute

tightness can be achieved by bell and spigot connection that is supplemented by

electro-fusion welding. The flange connection or butt-welding connections are

also available upon request.

Series PF pipes exhibit high degree of Ring Stiffness comprehensive

impact strength, thanks to their profile exteriors that provide shock-absorbing

effect.

Series PF pipes are specially designed pipes engineered to provide

maximum reliability without fracture in various severe applications like heavy

traffic loads, loads induced by backfilling material, adverse effects of ground

waters, etc.

The elongation of the pipe under the thermal stress is negligible and no

compensating bellows or mechanisms are required even for long pipe runs.


24

They are also flexible to compensate extraordinary elongation due to

earthquakes, etc.

Series PF pipes are manufactured in standard 6-meter sizes from UV

stabilized black HDPE and down to 1-meter pipe are also available upon

request to meet the design requirements.

2.1.1 Wall Structure for Profile Types of Series PF HDPE pipes

Figure 7: Sectional and Structural view and of Series PF HDPE pipes

a = profile distance [mm]

s1 = waterway thickness [mm]

s2 = coating thickness [mm]

h = profile height [mm] By using a profiled pipe it is possible to use a light pipe for a high static load. The supportable static

load is determined for every profile geometry by the factors elastic modulus [N/mm2] of the respective

material and the moment of inertia of the profile geometry [mm4/mm] referring to the pipe diameter.

The result is called ring stiffness.

The wall thicknesses of our pipes can be adapted in small steps to the respective load.

Table 4: Minimum wall thickness (S1) according to DIN 19566-100

Normal pipe size

DN [mm]

s1, by PE and PP

[mm]

300 3,0

350 3,3

400 3,5

450 3,8

500 4,0

600 4,5

700 5,0

800 5,5

900 6,0

1000 6,0

≥1200 6,0


25

Table 5: Minimum wall thickness (S1) according to ASTM F894

Nominal

Diameter

in.(mm)

RSC 40

in. (mm)

RSC 63

in. (mm)

RSC 100

in. (mm)

RSC 160

in. (mm)

18(460) 0.18 (4.57) 0.18 (4.57) 0.18 (4.57) 0.22 (5.59)

21 (530) 0.18 (4.57) 0.18 (4.57) 0.18 (4.57) 0.24 (6.10)

24 (610) 0.18 (4.57) 0.18 (4.57) 0.22 (5.59) 0.24 (6.10)

27 (690) 0.18 (4.57) 0.18 (4.57) 0.24 (6.10) 0.24 (6.10)

30 (760) 0.18 (4.57) 0.22 (5.59) 0.24 (6.10) 0.26 (6.60)

33 (840) 0.18 (4.57) 0.24 (6.10) 0.24 (6.10) 0.30 (7.62)

36 (910) 0.18 (4.57) 0.24 (6.10) 0.26 (6.60) 0.30 (7.62)

42 (1070) 0.24 (610) 0.24 (6.10) 0.30 (7.62) 0.38 (9.65)

48 (1220) 0.24 (610) 0.26 (6.60) 0.30 (7.62) 0.38(9.65)

54 (1370) 0.24 (610) 0.30 (7.62) 0.38 (9.65) 0.42(10.67)

60 (1520) 0.26 (6.60) 0.30 (7.62) 0.38 (9.65) 0.52(13.21)

66 (1680) 0.30 (7.62) 0.38 (9.65) 0.42 (10.67) 0.67(17.02)

72 (1830) 0.30 (7.62) 0.38 (9.65) 0.42 (10.67) 0.90(22.86)

78 (1980) 0.30 (7.62) 0.38 (9.65) 0.52 (13.21) 0.90(22.86)

84 (2130) 0.38 (9.65) 0.42 (10.67) 0.67 (17.02) 0.90(22.86)

90 (2290) 0.38 (9.65) 0.42 (10.67) 0.90 (22.86) 0.95(24.13)

96 (2440) 0.38 (9.65) 0.52 (13.21) 0.90 (22.86) 0.95(24.13)

108 (2740) 0.42 (10.67) 0.67 (17.02) 0.90 (22.86) 0.95(24.13)

120 (3050) 0.52 (13.21) 0.67 (17.02) 0.90 (22.86) 0.95(24.13)

Overlapping profile design

During extrusion a band is curled on a winding tool and molten together by

overlapping. At the same time the profile is extruded and exactly laid over the

lap joint of the band so that together with the band the profile forms a

homogeneous pipe wall. This procedure ensures an extremely durable and

strong elastic pipe wall.


26

Table 6: HDPE profiled pipes ring stiffness according to DIN 16961

Pipe

ID

TYPE 1

SR24=2 kN/m²

Profile kg/m

TYPE 2

SR24=4 kN/m²

Profile kg/m

TYPE 3

SR24=8 kN/m²

Profile kg/m

TYPE 4

SR24=16 kN/m²

Profile kg/m

TYPE 5

SR24=31.5 kN/m²

Profile kg/m

300 PF 21-0.4 7,60 PF 21-0.4 7,60 PF 21-0.4 7,60 PF 21-0.4 7,60 PF 21-0.4 7,6

400 PF 21-0.4 10,5 PF 21-0.4 10,5 PF 21-0.4 10,5 PF 21-0.4 10,5 PF 34-0.99 12

500 PF 21-0.4 12,60 PF 21-0.4 12,60 PF 21-0.4 12,60 PF 34-0.99 14,90 PF 42-1.9 18,55

600 PF 21-0.4 15,20 PF 21-0.4 12,20 PF 34-0.99 17,90 PF 42-1.9 22,25 PF 42-2.6 27,40

700 PF 21-0.4 17,65 PF 34-0.99 20,80 PF 34-0.99 20,80 PF 54-4.5 32,75 PF 54-4.5 32,75

800 PF 21-0.4 20,15 PF 34-0.99 23,80 PF 42-1.9 29,75 PF 54-4.5 37,50 PF 54-6.6 4820

900 PF 34-1.2 30,50 PF 34-1.2 30,50 PF 42-2.28 38,10 PF 54-4.7 45,50 PF 54-10.3 72,25

1000 PF 34-1.2 33,85 PF 42-1.9 37,00 PF 54-4.5 51,50 PF 54-7.0 63,40 PF 54-12.9 94,20

1200 PF 34-1.2 40,60 PF 42-2.6 55 PF 54-5.25 62 PF 54- 10.3 96,5 - -

1400 PF 42-2.28 59,25 PF 54-4.5 65,50 PF 54-8.0 96 PF 54-16.3 157,5 - -

1600 PF 54-4.5 74,84 PF 54-6.6 96,50 PF 54-11.8 142,5 - - - -

1800 PF 54-4.5 84,20 PF 54-8.5 130 PF 54-17.7 - - - - -

2000 PF 54-6.6 120,4 PF 54-11.36 175 - - - - - -

2200 PF 54-8.0 151 PF 54-16.3 247,5 - - - - - -

2400 PF 54-10.3 192 PF 54-19.8 - - - - - - -

2600 PF 54-12.9 244,9 - - - - - - - -

2800 PF 54-16.3 315 - - - - - - - -

3000 PF 54-19.8 388,5 - - - - - - - -

Pipe

ID

TYPE 6

SR24=63 kN/m²

Profile kg/m

TYPE 7

SR24=125 kN/m²

Profile kg/m

300 PF 34-0.99 9,0 PF 42-1.9 11,15

400 PF 42-1.9 14,85 PF 54-4.5 18,75

500 PF 54-4.5 23,40 PF 54-6.6 30,10

600 PF 54-5.5 33,25 PF 54-11.36 52,50

700 PF 54-8.5 50,60 - -

800 PF 54-12.9 75,40 - -

900 - - - -

1000 - - - -

1200 - - - -

1400 - - - -

1600 - - - -

1800 - - - -

2000 - - - -

2200 - - - -

2400 - - - -

2600 - - - -

2800 - - - -

3000 - - - -


27

Table 7: HDPE – Profiled Pipes Classes (E24=380N/mm2) according to ISO 9969

Class SN 2000 SN 4000

DN

mm

da-

Pipe

mm

da-

Bell

mm

Profile Type Weight

kg/6 m

Weight

kg/m

DN

mm

da-

Pipe

mm

da-

Bell

mm

Profile Type Weight

kg/6 m

Weight

kg/m

300 355 380 PF 21-0,4 45,30 7,55 300 355 380 PF 21-0,4 45,30 7,55

400 455 480 PF 21-0,4 60,50 10,08 400 455 480 PF 21-0,4 60,50 10,08

500 555 580 PF 21-0,4 73,45 12,24 500 576 580 PF 34-0,99 89,10 14,85

600 676 680 PF 34-0,99 106,90 17,82 600 678 680 PF 34-1,2 121,80 20,30

700 776 780 PF 34-0,99 124,80 20,80 700 792 780 PF 42-1,9 155,80 25,97

800 892 880 PF 42-1,9 178,00 29,67 800 920 880 PF 54-4,5 224,00 37,33

900 996 980 PF 42-2,28 228,00 38,00 900 1020 980 PF 54-4,5 252,60 42,10

1000 1096 1080 PF 42-2,6 272,20 45,37 1000 1124 1080 PF 54-5,5 332,00 55,33

1200 1320 1280 PF 54-4,5 336,25 56,04 1200 1332 1280 PF 54-9,6 566,00 94,33

1400 1528 1480 PF 54-7,0 530,00 88,33 1400 1552 1480 PF 54-16,3 944,00 157,33

1600 1736 1680 PF 54-11,36 839,00 139,83 1600 1772 1680 PF 54-24,25 1343,00 223,83

1800 1952 1880 PF 54-16,3 1079,00 179,83 1800 1962 1880 DW 54-31,5 1612,00 268,67

2000 2172 2080 PF 54-24,25 1679,00 279,83 2000 2178 2080 DW 54-49,5 2113,00 352,17

Class SN 8000 SN 16000

DN

mm

da-

Pipe

mm

da-

Bell

mm

Profile Type Weight

kg/6 m

Weight

kg/m

DN

mm

da-

Pipe

mm

da-

Bell

mm

Profile Type Weight

kg/6 m

Weight

kg/m

300 355 380 PF 21-0,4 45,30 7,55 300 376 380 PF 34-0,99 53,50 8,92

400 476 480 PF 34-0,99 71,50 11,92 400 492 480 PF 42-1,9 89,00 14,83

500 594 580 PF 42-1,7 96,00 16,00 500 620 580 PF 54-4,5 140,00 23,33

600 696 680 PF 42-2,28 147,00 24,50 600 722 680 PF 54-4,7 182,00 30,33

700 820 780 PF 54-4,5 196,50 32,75 700 830 780 PF 54-8,0 287,00 47,83

800 926 880 PF 54-5,5 265,00 44,17 800 936 880 PF 54-11,36 419,00 69,83

900 1030 980 PF 54-8,0 370,00 61,67 900 1052 980 PF 54-16,3 608,00 101,33

1000 1136 1080 PF 54-11,39 525,00 87,50 1000 - - - - -

1200 1362 1280 PF 54-19,8 932,00 155,33 1200 - - - - -

1400 - - - - - 1400 - - - - -

1600 - - - - - 1600 - - - - -

1800 - - - - - 1800 - - - - -

2000 - - - - - 2000 - - - - -


28

Table 8: Tolérances on pipe inside diameter

Nominal size

Pipe internal

diameter

(mm)

Lower Limit

diameter

(mm)

for series 1 to 7

Upper limit

diameter

(mm)

for series 1 to 4

Upper limit

diameter

(mm)

for series 5 to7

300 300 -8 +4 +6

400 400 -10 +6 +8

500 500 -13 +7 +10

600 600 -15 +9 +12

700 700 -18 +10 +14

800 800 -20 +12 +16

900 900 -23 +13 +18

1000 1000 -25 +15 +20

1200 1200 -30 +18 +24

1400 1400 -35 +21 +28

1500 1500 -38 +22 +30

1600 1600 -40 +24 +32

1800 1800 -45 +27 +36

2000 2000 -50 +30 +40

2200 2200 -55 +33 +44

2400 2400 -60 +36 +48

2500 2500 -63 +37 +50

2600 2600 -65 +39 +52

2800 2800 -70 +42 +54

3000 3000 -75 +45 +60

3500 3500 -87 +52 +70

3600 3600 -90 +54 +72

Table 9: Technical data for HDPE-Profiled Pipe (PF Type) Profile Ix

(mm4/mm)

e

(mm) a

(mm)

sd

(mm)

S1

(mm)

S4

(mm)

h

(mm)

eq

(mm)

PF 21-0.4 39,50 6,85 90 21 4 3 27 16,80

PF 34-0.99 99,30 9,70 120 34 4 3 38 22,80

PF 34-1.2 122,30 11,00 90 34 4 3 39 24,50

PF 42-01.9 122,30 13,27 100 42 4 3 46 28,20

PF 42-2.28 228,50 13,63 120 42 5 4 48 30,15

PF 42-2.6 259,50 17,79 100 42 5 4 48 31,50

PF 54-4.5 454,70 18,27 120 54 5 4 60 37,90

PF 54-04.7 472,10 17,65 120 54 6 4 61 38,40

PF 54-05.25 526,00 20,32 120 54 5 5 61 39,80

PF 54-05.5 552,90 19,70 120 54 6 5 62 40,50

PF 54-06.6 665,50 21,58 120 54 6 6 63 43,10

PF 54-07.0 7035,00 21,12 120 54 7 6 64 43,90

PF 54-08.0 7983,00 22,72 120 54 7 7 65 45,80

PF 54-08.5 8492,00 22,41 120 54 8 7 66 46,70

PF 54-10.3 1029,70 23,70 120 54 9 8 68 49,80

PF 54-11.8 1177,40 24,88 120 54 10 9 70 52,10

PF 54-12.9 1291,70 26,14 120 54 10 10 71 53,70

PF 54-14.2 1427,80 26,05 120 54 12 10 73 55,50

PF 54-16.3 1632,10 26,20 120 54 15 10 76 58,10

PF 54-17.7 1770,60 26,44 120 54 17 10 70 59,67

PF 54-19.8 1984,30 32,20 120 54 20 10 81 62,00

Explanation: Ix = moment of inertia, e = distance of inertia, a= profile distance,

h= profile height, S1= water way wall thickness, S4= core tube coating,

sd= core tube diameter, se = equivalent solid wall thickness


29

Explanation of the profile no.

Pf 54 - 8,50

8,50 is the Moment of inertia (lx)

54 is the Diameter of the hole in the profile

The equivalent solid wall thickness (eq)

The equivalent solid wall thickness eq is calculated according the formula:

3 12 Ixeq In mm, Ix in mm

4/mm

The equivalent standard dimension ratio (eSDR)

To get an equivalent SDR value (eSDR) for the profiled pipes, in case that there is no

internal pressure; the following formula can be used:

s

DSDR e Or

s

sDSDR i

2

112

13

sI x [ mm

4/mm] and 3 12 Ixeq [ mm]

3

3

12

122

x

xi

I

IDeSDR

2.1.2 Applications of PF -pipes

PF-pipes are generally used for sanitary sewer systems and the gravity piping systems

such as storm water piping system. Many of the larger- diameter gravity sewer

polyethylene pipes have pipe ring stiffness of 4 kN/m2 and some even lower. Extreme

care must be taken during installation of these low- stiffness pipes because of the

possibility of over deflection and buckling due to soil load.


30

Sewer piping system

Figure 8: Installation of HDPE-Profiled Pipe

Storm water piping system

Figure 9: Connection to the concrete manhole


31

2.2 Series DW Pipes and Field of Applications

Series DW Pipes or so called closed profiled pipes in HDPE piping system are

the pipes that are generally designed for the fabrication of manholes, storage tanks and

reservoir for industrial applications. Although Series DW Pipes are similar in major

specifications to Series PF Pipes, however, their specific characteristics are as follows:

Since Series DW Pipes are generally designed for the fabrication of

manholes and tanks, their exterior surfaces are smooth as interior surfaces; the

multi-layered pipe walls are reinforced by profile inner layer(s). Series DW

Pipes are exclusively suitable within waste landfill projects and the fabrication

of methane manholes and storage tanks within waste disposal areas.

The manholes and tanks constructed by Series DW Pipes are ideal for

the storage of chemicals, since the material of manufacture of pipes, i.e., HDPE

is completely chemicals resistance.

Series DW Pipes are exclusively manufactured from HDPE. The pipes

with different internal surface color are also available. They are suitable for

butt-welding up to ID 1600 mm in size; however, they are generally electro-

fusion welded of the pipe ends.

The auxiliary components like ladders, partitioning, and connections

covers and relevant other engineering applications which are also made from

HDPE can also be constructed to have uniform material of fabrication together

with manholes and tanks constructed from the Series DW Pipes.

Series DW Pipes are manufactured in three types according to the field of

Applications.

2.2.1. Wall Structure of Series DW1-Pipes

Figure 10: Sectional and Structural view of Series DW HDPE- pipes with single layer


32

Table 10: Specifications of Series DW1 Pipes

Profile No.

Sae

mm

e

mm

Ix

mm4/mm

DW1 34- 9 48,3 26,00 9411 DW1 34-10 49,5 26,08 10089 DW1 34-11 51,6 26,32 11461 DW1 34-12 53,6 26,65 12863 DW1 34-15 57,4 27,53 15794 DW1 34-18 61,0 28,63 18945 DW1 34-22 64,5 29,89 22381 DW1 34-26 67,9 31,27 26107

Sae : equivalent wall thickness

Ix : Sectional moment of inertia

e : distance of inertia

2.2.2. Wall Structure of Series DW-pipes with two layers and more

Figure 11: Sectional and Structural view of Series DW pipes with double layers

Figure12: Sectional and Structural view of Series DW pipes with multi layers


33

Table 11: Specifications of Series DW2 and DW3 Pipes

Profile No.

Sae

mm

e

mm

Ix

mm4/mm

DW2 34- 46 82,60 48,50 46884

DW2 34- 53 86,50 48,59 53949

DW2 34-65 92,50 49,06 65854

DW2 34-78 97,90 49,87 78078

DW2 34-90 102,90 50,93 90771

DW2 34-104 107,70 52,20 104058

DW2 34-118 112,30 53,62 118056

DW2 34-132 116,80 55,18 132840

DW3 34-164 125,60 74,00 164992

DW3 34-181 129,60 74,10 181439

DW3 34-197 133,40 74,31 197956

DW3 34-214 137,10 74,61 214587

DW3 34-245 140,50 74,99 245370

DW3 34-248 143,90 75,45 248343

DW3 34-265 147,20 75,98 265538

DW3 34-282 150,30 76,56 282986

Sae : equivalent wall thickness

Ix : Sectional moment of inertia

e : distance of inertia


34

2.2.3 Connection Details of Series DW pipes

(1) Pipe section with bell supplemented by electro-fusion welding at one end

And centered spigot at the other.

(2) Pipe section with centered spigot at both ends.

(3) Pipe section with plain ends.

(4) Pipe section with plain pipe end at one side and plain for butt-welding at

the other.

(5) Pipe section with plain for butt-welding ends.


and spigot for butt-welding at the other.

(7) Pipe section with centered spigot at one end bell and plain for butt-

welding at the other.

(8) Pipe section with bell threaded centered flange at one end and centered

spigot at the other.


and male centered flange at the other.

(10) Pipe section with flange at one end and centered spigot at the other.

(11) Pipe section with bell supplemented by electro-fusion welding at one

end and flange at the other.

2.2.4 Applications of DW Series Pipes

Series DW pipes in HDPE profiled piping system are the pipes that are

generally designed for very high long-term ring stiffness there for it is suitable

for extremely high load and big diameter.

Figure 13: HDPE-manholes with DW1 profile type


35

2.3 Series SW Pipes and Field of Applications

Series SW Pipes in HDPE piping system for industrial applications are the

pipes that have smooth internal and external wall surfaces without profiles. These pipes

are used within the projects where high degree of strength is requested for fabrication

of manholes, tanks and pipes. Their specific characteristics are as follows:

Series SW Pipes designed for the severe operation condition feature

smooth internal and external wall surfaces. The pipe wall is soiled. Different

colors are available for the internal and external pipe surfaces for those, which

are manufactured from HDPE only.

Series SW Pipes are manufactured from HDPE and PP. The pipes

manufactured from HDPE may have wall thickness in the range of 5 mm to 150

mm, whereas this range is specified as 5 mm to 80 mm for the pipes

manufactured from PP. Thicker pipes are also possible, even though they are

not economic in regard to the welding and pipe fitting for connections.

The special purpose components, like flange adapters can be produced

by machining specially manufactured pipes with heavy wall thickness.

The butt welding operation can be performed on Series SW Pipes with

ID dimensions up to 1600 mm and wall thickness of up to 80 mm. In general,

such pipes are connected by electro-fusion welding on both inner and outer side

of the pipe ends.

Series SW Pipes are manufactured from UV stabilized black HDPE;

however those produced from up PP exhibit inferior UV stability, since PP is

light in color and therefore they are used for the applications within enclosed

areas only.

2.3.1. Wall Structure of Series SW HDPE- Pipes

Figure 14: Sectional and Structural view of Series SW HDPE pipes


36

Table 12: Weight of SW HDPE solid pipes

Weight of pipes (kg/m)

S

Di

5 10 15 20 25 30 35 40

300 4,6 9,3 14,2 19,3 24,5 29,9 35,4 41

400 6,1 14,4 18,8 25,3 32 38,9 45,9 53,1

500 7,6 15,4 23,3 31,4 39,6 48 56,5 65,1

600 9,1 18,4 27,8 37,4 47,1 57 67 77,2

700 10,6 21,4 32,3 43,4 54,7 66 77,6 89,3

800 12,1 24,4 36,9 49,5 62,2 75,1 88,1 101,3

900 13,6 27,4 41,4 55,5 69,7 84,1 98,7 113,4

1000 15,2 30,5 45,9 61,5 77,3 93,2 109,2 125,5

1100 16,7 33,5 50,4 67,6 84,8 102,2 119,8 137,5

1200 18,2 36,5 55 73,6 92,4 111,3 130,4 149,6

1300 18,7 39,5 59,5 79,6 99,9 120,3 140,9 161,6

1400 21,2 42,5 64 85,6 107,4 129,4 151,5 173,7

1500 22,7 45,5 68,5 91,7 115 138,4 162 185,8

1600 24,2 48,6 73,1 97,7 122,5 147,5 172,6 197,8

1700 25,7 51,6 77,6 103,7 130,1 156,5 183,1 209,9

1800 27,2 54,6 82,1 109,8 137,6 165,6 193,7 222

1900 28,7 57,6 86,6 115,8 145,1 174,6 204,2 234

2000 30,2 60,6 91,2 121,8 152,2 183,7 214,8 246,1

2100 31,7 63,6 95,7 127,9 160,2 192,7 225,4 258,2

2200 32,2 66,7 100,2 133,9 167,8 201,8 235,9 270,2

2300 34,8 69,7 104,7 139,9 175,3 210,8 246,5 282,3

2400 36,3 72,7 109,2 146,0 182,8 219,9 257 294,3

2500 37,8 75,7 113,8 152 190,4 228,9 267,6 306,4

2600 39,3 78,7 118,3 158 197,9 237,9 278,1 318,5

2700 40,8 81,7 122,8 164,1 202,5 247 288,7 330,5

2800 42,3 84,8 127,3 170,1 213 256 299,2 342,6

2900 43,8 87,8 131,9 176,1 220,5 265,1 309,8 354,7

3000 45,3 90,8 136,4 182,2 228,1 274,1 320,4 366,7


37

2.3.2. Connection Details of Series SW - Solid Wall ipes


and centered spigot at the other.

(2) Pipe section with centered spigot at both ends.

(3) Pipe section with plain ends/for butt-welding.

(4) Pipe section with plain pipe end at one side and plain for butt-welding at the

other.

(5) Pipe section with centered spigot at one end bell and plain for butt-welding

at the other.

(6) Pipe section with centered spigot at one end bell and plain for butt-welding

at the other.


and male centered flange at the other.

(8) Pipe section with flange at one end and centered spigot at the other.


and flange at the other.


38

3. HDPE FITTINGS

All fittings are fabricated from pipes of the type SW or DW. Generally the fittings are designed

corresponding to the required stiffness and in consideration of the welding factors. Every fitting can

have any kind of pipe end and any jointing techniques including the integrated Electro-Fusion socket

and spigot.

All pipe end dimensions fulfill the requirements of the EN 14376 standard, like minimum lengths and

stiffness. The standard spigot length (Ls) is 140 mm and the standard socket length (Lm) is 140mm.

3.1 Bends

Bends can be manufactured and segmented in different angles and the related radius of the bend to pipe

diameter can be selected independently.

Table 13:Bend dimensions as per standard DIN 16961

Dimension L in mm (approx.)

Number of Segments

Di (mm) 2

α= 15o

2

α= 30o

3

α= 45o

3

α= 60o

4

α= 75o

4

α= 90o

300 100 190 230 280 330 410

400 160 210 270 330 410 510

500 170 235 310 390 490 600

600 180 270 350 450 560 700

700 200 300 400 510 550 820

800 210 320 430 560 720 900

900 220 340 470 620 790 1.000

1.000 240 380 520 680 870 1.100

1.100 250 400 560 750 950 1.200

1.200 270 430 600 800 1.020 1.300

1.300 300 460 640 860 1.100 1.400

1.400 330 490 680 920 1.180 1.500

1.500 360 520 720 980 1.260 1.600

1.600 390 650 760 1.040 1.340 1.700

1.800 420 580 800 1.040 1.420 1.800

2.000-3.000 Special construction as per design dimensions


39

3.2 Branches

Branches can be manufactured and delivered in every type and form. The angle can be adapted

individually from 30° to 90° as well as the ends and the respective segment lengths.

Table 14:Tee dimensions as per standard DIN 16961

Di1 (mm) Di2 (mm) Lt (mm) L1 (mm) L2 (mm) 300 100/150/200/250 1.100 350 750

400 100/150/200/250/300 1.300 400 900

500 100/150/200/250/300 1.400 400 1.000

600 100/150/200/250/300 1.650 450 1.200

700 100/150/200/250/300 1.900 500 1.400

800 100/150/200/250/300 1.900 500 1.400

900 100/150/200/250/300 2.000 500 1.600

1.000 100/150/200/250/300 2.000 500 1.600

1.100 100/150/200/250/300 2.100 500 1.600

1.200 100/150/200/250/300 2.100 500 1.800

1.300 100/150/200/250/300

1.400 100/150/200/250/300

1.500 100/150/200/250/300

1.600 100/150/200/250/300

1.800 100/150/200/250/300

2.000-3.000 Special

construction as per

design dimensions


40

3.3 Reductions

Reductions can be made both centric and eccentric so that the reduction will always meet the

requirements.

Table 15:Reduction dimensions as per standard DIN 16961

Di1 (mm) Di2 (mm) Lt (mm) L1 (mm) L2 (mm) 300

400

500

1.200

1.300

500

500

500

500

400

500

600

1.400

1.400

500

500

500

500

500

600

700

1..500

1.500

500

500

500

500

600

700

800

1.600

1.600

500

500

500

500

700

800

900

1.700

1700

500

500

500

500

800

900

1.000

1.800

1.800

500

500

500

500

900-4000 1.000-3600 Special construction as per design dimensions


41

3.4 Puddle flanges

In order to lead HDPE pipes through walls, e.g. in sewage plants or concrete shafts, we recommend our

puddle flanges which can be flush mounted in concrete. The tightness is secured by a ring made of

EPDM.

Type 1 Type 2 Type 3

Table 16:Puddle flange dimension

Di

(mm)

Type 1

d 1 b1

( mm) ( mm)

Type 2 and Type 3

d2 d3 d4 b2 b3 b4

(mm) (mm) (mm) (mm) (mm) (mm)

300 - - 336 442 517 200 130 140

400 - - 436 542 617 200 130 140

500 - - 536 642 717 200 130 140

600 - - 636 742 817 200 130 140

700 770 160 736 842 917 200 130 140

800 870 160 836 942 1017 300 130 140

900 970 160 936 1065 1131 300 130 140

1.000 1070 160 1036 1156 1231 300 130 140

1.100 1170 160 1136 1256 1331 300 130 140

1.200 1270 160 1236 1356 1431 300 130 140

1.300 1370 160 - - - - - -

1.400 1470 160 - - - - - -

1.500 1570 160 - - - - - -

1.600 1670 160 - - - - - -

1.700 1770 160 - - - - - -

1.800 1870 160 - - - - - -

1.900 1970 160 - - - - - -

2.000 2070 160 - - - - - -


42

Table 17: Dimension of wall passes

D (mm)

s1 (mm)

s2 (mm)

h (mm)

b (mm)

L (mm)

900 25 15 150 80 1000

450 20 15 120 80 1000

400 20 15 120 80 1000

315 20 15 100 80 1000

200 20 15 100 80 1000

Figure 15: HDPE- wall passes

3.5 House connection

The house connection fittings are developed to ensure reliable and practical house

connection effluent water connections. There is no need to provide connection points on the

header pipe to make branch connection or tee. The house connection fitting adapters are

completely independent component, which are use for providing connection point at the

discharge point of the house connection effluent water. The house connection within HDPE-

profiled piping system is provided by the standard fittings having standard sizes of 160 mm

and 200 mm.


43

Figure 16: House connection on profiled pipe

3.5.1 House connection fitting components

Standard house connection fittings component within HDPE-profiled piping system are

illustrated at the table below. During the house connection application, the quickest and

reliable procedure includes the opening a hole on the header pipe with a diameter equal to the

OD of the branch pipe by using the drilling machine as illustrated and drilling the fastening

points on the pipes for the connection.


44

3.5.2 House connection procedure

The installation of the house connection is indicated in the below pictures:

Figure 17: Flow poocess to install the house connection


45

3.6. Manhole and Tanks

HDPE piping system provides complete solutions for the relevant applications,

especially manholes, which are the main problems experienced within sanitary sewer

projects, are constructed within HDPE piping system reliably and in a practical

manner.

3.6.1. Manholes

The manholes are required at several inspection points, ventilation, controlling, and

pipe turning points within the sanitary sewer systems. The manholes are completely

constructed from HDPE together with relevant top cover and the recesses, with the

possibility of concrete tops. The top cover systems of the manholes and the flues

completely constructed from this material are telescopic. The covers constructed in this

manner have the advantage of elevating the manhole covers at the final level of the

road surface, in case of any increase in the elevation of the road surface after coating of

the road surfaces.

Figure 18: HDPE-manhole for landfill application

The manholes are constructed in accordance with the design project, installed

within the piping system together with additional incoming and outgoing branch

piping, thus providing convenient application of the pipe installation within the

construction site.

The design of manholes, together with their nominal diameters, wall thickness, etc.,

is based on the anticipated loading conditions and the ground water level.

Internal surfaces of the manhole piping are made in different colors to ensure ease

of inspection, while the auxiliary equipment like access ladder, inspection steps and the

canals can also be incorporated into the manholes during fabrication. The problems

like corrosion, leakage, etc. on the bottom of manhole and inlet and outlet connections

can be prevented, thanks to the properties inherent to HDPE and PP.

Two types of manhole design are incorporated within Profiled HDPE- piping system.


46

3.6.1.1 Straight Passage Manholes

These manholes are designed for use within pipe turning points having several inlet

and outlet branch connections. Such manholes are suitable for the pipes having inlet

and outlet branch connections with a nominal pipe sized in the range of ID 300 mm to

ID 700 mm.

The manholes having nominal diameters of ID 1000 mm and ID 1600 mm are

suitable for the branch connections with a nominal pipe sizes in the range of ID 300

mm to ID 500 mm and for the branch connections with a nominal pipe sizes in the

range of ID 600 mm to ID 900 mm, respectively.

The bottoms of the manholes, made from HDPE, are welding construction and

therefore, absolute tightness is ensured. The steps and canals on the bottom plate and

the access steps can be constructed with the same material, although it is not

recommended.

Figure 19: : Straight passage manhole with concrete cover


47

3.6.1.2. Tangential Manholes

The tangential manholes are practical and economic manhole application within

Profiled HDPE-piping system for the pipes with ID 800 mm and higher. Such

applications are possible via standard manufacturing for the pipe size of ID 1000 mm

and the manhole is installed tangential to the center of the pipe line.

The steps and telescopic HDPE or concrete cover are available within

tangential manhole system. Such application is available both on straight pipe runs or

turning points.

Figure 20 : Tangential manhole with telescopic standard cover


48

Figure 21: Details of the telescopic cover

Figure 22: Details of Tangential manhole


49

Figure 23: Tangential manholes with 90o and reduced passage

Specifications of HDPE-manholes:

Internal surfaces are made in yellow for ease of inspection.

Features reduced weight compared with conventional applications.

Available up to ID 4000 mm.

Internal and external pipe surfaces are smooth.

Provides absolute tightness.

Not effected from seismic movements and earthquakes.

The friction loss is at minimum level.

High resistance to chemicals.

Minimum service life is 100 years.


50

3.6.2 HDPE-Tanks

HDPE- piping system incorporates the production of cylindrical, vertical and

horizontal tanks with diameters ID 300 mm to ID 4000 mm. The tanks are available

together with any kind of inlet and outlet nozzle connections, covers, valves, etc. In

standard manufacture, HDPE tanks are in the capacities between 2000 to 75000 liters.

The material of construction for HDPE tanks allows the resistance to chemicals,

suitable to storage of any kind of solid and liquid foodstuff, thanks to the hygienic

properties. The internal and external tank surfaces are smooth and the various internal

surface colors are also available. The wall thickness of the tanks manufactured from

HDPE between 5 mm to 100 mm maximum and with different wall thickness in one

pipe to save material. The tanks manufactured from HDPE are resistant to UV by the

virtue of the dark material of construction and suitable for outdoor applications. The

tanks manufactured from PP are in light colors and suitable only for indoor

applications away from the sunlight.

Figure 24: HDPE tank with steps wall tickness

The major field of applications of HDPE tanks:

Water storage (especially indoor tanks).

Storage of liquid foodstuffs.

Storage of cereals and beans.

Storage of industrial powder chemicals.

Storage of waste disposal area.

Water treatment plant.

Acid tanks and others chemicals

Storage of mineral oils.


51

4. Piping design calculation

4.1 Hydraulic Calculation

4.1.1 Wall Roughness

The flow resistance of HDPE pipes is comprehensively low due to their smooth

internal surface. Today, one of the most important causes for bottleneck formation,

linked with the disposal of the effluent water using conventional piping system, is

precipitation within the pipe. The sand, gravel, etc., that enter the piping, together with

the sedimentation, restrict the useful cross sectional area of the piping. In addition to

the bottleneck generation, abrasion is induced on the pipes internal surface. As a result,

the deposits carried along with the effluent waters into the water treatment plant cause

operational problems within the system. These are frequent malfunctions and

interruptions, thus creating another operational cost factor.

Further, the ingress of the ground water into the piping system reduces the

efficiency and capacity of the sanitary sewer system as a whole and the load of the

water treatment plant. Therefore, also the operational expenses do increase.

Thanks to the low value of the HDPE roughness constant (K), the accumulation

of sediment is prevented. The absolute tightness of the pipe joints, which is ensured by

the electro-fusion welding method, prevents the ingress of any foreign matter or

ground water into the piping system.

Table 18:Roughness constant K of various pipe materials

Type of pipe Kb Value (mm)

New steel pipes

New ductile iron pipes

Cast iron , concrete or bitumen coat

General plastic pipes

HDPE pipes

New concrete pipes

Vitrified clay pipes

Old pipes, aggressive/ corrosive waters

0,01 - 0,1

0,0001 - 1

0,03 - 0,2

0,01 - 0,1

0,007 - 0,5

1,0 - 2,0

0,1 - 1

2

The roughness characteristics of the internal pipe surface of HDPE- pipes are suitable

for efficient flow conditions. Hydraulic calculations of HDPE- pipes are based on ATV

110 guidelines. However, the hydraulic calculations must also consider the amount of

the flow with respect to the useful cross sectional area of the pipe.

Based on ATV 110 guidelines, hydraulic calculations must also take into

account the friction loss within the pipe, manholes, auxiliary parts, etc. (roughness

factor)

The value of the Kb constant, considered within hydraulic calculations for

HDPE pipes, is 0.1 mm.


52

4.1.2 Calculation of the Flow Rate

4.1.2.1 PRANDTL-COLEBROOK FORMULA

For the calculation of the flow rate Q of a fully filled pipe in a continuous

discharge, the so called "normal discharge" for public sewer pipes, the ATV A 110

guideline and also the European standard DIN EN 752 recommend the use of the

PRANDTL- COLEBROOK formula, the so called "general discharge formula"

i

i

b

ii

dJgd

k

dJgdv ...2.

.71,3...2

.51,2lg.2

in m/s

Where:

v: Flow speed (m/s)

J: Hydraulic slope (-)

Kb: Roughness constant (mm)

g: Gravity constant (m/s²)

υ: Kinematics viscosity of sewage acc. to ATV A 110 υ= 1.31x10-6

(m²/s)

di: Internal pipe diameter (mm)

The flow rate of the effluent water:

AvQ .

Where:

Q: Discharge (m3/s)

A: Cross sectional area (m2)

Depending on the various kinds of sewage canals the value of Kb can be allocated

according to ATV A110 guideline as follows:


53

Operation Conditions Kb recommended for

HDPE (mm)

Kb specified in ATV A 110

(mm)

Throttle lines, pressure

pipelines, drains and

relining of existing

pipelines without

manholes

Transport pipelines

connected to manhole –

based on ATV 110

guidelines

Collecting pipelines

connected to manhole –

based on ATV 110

standard

Additional incoming

pipelines to main

collector pipelines,

pipelines with special

manholes

0,10

0, 25

0,50

0,75

0,25

0,50

0,75

1,5

4.1.2.2 MANNING FORMULA

Manning's formula is used for the design of sewer systems:

AvQ .

2/13/2 ..1

JRn

v

2/13/22

..1

.4

.JR

n

DQ

Where:

Q: Discharge (m3/s)

v: Velocity (m/s)

n: Mannings roughness coefficient (-)

R: Hydraulic radius (m)


Table 19: Manning’s roughness coefficient

Pipe Material "n" Value

Vitrified clay pipe 0,013

Plastic pipes 0,012

Class Reinforced Plastic Pipe (GRP) 0,012


54

4.1.2.3 HAZEN -WILLIAMS FORMULA

The Hazen-Williams equation is widely accepted for pressure flow pipelines.

54,063,0 ...85,0 JRCv

852,1

167,1

852,1

..170,1

vd

L

Chf

852,1

87,4

852,1

.59,3

d

Q

CS

Where:

v: Velocity (m/s)

c: Roughness coefficient of pipe (mm)

d: Internal pipe diameter (m)

L: Pipe length (m)

hf: Hydraulic head losses in pipe line (m)


Table 20: Hazen-Williams roughness coefficient "C" for various pipe materials:

Material of pipes Value of "C"

Cast iron pipe

New 130

5 years old 120

10 years old 110

20 years old 90-100

30 years old 75-90

Concrete pipe 120-140

Plastic pipe 150

Asbestos cement pipe 120-140

4.1.3 Calculation of the Flow Rate for Partially Filled Pipes

The hydraulic calculations for the flow rate in partially filled pipes are difficult.

It is because the water level in the pipe is not exactly known in general. However, for

the sanitary sewer piping the ratio between partially and fully filled pipes is taken into

account by omitting the pipe slope, which is a fair approximation.

Partially filled pipes for the purpose of aeration and eliminating should be taken

in consideration: hT/d=0.827.

For the calculation of the filling ratio, i.e., hT/d, attention should be played to

the measurement of hT with respect to the pipe main axis.


55

625,0

hV

hT

V

T

R

R

V

V

Vv: Flow rate at fully filled pipe

Vt: Flow rate at partially filled pipe

Lu

ARhT

Lu: Partial perimeter

A: Partial sectional area

RhT: Hydraulic radius of partially filled pipe

4

dRhV

d: Internal diameter

RhV: Hydraulic radius of fully filled pipe

625,0

.

hV

hT

V

T

V

T

R

R

A

A

Q

Q

QT: Discharge for partially filled pipe

QV: Discharge for fully filled pipe

AT: Partial cross sectional area

4.1.4 Gradient

Waste water contains faeces, kitchen slops, and other waste substances from the

households. Storm water contains sand, gravel and also wastes substances from the

streets. If the velocity of the waste water is low, heavy substances will deposit on the

invert of the pipeline. In case of high velocity the pipe invert will be washed away. The

prominent factor for this process is the shearing stress η.

JRg ...

η = kg/m3 * m/s

2 * m * 1 = kg/m*s

2 = kg/s

2 * 1/m = N/m * 1/m = N/m

2

η = 1000. 9, 81. d/4 . 1/(d.1000) by full filling, R=d/4

Approximate value:

η = 10.000. d/4. 1/(d.1000) = 2,5 N/m2

For example: DN 300, J=1:300, with R=d/4=0,3/4=0,075 m

η = 10.000. 0.075 . 1/300 =2,5 N/m2

Where:

ρ: Fluid density (kg/m3)

g: Gravity constant (m/s2)

R: Hydraulic radius (m)


In the practice, the engineers refer to the velocity. The minimum should be


56

υ = 0,5 m/s, and according to the ATV-A118 a maximum of 6 to 8 m/s is

recommended, dependent from the pipe material.

Table 21: Gradient slope of sewer pipes

Lines in mm=d Minimum slope Maximum slope Recommended

slope

House connection 1:100 1:10 1:50

Φ 200 to 300 1:200 to 1:300 1:10 to 1:15 1:50 to 1:200

Φ 300 to 600 1:300 to 1:600 1:20 1:100 to 1:300

Φ 600 to 1000 1:600 to 1:800 1:30 1:200 to 1:400

Φ 1000 to 2000 1:1000 1:50 1:300 to 1800

The optimal velocity is between 0,6 to 1,5 m/s

4.2 Static Calculations

HDPE pipes have specific properties and there by other demands on

Dimensioning calculations than example concrete and steel pipes. In general

the HDPE-pipes(plastic pipes) are flexible, that is they deformed under load.

This is positive in the meaning that the pipe has the ability together with the

backfilling material to cause a horizontal earth pressure towards the side wall

of the pipe, which increase the ability of the pipe to carry the load?

The Vertical load, Q, on the buried pipe is the sum of 3 different loads.

wts QQQQ in Mpa

Where:

Q : Total vertical load

Qs: Soil load

Qt: Traffic load

Qw: Water load

2.2.1. Deformation of a HDPE-buried pipe

The vertical deformation, δv, of a buried pipe can be calculated by the

Following formula, in words:

Deformation= Load on the pipe/ ( Pipe Stiffness + Ground Stiffness)

122,0

083,0

SE

Q

D s

v

Where:

δv : vertical pipe deformation in mm

D : Pipe diameter in mm

Q : Total vertical load in MPa

Es : Secant modulus of Supporting soil, MPa

S : Stiffness factor

3

3

2

D

e

E

ES

s


57

E : Modulus of elasticity of the pipe material in MPa

e : Wall thickness in mm, in case of profiled pipe, the equivalent wall

thickness

122,0

083,0

SE

QD

s

v

The deformation of the pipe after backfilling is recommended not exceed 6%

according to ATV-A-127.

2.2.2. Strain in the pipe wall

The strain in the pipe wall can be calculated by the following formulas:

DD

e v 6 if S≤0,012

003,025,018

2

S

e

D

E

E

D

sv if S>0,012

Where:

ε : Strain in the pipe wall

e : wall thickness / equivalent wall thickness in mm

D : main pipe diameter in mm

δv : vertical pipe deformation in mm

Es : Secant modulus of supporting soil in MPa

E : Modulus of elasticity of the pipe material in MPa

S : Stiffness factor

Allowed initial strain in the pipe wall is 1,5% for HDPE.

4.3. Pipe Class/ Pipe Ring Stiffness

The Ring Stiffness, or oval resistance, is one of the main parameter for the

classification of the flexible pipes. Due to its correlation with the both the geometrical

data (the moment of inertia of the wall) and the material characteristics (modulus of

elasticity), the Ring Stiffness is defined.

Technically, the Ring stiffness can be calculated according to all different kinds

of standards as follows:


58

1) According to DIN 16961 ring stiffness is defined as:

3

2424

.

m

CR

r

IES in kN/m

2

Where

Ec24: creep modulus in kN/m2 in accordance with DIN 16961-2, Table 2

I : moment of inertia of the pipe profile, in m4/m

rm : radius up to the neutral line of the pipe wall in m

When pipe tested according to DIN 16961, the mean vertical deflection (i.e. the

ratio of the change in inside diameter) shall be no greater than 0,03xdi. Table below

sets out the required ring stiffness for pipe series 1 to 7.

Table 22: Ring stiffness classes according to DIN 16961

Pipe class no 1 2 3 4 5 6 7

Minimum ring

Stiffness, SR24

in kN/m2

2

4

8

16

31,5

63

125

1) According to ISO 9969

The rig stiffness is determined using the method prescribed in EN ISO 9969 by

means of formula:

L

F

D

ySN

i

025,00186,0 in Pa

Where:

SN : nominal ring stiffness, in Pa Pa=N/m2

F : force necessary to obtain required deformation, in N

L : length of sample pipe, in m

Y : deformation of pipe diameter, in m

The ring stiffness can also be calculated using the formula linking the modulus

of elasticity, E, of the pipe material, the moment of inertia, I, and the mean pipe

diameter, Dm, as follows:

m

ck

D

IESN

3

. in kN/m

2

Where:

SN : nominal ring stiffness in kN/m2

Eck : elastic modulus after 1 minute in kN/m2

I : moment of inertia of the pipe profile, in m4/m

Dm : mean diameter in meter


59

When tested in accordance with the test method as specified in ISO 9969, the

pipe shall be designated in one of the following nominal ring stiffness classes (SN)

conforming to the requirements in prEN 13476-1.

DN ≤ 500: SN 4, SN 8, SN 16;

DN > 500: SN 2, SN 4, SN 8, SN16;

For DN ≥ 500 the manufacturers guaranteed minimum stiffness, between the SN

values, of a component may be used for calculation purposes.

Table 22: Material characteristic values

Material Modulus of elasticity

Ec

Bending tensile strength

ζ

Specific

gravity χ

Short-term

N/mm2

Long-term

N/mm2

Short-term

N/mm2

Long-term

N/mm2

kN/m3

HDPE 800 160 21 14 9,4

PPH 1250 312 39 17 9

PPR 800 200 27 14 9

4.4 External Load

The loads imposed on conduits buried in the soil depend upon the stiffness properties

of both the pipe structure and the surrounding soil. When designing rigid pipes( for

example concrete or clay pipes), it is customary to assume that pipe is affected mainly

by a vertical pressure caused by soil and traffic, a horizontal reacting pressure is either

nonexistent or negligible. In the rigid pipes, the deformation is practically non existing,

before the pipe breaking.

For flexible pipes, the vertical load causes a deflection of the pipe, which in turn results

in a horizontal supporting soil pressure. If the horizontal soil pressure and vertical

pressure are close to being equal, the load around the pipe approximates a hydrostatic

load. The stress in the pipe wall are then mainly circumferential (hoop) compressive

stresses, and the deep burial will give rise to buckling.

Under the soil load, the flexible pipe tends to deflect, thereby developing passive soil

support at the side of the pipe. At the same time, the ring deflection relieves the pipe of

the major portion of the vertical soil load which is picked up by the surrounding soil in

an arching action over the pipe.

4.4.1. Soil load

When the side fill and the pipe have the same stiffness, the amount of the ground load

that is proportioned to the pipe can be found merely on a width basis. The load will be

uniformly distributed as shown in Fig. 1 and accordnace with Marston ground load

theory

The load of the ground on the unit length becomes


60

ded BDCW in N/m (1)

Where:

Cd : Load coefficient of the ground

: specific weight of the backfill material, in N/m3

De : external diameter of the pipe, in m

Bd : width of the trench measured at the top of the pipe, in m

The function:

K

eC

dBHK

d2

12

(2)

Where:

H : height of cover measured from the top of the pipe, in m

μ : coefficient of friction between the backfill and trench material

K : Rankine coefficient

Table 23: Approximate Values of Soil Unit Weight, Ratio of Lateral to Vertical Earth

Pressure, and Coefficient of Friction against Sides of Trench

Soil type Unit weight

Ib/ft3 kg/m

3

Rankine’s ratio

K

Coefficient of

friction μ

Partially compacted

damp topsoil

Saturated topsoil

Partially compacted

damp clay

Saturated clay

Dry sand

Wet sand

90 1440

110 1760

100 1600

120 1920

100 1600

120 1920

0,33

0,37

0,33

0,37

0,33

0,33

0,50

0,40

0,40

0,30

0,50

0,50


61

Figure 25 : Load distrobution according to Marston s theory for flexible pipe

When a load is placed on a flexible pipe, the pipe also deflects and resists deflection

because of its stiffness. It is even possible to think of soil as being a nonlinear spring

that resists movement or deflection because of its stiffness(figure 26).

Linear spring Flexible pipe is like a spring

Figure 26: Graphic of spring, pipe and soil

When we draw an analog between a rigid pipe represented by stiff spring in

comparison to soil at its sides, represented by more flexible springs, and than place a

load on this spring system representing a rigid pipe in soil, we can easily visualize the

soil deforming and the pipe carrying the majority of the load (see a in Fig. 27).

If the situation is reversed and we place a flexible spring between two springs which

are much stiffer, representing the soil, we can again picture the pipe deflecting as a

load is applied and the soil in this case being forced to carry the load to a greater

extent.(see Figure 27)

Figure 27: Flexible and stiff springs working together


62

When a flexible pipe( HDPE- pipe) is buried in the soil, the pipe and soil then work as

a system in resisting the load (Fig.28), and that means, that the soil at the sides of the

pipe resisting the load (Fig. 29)

Figure 28: Graphic of pipe and soil working together as a system

Figure 29: Graphic showing the contribution of sidefill soil and the flexible pipe.

Prism load theory

A more realistic design load for a flexible pipe would be the prism load, which is the

weight of a vertical prism of soil over the pipe. Research data indicate that the effective

load on a flexible pipe lies somewhere between the minimum predicated by Marston

and the prism load. On a long-term basis, the load may approach the prism load. The

prism or embankment load is given by the following equation (see Fig. 30).

HP in N/m2 (3)

Where : P : pressure due to weight of soil at depth H, in m

: specific weight of the backfill material, in N/m3

H : cover depth on the pipe, in m


63

Figure 30: Graphic of the prism load on a pipe

Example Problem 1: Assume an 0,8 mm flexible HDPE- pipe is to be installed in a 1,8

m wide trench with 4 m of clay soil cover. The unit weight of the soil is 1920 N/m3.

What is the load on the pipe?

For the Marston load ,

ded BDCW in N/m

Cd = 1,6

= 1920 N/m3

Bd = 1,8 m

De = 0,8 m

Marston load=W=(1,6).(1920).(0,8).(1,8)= 4424 N/m

For the prism load,

HP in N/m2

Prism load =P= (1920).(4) = 7680 N/m2

To obtain load in Newton per meter, multiply the above by the outside diameter of the

pipe:

W= (7680).(0,8)= 6144 N/m

The Marston load for this example is 72 percent of the prism load and is un-

conservative for design. For flexible pipe, the prism load theory represents a realistic

estimate of the maximum load and is slightly conservative.

One of the advantage of the prism load is that it is independent of the trench width.

4.4.2. Taraffic load

The influence of traffic load is calculated by applying the pressure distribution

according to the theory of Boussinesq. The most common design traffic load


64

recommended as a wheel load of 140 kN. A dynamic effect is considered represented

by an impact factor of 1.75, which is included in the load. In Figure the calculated

load pressure qtr in the pipe due to traffic is shown. The traffic from 14 ton distributed

on 2 wheels with a distance of 1.8 m. With a height of backfilling above 3 m the

contribution from traffic load to the total vertical load on the pipe is normally

neigligeable.

Figure 31: Traffic pressure with height of backfilling

4.5 Stability (Buckling) Calculations

The underground pipes are subject to various loads in addition to the load

imposed by the backfilling above the pipe. They are mainly loads like those forces that

are imposed by the ground water in case of the open sea discharge applications, even if

the piping are installed under the ground.

In addition, for the applications where two pipes one inserted into another are

used, the liner concrete for filling the space between the two pipes or pipeline

operating under vacuum for suction piping, the additional forces are encountered,

where the stability (buckling) calculations should be performed for extreme operational

conditions.

Stability (Buckling) Calculations for HDPE- pipes

2

214

10

mr

SEcPk

..

Pk: Critical denting pressure (bar)

Ec: Modulus of elasticity (N/mm²)

: Transverse thermoplastic constraint (0.4)

S: Wall thickness

rm: Average pipe radius (mm)

Allowable stability (Buckling) Calculations for HDPE-pipes

S

frPkperPk .,

Pk,per: permissible critical denting pressure (bar)

fr: Reducing factor (0.9 ...0.95) (-)

S: Safety factor (2) (-)


65

Stability (Buckling) Stress Calculations for HDPE- pipes

S

rmPkQk

Qk : Stability (buckling) stress (N/mm²)

Pk : critical buckling pressure (bar)

S : Safety factor (2) (-)

rm : Average pipe radius (mm)

4.6. Thermal Longitudinal Elongation Calculation

When used for the transportation of industrial hot waters, HDPE-pipes

elongates in longitudinal direction under effect of the heat induced.

However, if the backfill is made correctly, no longitudinal movement is

Foreseen as the compacted ground surrounding the ribs brakes any effects

of expansion.

The elongation calculation is based on the formula illustrated at the table

below, in conformity with the fluid to be transported.

Table 24: Expansion Constant of Several Plastics

Type of Plastics Linear Expansion coefficient

(HDPE) High density polyethylene

(PP) Polypropylene

(PVDF) Polyvinylidenfluorid

(PB) Polybuthadiene

(PVC) Polyvinyl chlorine

(GRP) Glass-Reinforced Plastic

0,16

0,15

0,14

0,12

0,07

0,02

TLL

Where:

ΔL: Change in length due temperature change (mm)

: Linear expansion constant (mm/m K)

L: Pipe length (mm)

ΔT: Difference in temperature (K)

ΔT is the difference between the operation temperature and maximum ambient

temperature during the installation of the pipeline.

5. HDPE PIPE CONNECTION

HDPE pipes are available to suit any kind of pipe connections, thank to the

properties of HDPE used as material of construction. The connection method of HDPE

pipes is mainly determined on the basis of field of application.


66

5.1 Welded connection

5.1.1. Electro-fusion Welding Method

The pipes connected with this method usually incorporate bell (socket) and

spigot supplemented by electro-fusion welding over outer end inner circumference of

the pipe. Special alloy welding electrodes used for electro-fusion welding are inserted

into the bell to prevent deformation and the welding machine welding leads are left

free to enable the welding operation under any working conditions.

HDPE-profiled pipes suitable for electro-fusion welding range between the

pipe sizes from ID 300 mm to ID 4000 mm.

Figure 32: HDPE-profiled pipe section indicating bell (socket) and spigot

connection supplemented by electro-fusion welding

Pipes Electro-fusion Welding Machine

The specification of welding machine used in welding of HDPE-profiled

pipes are as follows:

Output power

Input voltage

Output voltage

Operating temperatures

4kW

380 V

15-48 V

Up to 50oC

The precautions to be observed in welding operations of HDPE profiled pipes

with electro-fusion methods are given as below:

The welding area needs to be clean , dry, the welding area should be

protected against sunlight to prevent the contamination, the welding operation

should be performed in the ambient temperatures over 5ºC.

Any package material within the socket and spigot end should be removed

in advance of the welding operation. Any failure of the removal of the

packaging material in advance the welding operation would result the

contamination.


67

The portion of the pipe that will be welded should be completely treated

with cleaning agents or industrial type of alcohol prior to welding operation.

Figure33: Required tools for the electro-fusion pipe welding

The portion of the spigot that will be inserted into the socket of the adjacent

pipe should be measured prior the erection and the insertion of the pipes one

into another should be made in accordance with these measurements.

The welding point should be axial and vertical to pipe axis and without an

angle laying in the bedding. Turn the HDPE-pipe for the welding contacts are

up (at 12 o ,clock position)

HDPE-profiled pipes, bigger than DN 800 come with a pressing ring, what

needs to be installed inside, close to the welding area as indicated in the above

drawing. Wall connection will come in all dimensions more than DN 300 with

a tightening strap. Put the tightening strap in the for this made groove on the

socket, tighten it with the special toll until there is no slit between the socket

and the spigot end. If necessary, tighten it during welding.

The resistance leads must be carefully inserted into the adapter and

tightened by screwing in that way, that there is no tension from the cables

weight. It is very important, that there are no forces on the welding wire

coming from the connected cables during welding. .

The welder should insert the barcode card with the reading pen.

Start the welding with the showed instructions on the welding machine.

After welding, disconnect the welding machine and adapter from welding

wire.

During cooling down, keep the tightening strap and the pressing ring

(bigger as DN 800 mm) in place. Do not move the pipe during this time. It is

very important to keep the cooling time.

The tightness test of the pipe welding should be performed in advance the

removal of the pipe upper welding filling.

Important: During the welding and cooling time do not move the pipe at

all!


68

Table 25: Electro-fusion welding parameters

Welding Preheat Intervals

Electro-fusion Welding Parameters of HDPE-profiled

Pipes (ID 300-1600 mm)

ID

mm

Welding

Voltage

Preheat

Interval

ID

mm

Welding

Voltage

Welding Period (second) 30

oC 20

oC 15

oC 10

oC 5

oC

300 15 800 300 15 1080 1200 1320 1450 1500

400 18 800 400 18 1080 1200 1320 1450 1500

500 22 800 500 22 1080 1200 1320 1450 1500

600 25 800 600 25 1080 1200 1320 1450 1500

700 28 800 700 28 1080 1200 1320 1450 1500

800 32 800 800 32 1080 1200 1320 1450 1500

900 35 800 900 35 1080 1200 1320 1450 1500

1000 38 800 1000 38 1080 1200 1320 1450 1500

1100 42 800 1100 42 1080 1200 1320 1450 1500

1200 45 800 1200 45 1080 1200 1320 1450 1500

1300 48 800 1300 48 1080 1200 1320 1450 1500

1400 48 860 1400 48 1080 1200 1320 1450 1500

1500 48 920 1500 48 1080 1200 1320 1450 1500

1600 48 980 1600 48 1080 1200 1320 1450 1500

The preheating should be applied on the pipes to be welded, as shown in the table

above, in case of the ambient temperature of the welding location is lower than 5 ºC.

Except under extreme conditions, welding operation under the ambient

temperature below 5ºC is not recommended.


69

5.1.2. Butt Welding Method

The precautions for the welding operations on HDPE solid pipes are as

follows:

The ambient temperature of the welding location should not be lower than 5

ºC.

The pipes to be connected should have the same wall thickness, or

otherwise the difference between the wall thicknesses of two pipes should not

be higher than 10%.

Prior welding preparation, the surfaces to be welded must be ground to

remove any oxidation formed and the full contact of the welded surfaces must

be ensured.

Prior welding operation, the welding edges should be cleaned with

industrial type alcohol.

The temperature of the heating element must be in the rage of 200-220 ºC.

upper and lower limits indicated for the thinnest and thickest pipes,

respectively.

Upon the commencement of the welding operation, the tensioning of the

piping during overall quenching period must be kept constant.

The welding pressure test of HDPE pipes sanitary sewer piping according

to DIN 16961 and pressurized potable water piping should be based on DIN

4279.

Figure 34: Butt welding machine


70

The important welding parameters will be calculated as follows:

. Calculation of the welding area:

4

22 didaApipe (mm

2)

Or sdm (mm2)

A pipe : Pipe welding area (mm)

da : Outside diameter (mm)

di : Inside diameter (mm)

dm : Mean diameter (mm)

s : Wall thickness (mm)

. Calculation of welding force

pipespecific ApF (N)

F: Required welding force (N)

P specific : Specific welding pressure

for PE = 0,15 N/mm2

for PP = 0,10 N/mm2

Figure 35: Butt welding process


71

. Calculation of joining pressure

movement

n

i

nweld pAFp

)(1

P weld : joining pressure an cooling pressure (N/mm2)

An : The Sum of hydraulic cylinder area of the welding machine (mm2)

P movement: the movement pressure of the welding machine (N/mm2)

Table 26: Optimum welding parameters of HDPE pipes under 20ºC ambient

temperature

Wall

Thickness

(mm)

Bead height

(mm)

By P weld

Pre-Heating

time by

0.02 N/mm²

(sec)

Adjusting

time

(sec)

Joining

pressure

Build-up

time (sec)

Cooling

time

(minutes)

.… 4,5 0,5 …45 …5 ….5 ….6

4,5…7 1,0 45…70 5…6 5…6 6…10

7…12 1,5 70…120 6…8 6…8 10…16

12…19 2,0 120…190 8…10 8…11 16…24

19…26 2,5 190…260 10…12 11…14 24…32

26…37 3,0 260…370 12…16 14…19 32…45

37…50 3,5 37…500 16…20 19…25 45…60

50…70 4,0 500…700 20…25 25…35 60…80

5.1.3. Extrusion Welding

Extrusion welding is a manual or semi-mechanized welding process for the

joining of thick-walled parts. The pipes having plain connections without a

bell/socket can also be the extrusion welding, however, such connection type

is exclusively used for HDPE pipes within special project applications for the

fabrication of the elbow, tee and the relevant other fittings, including special

applications like manhole, tans, etc.

The extrusion welding is generally used for the low-pressure gravity pipes.

The welding quality depends upon proper weld preparation, cleanliness during

handling, heating of filler and faces to be joined. The welding factor according

to DVS 2207/4 will be achieved at least:

- Short-time welding factor for HDPE : 0,8

- Long-time welding factor for HDPE : 0,4…0,6


72

Figure 36: Extrusion welding

The extrusion welding machines, although operating with the same principle,

are two types:

Hot air spraying welding machines with electrodes

Hot air spraying welding machines spraying granular hot extrusion raw

material. This is performed (extrusion welding) on the basis of DVS -2207

standard.

Figure 37: Extrusion welding possibilities


73

The precaution of the extrusion welding operation of HDPE pipes or fittings are

as follows:

The ambient temperature of the welding location should not be lower than 5

ºC.

In no case the extrusion welds are used for gas piping and high pressurized

potable water piping.

The material to be welded and the welding electrode should be of the same

material.

The surface of the welding areas should be very clean and any surface

oxides should be removed prior the welding operation.

Table 27: DVS 2207 extrusion welding parameters

Welded Part

Material

Welding Force

(N)

Heat Rating of Hot

Air

(oC)

Quantity of Hot Air

(l/min)

HDPE 25…30 300…350 40…60

PP 25…30 280…330 40…60


74

5.2. Mechanical connection

5.2.1. Rubber sealing connection

The HDPE-profiled pipe consist of integrally formed socket and spigot, the spigot end

is designed to accommodate a gasket, which when assembled forms a watertight seal

by the radial compression of the gasket between the spigot and the socket ends.

Profiled pipes of the connection type of bell and spigot with gaskets are available in

accordance with DIN 16961 and F 894. The gaskets used within the gasket type

connections are produced from EDPM rubber under the specifications of DIN 4060

and EN 681. Standards.

Figure 38: Sectional view of bell and spigot with groove to assembly the gasket


75

5.2.2. Flange Connection

HDPE-profiled pipes are also available to incorporate the flange connections in

conformity with the specifications given under DIN 16961. This type of connection is

preferred for open sea discharge applications, tank connections, for the connections

including different materials. The major advantage of the flange connection is the ease

of the dismantling.

The flanges used for the flange connections are manufactured from galvanized

steel or stainless steel in conformity with the specifications given under DIN 2573 and

DIN 2576. The flange adapters are manufactured complete with the piping, however,

the flanges are also available as independent fitting for welding operations to be

performed at the construction site.

Flange end of the flanged pipes are manufactured either centered slip-on bell

type or plain end. EPDM rubber plain gaskets are used for the connection of the plain

end pipes, which are manufactured in conformity with DIN 4060 and EN 681. On the

other hand, centered flanged connections can accommodate either the same gasket or

the tightness is obtained by the welding operation in accordance with the electro-fusion

method applied inside the pipe without using any gasket.

Figure 39: Profiled pipe with flanged connection


76

6. Installation of HDPE/ PP Pipes

6.1 Pipe in trenches

Plastics pipes are flexible. When loaded a flexible pipe deflects and presses into

the surrounding material. The amount of deflection which occurs is limited by

the care exercised in the selection and laying of the bedding and side fill

materials.

In case of rigid pipes, the load on a pipe is borne primarily by the inherent

strength of the pipe material and when this load exceeds a limiting value the

pipe breaks. Flexible pipes on the other hand deflect under load and can be

deflected to a high degree without fracture. The level of deflection reached by a

buried pipe depends on the properties of the surrounding material and to a

much less extent on the stiffness of the pipe.

6.1.1 Choice of pipe ring stiffness

The choice of pipe ring stiffness shall made either using the below tables

according to EN 1046 or in the basis of static calculation in accordance with

ATV A 127 guidelines of German Association for water, wastewater and waste

or on the basis of previous experience. If such experience is not available then

the minimum stiffness required shall be selected from tabl 28 and table 29.

These tables are prepared to cover the following conditions:

a) Non-trafficked areas with depths cover between 1 m and 6 m.

b) Trafficked areas with depths cover between 1 m and 6 m.


77

Table 28: Recommended minimum stiffness for non-trafficked areas

Backfill

Material

Group 3)

Compaction-

Class 2)

Pipe ring stiffness 1)

For depth of cover ≥ 1 m and ≤ 3 m

Undisturbed native soil group 3)

1 2 3 4 5 6

1

W

M

N

1250

1250

2000

1250

2000

2000

2000

2000

2000

2000

4000

4000

4000

5000

8000

5000

6300

10000

2

W

M

N

2000

2000

4000

2000

4000

6300

4000

5000

8000

5000

6300

8000

5000

6300

***

3

W

M

N

4000

6300

***

6300

8000

***

8000

10000

***

8000

***

***

4

W

M

N

6300

***

***

8000

***

***

8000

***

***

For depth of cover > 3 m ≤ 6 m

1

W

M

2000

2000

2000

4000

2500

4000

4000

5000

5000

6300

6300

8000

2 W

M

4000

5000

4000

5000

5000

8000

8000

1000

8000

***

3 W

M

6300

***

8000

***

10000

***

***

***

4 W

M

***

***

***

***

***

***

1) Pipe ring stiffness in N/m2 according to ISO 996

2) See table

3) See table

**) Structural design is necessary to calculate the pipe stiffness


78

Table 29: Recommended minimum stiffness for trafficked areas

Backfill

Material

Group 3)

Compaction-

Class 2)

Pipe ring stiffness 1)

For depth of cover ≥ 1 m and ≤ 3 m

Undisturbed native soil group 3)

1 2 3 4 5 6

1 W 4000 4000 6300 8000 10000 ***

2 W 6300 8000 10000 *** ***

3 W 1000 *** *** ***

4 W *** *** ***

For depth of cover > 3 m ≤ 6 m

1 W 2000 2000 2500 4000 5000 6300

2 W 4000 4000 5000 8000 8000

3 W 6300 8000 1000 ***

4 W *** *** ***

1) Pipe ring stiffness in N/m2 according to ISO 9969

2) See table

3) See table

**) Structural design is necessary to calculate the pipe stiffness

6.1.2 Compaction degree and Methods

The degree of compaction can be varied by using different type of equipment and by

varying the numbers of layers. The table 33 gives for groups of material classified in

conformance with tabl 30 ( soil group) the degree of compaction expressed in Standard

Proctor Densities ( SPD) for the three classes of compaction W, M, and N.

Table 30: Standard Proctor Densities ( SPD) for compaction classes

Compaction

class

Description

Backfill material group

4

SPD

%

3

SPD

%

2

SPD

%

1

SPD

%

N

M

W

Not

Moderate

Well

75 to 80

81 to 89

90 to 95

79 to 85

86 to 92

93 to 96

84 to 89

90 to 95

96 to 100

90 to 94

95 to 97

98 to 100

Table 31 Gives the recommended maximum layer thickness and the number of passes

required to achieve the compaction class’s for the various type of equipment and pie

zone materials. Also included the minimum cover thicknesses required above the pipe

before the relevant piece of equipment can be used over the pipe.


79

Table 31: Recommended layer thickness and number of passes for compaction

Equipment Number of passes

for compaction

class

Maximum layer thickness,

in meters, after

compaction for soil group

Minimum

thickness over

pipe crown before

compaction

Well Moderate 1 2 3 4 m Foot or hand

tamper min. 15 kg

3

1

0,15

0,10

0,10

0,10

0,20

Vibrating tamper min.

70 kg

3 1 0,30 0,25 0,20 0,15 0,30

Plate vibrator

min. 50 kg

min. 100 kg

min. 200 kg

min. 400 kg

min. 600 kg

4

4

4

4

4

1

1

1

1

1

0,10

0,15

0,20

0,30

0,40

-

0,10

0,15

0,20

0,25

-

-

0,10

0,15

0,20

-

-

-

0,10

0,15

0,15

0,15

0,20

0,30

0,50

Vibrating roller

min. 15 kN/m

min. 30 kN/m

min. 45 kN/m

min. 65 kN/m

6

6

6

6

2

2

2

2

0,35

0,60

1,00

1,50

0,25

0,50

0,75

1,10

0,20

0,30

0,40

0,60

-

-

-

-

0,60

1,20

1,80

2,40

Twin vibrating roller

min. 5 kN/m

min. 10 kN/m

min. 20 kN/m

min. 30 kN/m

6

6

6

6

2

2

2

2

0,15

0,25

0,35

0,50

0,10

0,20

0,30

0,40

-

0,15

0,20

0,30

-

-

-

-

0,20

0,45

0,60

0,85

Triple heavy roller

( no vibration)

min. 50 kN/m

6

2

0,25

0,20

0,20

-

1,00

6.1.3 Material of pipe zone and remaining backfill

The material of the pipe zone dependent upon the pipe stiffness, the depth of cover and

the nature of the native soil. Where imported material is used for the pipe zone it is

recommended that a well-graded granular material with a maximum particle size in

conformance with Table 32 used. Where single-sized material is used it is

recommended that the maximum particle size should be one size smaller than that

given in Table 32.The native soil may be used for the pipe zone backfill providing it

conforms to all of the following criteria: a) No particles greater than the applicable limit given in Table 32

b) No soil lumps greater than twice the applicable maximum particle size given in Table32

c) no frozen material;

d) no debris ( e.g. asphalt, bottles, cans; trees);

e) Where compaction is specified, the material shall be compactable.

Table 32: Maximum particle size according to EN 1046

Nominal diameter

DN

Maximum size

mm


80

100 ≤ DN ‹ 300

300 ≤ DN ‹ 600

600 ≤ DN

20

30

40

Table 33: Soil group in accordance with EN 1046

Soil group

Soil type # Typical name Symbol Example(s) To be used as

backfill

Granular 1 Single-sized gravel (GE)

[GU]

Crushed rock, river and beach

gravel, scoria, volcanic ash

YES

Well-graded gravels, gravel-

sand mixtures

[GW]

Poorly graded gravel-sand

mixtures

(GI)

[GP]

2 Single-sized sands (SE)

[SU]

Dune and drift sand, valley sand,

basin sand

YES

Well-graded sands, sand-gravel

mixtures

[SW] Morainic sand, terrace sand, beach

sand

Poorly graded sand-gravel

mixtures zones

(SI)

[SP]

granular 3 Silty gravels, poorly graded

gravel-sand-silt mixtures

[GM]

(GU)

Weathered gravel, slope debris,

clayey gravel

YES

Clayey gravels, poorly graded

gravel-sand-clay mixtures

[GC]

(GT)

Silty sands, poorly graded sand-

silt mixtures

[SM]

(SU)

Liquid sand, loam, sand loess

Clayey sands, poorly graded

sand-clay mixtures

[SC]

(ST)

Loamy sand, alluvial clay, alluvial

marl

Cohesive 4 Inorganic silts, very fine sands,

rock flour, silty or clayey fine

sands

[ML]

(UL)

Loess, loam YES

Inorganic clay, distinctly plastic

clay

[CL]

(TA)

(TL)

(TM)

Alluvial marl, clay

Organic 5 Mixed grained soils with

admixtures of humus or chalk

[OK] Top soils, chalky sand, tuff sand NO

Organic silt and organic clay [OL]

(OU)

Sea chalk, top soil

Organic clay, clay with organic

admixtures

[OH]

(OT)

Mud, loam

6 Peat, other highly organic soil [Pt]

(HN)

(HZ)

Peat NO

Muds [F] Muds

* The symbols used are taken from two sources. Symbols in square brackets [..] are taken from British

Standard BS 5930. Symbols in round brackets (..) are taken from German Standard DIN 18196.


81

6.1.4 Type of installation

The two most commonly used practices for the installation of plastics pipes are either

to surround the pipe with the same material (see Figure 40) or splitting into two

materials (see Figure 41). The use a split embedment is normally only found to be

practical with pipes of nominal sizes greater than DN 600.

Figure 40: Trench with full surround pipe zone

1 Split level

2 Secondary pipe zone backfill

3 Primary pipe zone backfill

0,5de ≤ height ≤ 0,7 de

4 Bedding

5 Invert

Figure 41: Trench with spilt surround pipe zone

1

2

bs

1 Pipe zone

2 Bedding

2

4

1

3

5


82

6.1.5 Parallel piping systems

In case of parallel piping systems laid with a stepped trench (see Figure 42) the

pipe zone backfill material shall be granular and shall be compacted to

compaction class W.

1 well compacted (class W)

Figure 42: Parallel pipes in a stepped trench

6.1.6 Trench width

The width of the trench at the spring line of the pipe need not be greater than

necessary to provide adequate room for jointing the pipe in the trench and

compacting the pipe zone backfill at the haunches. Typical values for bs (see

table34) are given in table .

Table 34: Typical values for bs

Nominal size

DN

bs

mm

DN ≤ 300

300‹ DN ≤ 900

900‹ DN ≤ 1600

1600‹ DN ≤ 2400

2400‹ DN ≤ 3000

200

300

400

600

900


83

6.2 Application of HDPE-profiled pipes

6.2.1 Sewer and Storm Water Lines

Figure 43: HDPE Storm water pipe line in Kuwait

Bild 44: HDPE Sewer pipe line

6.2.2 Sea outfall and intake pipes


84

The effluent waters and the sanitary sewer lines are generally released to open sea

discharges. The open sea discharge of he effluent waters and the sanitary sewer lines

should be performed upon the treatment of the effluent and sanitary sewer water

through specific water treatment process to process them to be discharged to the sea to

prevent any further pollution of the sea and endangering the underground sea life.

For such critical applications, the practical and reliable solutions are permanently

provided by HDPE piping in a most economic way.

The effluent water, after being treated within the water treatment plant is discharged to

the open sea via the pipe installed on the sea bed after a final manhole installed prior

the entry of the water. Being lighter than the sea water, HDPE piping is sunk into the

water by concrete blocks fixed onto the piping at specified intervals. The piping

sections for the open sea discharge are prefabricated at 250 m to 500 m in lengths at

the sea shore, plugged with the blind flanges at the ands, floated on the sea surface and

transported at the installation location in the sea.

The floating piping sections are connected to each other onto the sea to the

interconnection points at the land. The floating pipes with the air entrapped inside are

sunk into the seabed by replacing the air with the sea water. In order to prevent the

sedimentation of the effluent water towards the end of the piping, the diffuser should

be incorporated at the discharge point. The diffuser exits are provided at 120º intervals

with respect to the pipe section. Special diffusers are provided for the critical project,

which are equipped with filters.

Figure 45: HDPE-sea outfall piping during sinking procedure


85

Figure 46: Sea intake pipelines

6.2.3 Relining

The construction of the infrastructure is proved to be difficult and time

consuming. There is always the possibility of encountering the unexpected occurrences

during the application of the project. In most cases, the installation of the pipe should

be performed within narrow and confined areas, where the excavation operations are

almost impractical.

Such problems are usually encountered during the renovation works performed within

the settlement areas, which include the demolishing of the existing building to

construct multistory buildings. In some cases, the infrastructure system must be

replaced in any event that it is out use due to the collapsing, blockage, or any other

similar reasons or becomes insufficient in capacity.

In such cases, HDPE-profiled pipes are inserted into the existing piping

systems via long pipe or short pipe relining method. Since the friction losses of HDPE-

pipes are much lower than the conventional concrete pipes, the existing concrete piping

system can be utilized via relining of profiled pipes, thus the renewal of the

infrastructure can be accomplished without any excavation operation. Consequently,

the permanent solution of the infrastructure can be achieved.

During relining operation, HDPE-profiled pipes are inserted into the existing piping

via excavating down to the beginning of the existing pipe run. The profiled pipes are

further driven via continuous driving and welding the pipes one into another. The most

important factor to have reliable operation of the system over prolonged service life is

to perform suitable lining operation by injecting concrete into the gap between the

profiled pipes and the existing concrete pipe, upon completion of the installation of

HDPE-profiled pipes.


86

Figure 47: Long pipe relining with HDPE-profiled pipe

6.2.4 Landfill drainage systems

The huge mountains of the solid waste garbage of the household disposal is a

phenomenon specific to the contemporary industrialized societies undergoing rapid

development of industry, together with the high rate of increase of the population. In

addition to the danger faced by the society due to the huge garbage wastes for human

health, the ground water resources that are eventually diminishing are under the risk of

the pollution.

The most reliable solution accepted throughout the contemporary societies and in our

country is disposing the waste solids within the waste disposal areas, collecting and

treating the leaking effluent waters, disposing or recovering the generated methane

gases within power plants. The appearance pollution is further eliminated by covering

the waste disposal areas with the water tight soil and vegetation to be provided on the

soil covered on top of the area thus insulated.

The solid wastes include many chemical substances, in addition to formation of many

chemical via decomposition. This process continues for years. Therefore, HDPE is

ideal for resisting the load imposed on the heavy garbage wastes and the chemicals

formed by decomposition.


87

HDPE pipes are reliably used under the conditions stipulated by DIN 16961 both in

collecting of the leaking effluent waters and the disposal of methane gases. The

conditions of the installation and the operation of the pipes to be used for the collection

systems are established in conformity with DIN 19677, while the tightness test and

inspections are conducted as per DIN 4266.

Figure 48: HDPE-manhole using for landfill drainage


88

6.2.6 Lined pipes

Gravity sanitary and storm sewer lines are the most common type of

underground infrastructure system installed by micro tunneling or so called

pipe jacking operation.

The pipes used for jacking is nonpressure applications as most often lined

With GRP, UPVC and HDPE-sheets. All these pipe material have a

substantial installation history in sewer application. But these methods are

prone to failure due to the disbanding of the liners used. By using a

HDPE-profiled pipes as a lining instead of HDPE-sheet due to its

excellent bonding property to concrete. Furthermore, in case of the concrete

pipe wall cracks , the HDPE profiled pipe used as liner will hold.

The jacking concrete pipes lined with HDPE- profiled pipes are manufactured

according to DIN 4032 or 4035 and with high quality guideline requirements.

The jacking pipes are being used for sewage and drainage piping system.

Figure 49: View of jacking pipes lined with HDPE- profiled pipe

Figure 50: Section of jacking pipe lined with HDPE-profiled pipe


89

6.2.6.1. Joint of the pipes

All jacking pipe should have these characteristics:

. Gasket-sealed joints are needed to facilitate rapid assembly.

. Flush joints are important (joint OD same as OD of pipe barrel) see Fig.51

. Smooth outer surface is needed to reduce jacking force.

In Spigot of the HDPE pipes is a groove with a width of 52 mm and depth to

insert the rubber seal. The seal is designed primarily for concrete pipes application.

The seal is compressed when the pipe spigot is inserted into the socket.

Figure 51: RCC pipe lined HDPE-profiled pipe with inner and outer gasket-seal

The special design of the seal gives:

. Low assembly force

. Excellent sealing capability under loads

. Watertight seal connection up to 3 bars (30 m water head)

. Good distribution

The spigot seal meets and exceeds the requirements of the new standard prEN1961.

Material:

. EPDM

. Hardness 40

. Approved in accordance with EN 681-1

. Protected against ozone

Figure 52: The outer joint with steel/GRP sleeve


90

1) HDPE liner spigot & bell type 2) Internal point in HDPE liner with EPDM sealing rubber ring.. 3) 18mm thick peaking

ring (chip wood) in between the concrete surface of two pipes. 4) Reinforcement, 1 or more steel cages according to the

requirement of the pipe dia. 5) GRP/steel sleeve for outer joint of pipes. 6) EPDM sealing rubber for outer joint of pipes. 7) Concrete.

Figure 53: Section of the joint the jacking pipe lined with HDPE-profiled pipe

6.2.6.2. Requirement and Tests

The specification, requirements and test methods for the HDPE lined RCC

jacking pipes are contain in the following standard:

1. Proof load test according to the test method BS 5911 part 120, the

result of the test should be no cracks developed in the pipe wall.

2. Ultimate load test according to the test method BS 5911 part 120, the

result of the test shall be no separation of the HDPE liner from the wall

of the pipe.

3. Cover to reinforcement according to the test method BS 5911 part

120, the concrete cover of the second steel reinforcement should be at

least 30 mm.

4. Joint water tightness test according to the test method BS 5911 part

120, the required test pressure should be 3 bars.


91

6.2.6.3. Advantages of jacking pipes lined with HDPE-profiled pipes

The advantages of jacking pipes lined with HDPE-profiled pipes over the

conventional lined materials methods (likes GRP, PVC or HDPE- sheet) as

follows:

1) Our lined pipe is one unit, without any weld ( Weak point with a liner

in the welding, welding factor from 0,8 by butt welding according to DVS

2207/1), in order to do circular shape by using HDPE or PVC-sheets.

2) HDPE-pipes have bright inner surface as yellow or any required color. This

kind of color ensures inspection friendliness.

3) The joint well be gasket rubber sealing, there are no welding. By any welding

Methods ( Extrusion welding according to DVS 2209 or warm gas hand

welding according to DVS 2207/3 or overlap welding according to DVS

2225/2) are depended on cleanliness and personals skill). The working

conditions 30 m under ground are not comfortable to do any of the above

mentioned welding methods.

4) By using HDPE-profiled pipe it is possible to do any required ring stiffness

in order to resist the under ground water pressure in case of cracks or any

damages in the wall of the concrete pipe.


92

7. HDPE PIPE STORAGE AND TRANSPORTATION

HDPE pipes and manholes should be handled carefully during the transportation and

storage. Since they are elastic in nature, they are mostly effected from impact loads,

rather than falling on the ground or rolling over. To this effect, the following

precaution should be observed for the storage, loading and transportation of HDPE

profiled pipes.

7.1. Storage Methods

Figure 54: Stockpiling and Telescopic Storage

HDPE profiled pipes should be stored away from the direct sunlight,

preferably under the shelter or enclosed areas.

Prolonged storage within warm and completely enclosed places should be

avoided.

Maximum period of storage under direct sunshine is half year.

The storage area should be free of sharp and hard objects like stones, etc.

The relevant measures should be observed within the storage area, since the

material of construction of HDPE pipes is combustible.

Stockpiling of pipes stored in telescopic method should be avoided.

Telescopic pipes should not be stockpiled.

Up to 3 crosswise stockpiling is permitted for the pipes up to ID 600 mm.

The bells of the pipes should be alternatively placed during stockpiling.

Up to 2 crosswise stockpiling is permitted for the pipes between ID 600 mm

to ID 1000 mm. The bells of the pipes should be alternatively placed during

stockpiling.

No stockpiling is permitted for the pipes over ID 1.000 mm.


93

7.2. Transportation Methods

HDPE profiled pipe pipes are packed to protect the bell and spigot ends of

the pipes. Care should be exercised to prevent the welding edges within the bell

and spigot.

HDPE profiled pipes are available as standard in 6 mm lengths.

The lifting ropes should be used for the loading and installing into pipe

trench. They should be simultaneously hanged on both hands with textile ropes.

The handling with fork lifts should be performed carefully to extend the

forklift legs outwards as much as possible, avoiding hard impacts.

The end of the pipes are accurately machined to avoid any problem during

the welding operation at site, therefore, care should be observed during the

handling of the pipe to prevent damaging of the ends of the pipe, pipe ends

should be carefully rested onto the vehicle box during loading.

The precaution should be observed to prevent the side stays of the vehicle

box to induce any damage on the pipe, textile ropes should be used to clamp the

pipe on the box of the vehicle, tied at the middle and end of the pipe.

In no case the loads are carried away by pulling the pipe on the ground,

they should be roller over on smooth surfaces without inducing any damage to

the pipe.

Care should be exercised to prevent abrasion of the pipes during the

inserting the pipes one into another for telescopic loading. The bell portions

should be located at alternate locations. The protection of welding edges at the

pipe ends should be exercised.

The bells of the pipes should be alternatively located onto the vehicle.

The simultaneous installation of the pipes having different pipe sizes at the

construction site will allow telescopic loading that greatly contributes to the

transportation. This should be taken into consideration during the working

scheduling of the site construction.


94

8. HDPE PIPE MANUFACTURING AND QUALITY CONTROLL

Profiled pipes manufactured from HDPE and PP feature high quality levels. All

tests anticipated within the relevant standards are implemented at every stage of the

production starting right from the introduction of the raw materials. The results of the

tests are continuously monitored and the relevant documentation regarding the welding

operations performed both by us and by the end user is taken into consideration. The

service life of HDPE-profiled pipes which are proved to be successful during the tests

performed for 1 minute, 24 hours and 2000 hours as per DIN 19537 is 50 years

minimum.

8.1. Test Methods of HDPE-profiled pipes

The following monitoring and tests operations are performed on profiled pipes

performed at every stage of the production starting right from the introduction of the

raw materials are as follows:

a) Raw materials test and relevant standards

The raw material and any other new delivery of material is tested before it is stored.

Every test is documented and filed. The following tests are required or from raw

material supplier submitted for each new HDPE incoming raw material:

Table 35: Characteristic of HDPE raw material Characteristic Test Method Requirements Responsibility

1 Density ASTM D1505

ISO 1183

≥941 kg/m3 Raw Material Manufacturer

2 Modulus of elasticity @ 23oC EN/ISO 527-2 ≥ 800 N/mm

2 Raw Material Manufacturer

3 Modulus of elasticity @ 40oC EN/ISO 527-2 ≥ 650 N/mm

2 Raw Material Manufacturer

4 Tensile strength at yield @ 23 o

C

and 50 mm/min

ASTM D638

ISO 6259

≥ 21 N/mm2 Q.C. Laboratory

5 Elongation at break ASTM D638 ≥ 350 % Q.C. Laboratory

6 Thermal Stability @ 200oC (OIT)

Oxidation Induction Time

EN 728/

ISO 10837

≥ 20 minutes Q.C. Laboratory

7 Vicat Softening temperature under

1 kg

ASTM D1525

ISO 306

≥ 120oC Raw Material Manufacturer

8 Shore hardness type D ASTM D2240 ≥ 60 Q.C. Laboratory

9 Melt flow rate ISO 1133 0,4…0,6 g/10min Q.C. Laboratory

10 Coefficient of linear expansion ASTM D1204 0,16…0,2 mm/m. K Raw Material Manufacturer

11 Coefficient of thermal conductivity DIN 8075 ‹ 0,6 W/m K Raw Material Manufacturer

12 Flexural creep modulus ASTM D790

ISO 527

≥ 758 N/mm2 Raw Material Manufacturer

13 Resistance to liquid Chemical ISO 4433 As per standards Raw Material Manufacturer

14 Resistance to internal pressure with

hoop stress 3.9 Mpa at 165 h at

800C

EN 921 No failure Q.C. Laboratory

15 Resistance to internal pressure with

hoop stress 2.8 Mpa at 1000h at

800C

EN 921 No failure Q.C. Laboratory

16 ESCSR (Environmental Stress

Crack Resistance), FNCT (Full

Notch Creep Test)

ASTM D1693

ISO 16670

› 600 hours Q.C. Laboratory

17 U.V. Stabiliser ( Carbon Content) ISO 13477 ≥ 2 % Raw Material Manufacturer

18 Long Term Chemical resistance for

10000h

ASTM D3262 As per standards Raw Material Manufacturer


95

b) Product test and relevant standards

After production, the final product should be tested and compared to the requirements

of the customer. The required tests as follows:

Table36: Characteristic of HDPE-profiled pipes:

Characteristic Test Method Requirements Frequency

1 Pipe dimensions EN 13476-1

DIN 16961

As per standards Every 100 pipes

2 Marking and color EN 13476-1 As per standards Every pipe

3 Appearance and surface finish EN 13476-1 Visually inspected, internal

surface shall be smooth and

external surface shall be clean

and free from grooving or any

other surface irregularities

Every pipe

4 Pipe stiffness at 23oC for 5% and

10% deflection

ASTM D2412 - Every 1000 pipes

5 Ring stiffness EN/ISO 9969 Per standard 13476-1 Each size every 300

pipes

6 Impact resistance EN 744 No cracks or deformation Every 1000 pipes

7 Ring flexibility EN 1446 No cracks Every 600 pipes

8 Oven test (resistance to heating) ISO 12091 No cracks Every 600 pipes

9 Longitudinal bending test WIS4-35-1 Sag ≤ 5% Every 1000 pipes

10 Creep ratio EN/ISO 9969 ≤ 4% Once every year

11 Tightness of electro-fusion joint DIN 16961 No leakage Once every year/size

12 Tightness of elastomeric sealing ring

joint

DIN 16961

EN 1277

No leakage Once every year/size

13 Resistance to combined temperature

Cycling & External loading

ISO 1437 ≤ 9% vertical deflection Once every year

b) Application test and relevant standards

During the install of the pipes and after finishing the following tests are required:

Table 37: Characteristic of HDPE- pipeline

Characteristic Test Method Requirements Frequency

1 Tightness test of sealed or

welded joint

DIN 16961

EN 1277

No leakage at 500 mbar Once every day

2 Deformation test ATV A127 ≤ 3% after 24 hours Once

3 Backfilling compactness test Once every day


96

9. HDPE Pipe Sample Purchase Tender

9.1. SUBJECT This technical specification defines the technical and physical properties of sanitary sewer piping

manufactured from HDPE piping to be used gravity piping within sanitary sewer pipeline. We

recommend the following tender texts.

9.2. GENERAL PROVISIONS

1. The diameters specified for profiled HDPE piping shall refer to internal pipe

diameter. The pipe sectional view and the relevant definitions are as follows.

2. The pipes with ID 300 mm to ID 4000 mm shall be manufactured in 6.0 m in

lengths, excluding the length of the bell, in accordance with DIN 16961 Part 1 and

Part 2 and ASTMF-894 standards.

3. The material of construction to be used in manufacturing of piping shall be black PE

4. The internal surfaces of the pipe shall be in light colors via co-extrusion technology

to facilitate ease of inspection.

5. During extrusion the spiral band is curled on a winding tool and melted together by

overlapping. At the same time the reinforcement profile is extruded and exactly laid

over the lap joint of the band so that together with the bad the profile forms a

homogeneous pipe wall.

6. The specified material specifications shall be complied during the test and inspection

to be conducted upon the completion of the manufacturing. In addition to the

relevant standard for the tests, the equivalent international standards for the raw

material and the final products shall be also referred. In such case, the

manufacturing shall be performed in conformity with the standard referred.

7. The squareness of the pipe edges shall be within the specified tolerances, pipe

surfaces shall be free of any swelling and gaps, the texture shall be homogenous.

The minimum tolerances shall be complied during the test performed on the pipe

walls for the wall thickness. The pipes shall be free of any kind of defects like sharp

edges, burrs, etc.

8. The bell and spigot wall thickness shall be in conformity with the specified

dimensional tolerances, the wall thickness shall be homogenous. The allowance

between the outer diameter of the spigot and the inner diameter of the bell shall be

2 mm maximum. In order to ensure the smooth joining of the pipes, the end of the

bell and the spigot shall be cut at 45º in opposite directions, respectively.

9. The pipes shall be manufactured suitable for the electro-fusion welding, via inserting

the welding wire or by sealing joint by inserting EPDM gasket into the groove of

the spigot end without any damage induced onto the bell or spigot of the pipe.

The manufacturer shall supply the parameters for the welding operation.


97

9.3. MATERIAL TESTS

The following test shall be conducted during the inspection and the acceptance test of

HDPE pipes. These tests shall be performed in the manufacturer’s laboratory. Any

other tests that cannot be performed by the manufacturer shall be made by the

independent party to be approved by the client. If required, the client shall be entitled

to have the test performed by an independent testing party.

1. Raw Material Tests

HDPE Pipe

Specifications

Required Test Method

Material

Pipe Outside Color

Pipe Inside Color

Density of Raw Material

Melt flow rate (190/5)

Tensile Strength

Elongation

Amount of Carbon Black

HDPE PE 80 or 100

Black

Light color or Black

≥ 0.94 grams/cm 3

0.3 – 0.50 gram/10min

≥ 21 MPa

≥ 350%

2 – 3%

ISO 1183 & ASTM D1505

ISO 1133

ASTM D 638

ASTM D 638

ISO 6964

2. Product Tests

Tests Required Test Method

Dimension & Tolerance

a) Internal diameter of pipe

b) Length of pipe

c) Profile height

d) Pitch of profile

e) Waterway wall thickness

Ring Stiffness

Impact Test

Ring Flexibility

Tightness Test

a) Electro fusion joint

b) Electrometric

sealing ring joint

As per standard

SN2,SN4,SN8 kN/m2

No Cracking

30%

No leakage

DIN 16961

ISO 9699

EN 744

EN 1446

EN 1277


98

10. HDPE-profiled pipe and manhole questionnaire

10.1 Questionnaire for bueied pipes

Technical questionnaire for design calculations of the pipes as per ATV 127

standard

1. PROJECT

Date

Site address

Contractor

Person in charge of the project

Phone

2. PROFILED PIPE

Profile pipe (PF)

DW- pipe (DW)

Solid wall pipe (SW)

3. PIPE LOADS

Fluid

Density of fluid

Average temperature

Operating pressure

Service life

Traffic load

Other loads

ground water

Level of ground water

Fax

......Pipe ID:.....mm

......Pipe OD:.....mm

......Wall thickness (s):.....mm

................................................

... g/cm3

Maximum working Temperature (Tmax)...... oC

.....bar (gravity pipe, if not given)

50 years

No ,HLC 60,.HLC 30, HGV 12

.....kN

Yes/ No

......m from invert of the pipe


99

4. INSTALLATION DATA

Pipe trench: Trench width (b):…………mm

Trench inclination () ……mm

Cover height (h)…………..mm

Height above the pipe (h)

Pipe installation conditions

Bedding conditions

A1 B1

A2 B2

A3 B3

A4 B4

Laying angle 2 ......... 120o

180o

Note: Recommended figure 180º others:....

Bedding form: loose firm

5. Soil Conditions

Group

G1 – loose (sand, gravel)

G2- lightly bonded (sand, gravel)

G3 – mixed land bonding, muddy

G4- clay, wet clay

Degree of compacting 90% - 100%,

Dpr% ………………..%

E1

G1

G2

G3

G4

E2

G1

G2

G3

G4

E3

G1

G2

G3

G4

E4

G1

G2

G3

G4


100

10.2. Manhole Questionnaire

Technical questionnaire for design calculations of HDPE manholes

1. PROJECT

Date :

Site address :

Contractor :

Person in charge of the project :

Phone :

Fax :

2. FABRICATION DATA

Manhole ID : …………….mm

Installation depth (h1) : ………………mm

Manhole pipe length (h2)

Level of ground water (hw)

Working width (bA)

Density of bedding material

Manhole material HDPE /PP

3. SOIL CONDITIONS

Bedding Existing Soil

Soil class

Degree of compactness

(Proctor density)

G1, G2

………………….%

G1, G2, G3, G4

4. TRAFFIC LOADS

On the lid Near manhole lid

No traffic load

HLC 30

HLC 60

HGV 12


101

5- MANHOLE LID

6- FUNDATION

7- CONNECTION /INLET AND OUTLET PIPES

Diameter Wall Thickness Position

1. pipe ………… mm …………..mm ………o

2. pipe ………… mm …………..mm ………o

3. pipe ………… mm …………..mm ………o

4. pipe ………… mm …………..mm ………o

8- Details on construction

Thickness of concrete foundation plate …………………………………..mm

Diameter of Concrete foundation Plate ………………………………….mm

Concrete Filling Height ………………………………….mm


102

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