Technical Guide Wavin PVC Pressure Pipe Systems

Waste water drainage
TECHNICAL MANUAL
Wavin PVC Pressure

Pipe systems
PVC Pressure Pipe systems Product and Technical Guide 1

Contents
1. Materials for water distribution page 4
1.1 Classification of plastics for piping systems page 4

1.2 Standard Dimension Ratio SDR page 5
2. General material properties page 6
2.1 Polyvinylchloride PVC-U page 6

2.2 Chemical resistance page 6
2.3 Technical data page 7
2.4 Features & Benefits page 8
3. Apollo bi-axial PVC-O page 9
4. Standards & Regulations page 11
5. Product range page 13
6. Installation page 15
6.1 Rubber ring jointing page 15

6.2 Solvent cement jointing page 17
6.3 Connections page 21
6.4 Flange type connection page 22
6.5 Threaded or adapter joints page 23
6.6 Fixing page 27
6.7 Installation of Apollo page 28
2 PVC Pressure Pipe systems Product and Technical Guide Phone. +31(0)38 42 94 951
7. Design of water supply pipelines page 31
7.1 Piping design, pipe arrangement, linear expansion calculation page 33

7.2 Longitudal expansion and contracting of plastic pipes page 35
7.3 Hydraulic flow:Frictional losses page 36
7.4 Water flow diagram page 37
7.5 Pressure variations page 38
8. Laying instructions page 39
8.1 Pressure testing page 40
9. Anchorage page 42
10. Handling & Storage page 45
11. Notes page 47

1. Materials for water distribution
1.1 Classification of plastics for Procedure example, common PE pipe materials.

piping systems At different temperatures, different They have a MRS of 10 MPa. They are
internal pressures (= circumferen therefore called PE 100 in accordance
The development of plastics used in gas tial stress in the pipe wall) are applied with the new system.
and water distribution is continuous. In to the specimens. The (load) duration
recent years outstanding progress has until break is determined. The respec- Unlike the existing classification methods
been achieved. tive breaking stress is applied over the based upon the dimensional stress and
appropriate load time. This results in the the safety coefficients (sometimes dif-
The creation of new material types with load duration graph. ferent in each nation), the new system
increased strength, higher property con- refers to a uniformly determined mate-
sistency and at the same time good The circumferential stress values for rial parameter. This eliminates earlier
or better processability are paramount. 20C are extrapolated to 50 years accor- misunderstandings due to the different
Moreover, European standardisation ding to ISO/DIS 9080 and lead to starting points.
already shows the first conceivable
effects in as far as classification systems LTHS anticipated value, 50 years
the From classification to
come into use today, with subsequent (Long Term Hydrostatic Strength), application
lasting influences on pipe construction
the 97.5 % LCL (Lower Confidence
with plastics (prEN 1555, prEN 12201, Limit). The MRS value represents the long-term
EN1452). circumferential stress in the pipe where
This LCL value is categorised in accor- the break may occur after 50 years at
The starting point for the new classifica- dance with the Renard series of numbers the earliest. The calculation stress ss is
tion system according to ISO 12162 and (R10 or R20 in accordance with ISO 3 applied for dimensioning of the piping
EN 32162 is the long-term behaviour of and ISO 497). The calculated LCL value network. This is calculated from:
the respective material under internal is reduced to the next lower Renard
pressure. For this purpose, values are number. This results in the required MRS MRS
obtained with a pipe-type specimen fil- (Minimum Required Strength). s = ----------
led with water at different temperatures C
and evaluated by means of the Standard This MRS value in MPa is the basis with C= total operating coefficient.
Extrapolation Method in accordance for the classification. The MRS value
with ISO/DIS 9080. multiplied by 10 results in the The total operating coefficient replaces
classification of the material. As the classical safety coefficient and
considers the facts of application, the
installation conditions etc.
Within the course of harmonisation of 1.2 Standard Dimension Ratio SDR The relation between the SDR geo-
standards in Europe, uniform guideli- metrical code and the maximum
nes were also created by defining the In the relevant regulations for plastic permitted internal pressure in the pipes
minimum applied total operating pipes for distribution, specific pipe important for the user is produced from
coefficient. For PE materials primarily dimensions have been fixed based on the equations:
used in the distribution industry, the the pipe outer diameter and the pipe
minimum values for C are as follows: wall thickness in accordance with the u= p x (da e) / (20 x e)
respective pipe series. At the same time, and
each pipe series is geometrically defined
Material C by the SDR code = Standard Dimension v = u zul.
PVC-U <--> PVC 250 2.0 Ratio, whereby: The following equation:
PVC 315 1.6
PVC-O <-->
PVC 355 1.6 SDR = d / e SDR = 20 x (zul./p) + 1

PVC 400 1.6 If one defines, based on the PE tensile
PVC 410 1.4 or properties for the life span of 50 years
PVC 500 1.4 for example,
SDR = 2[s] +1
The responsibility of selecting the C zul.= MRS/C
factor to be applied lies with the plan- to calculate [s]: The following relation is produced:
ning engineer, who can/must also apply
higher values after taking into conside- outside diameter - wall thickness
ration all relevant operating and ambient [s] =
conditions. 2 x wall thickness
The essential pipe series used for gas SDR = (( 20/p) x (MRS/C)) + 1
and water distribution are described by
the pipe outer diameter d and the pipe As alternate you can use
wall thickness e.
outside diameter
SDR =
wall thickness
or
OD
SDR =
e

2. General material properties
2.1 Polyvinylchloride PVC-U From 2006 onwards Wavin replaced the nated hydrocarbons, nitro compounds,
tin stabilizers by a biological stabilizer some petrol/benzine mixtures, and simi-
Polyvinylchloride is more commonly to further improve the efforts in enviro- lar solvents which lead to a marked
known by its abbreviated name PVC. It mental care. swelling and softening of the material.
is the oldest and most common plastic, Consideration should also be given to
being used in many branches of the 2.2 Chemical resistance the effect of the fluid on the rubber
industry as well as in daily life. Contrary ring. Unless otherwise specified, rings
to popular belief, this plastic that comes PVC-U is resistant against most acids of natural rubber will be supplied. Rings
from the thermoplastic group is easily and alkalis. As a result, it is also used compounded in neoprene and styrene
cementable, fusible, repeatedly reshape- for storage and transport of aggressive butadiene are also available.
able under heat, and highly recyclable. media. That is why, PVC-U is preferred
Scrap PVC may be recycled. in pipe constructions like: Natural rubber gaskets are generally
resistant to most inorganic chemicals,
PVC is made by polymerising vinylchlo-
Drinking water main lines including acids, alkalis including salts,
ride, a gas-like monomer. Drinking
water supply lines together with organic acids, alcohols,
Discharge
lines
Wavin pipes, fittings and valves for buried ketones and aldehydes. They can
Irrigation
lines
pipelines and for installations of drin- be attacked by ozone, strong acids,
Plant
construction
king water systems are manufactured Piping systems for the industry oils, greases and many hydrocarbons

from PVC-U (PVC unplasticized) without however.
softener and without fillers. For indu- Plastic pipe systems are ideal for trans-
strial applications, besides PVC-U, even porting a wide variety of chemicals and Where soil conditions are unknown or
PVC-C (PVC rechlorinated) is used. are widely used in industries where con- known to be harmful, a soils analysis
PVC-C is distinguished by a higher veyance of highly corrosive liquids and should be carried out to determine any
temperature resistance and is exclusi- gases require products with excellent likely contaminents or talk directly to
vely solvent cemented. corrosion resistance. Wavin.
To enable working on extruding, calan PVC pipe systems have outstanding Wavin provides extensive technical sup-
dering and injection moulding machines, resistance to a wide range of chemical port and will be pleased to assist when
additives should be added to the PVC- reagents at temperatures up to 50 C. doubt exists over a products suitability.
U. They are lubricants and stabilizers;
moreover, if the product should be dyed, In general PVC is suitable to convey
then pigments should be added. The most strong acids, alkalies and aque-
total of all additives is below 5 %. ous solutions (except those which are
strongly oxidising), aliphatic hydrocar-
PVC-U fittings and valves are dark grey bons, fluorides, photographic and pla-
in color, in accordance with RAL 7011. ting solutions, brine, mireral oils, fats
and alcohols. The suitability of a PVC
Additives pipeline for conveying a given chemical
will depend on such factors as: the con-
Metal stabilizers are used for protection centration of the chemical in the fluid to
against thermal decomposition during be conveyed, flow rates, the presence of
treatment and against the effects of UV pockets or dead spots in the pipeline
radiation. Wavin uses tin stabilized PVC and other factors.
for manufacturing fittings and valves.
This ensures that the products can be PVC should not normally be used with
used worldwide in the food industry, aldehydes and ketones, ethers, cyclic
for example, drinking water applications. ethers, esters and aromatic and chlori-
2.3 Technical data Identification PVC dimensions
Wavin pressure pipes bear the following In the pipe industry there are two dif-
Wavin PVC-U pressure pipes are in signs: ferent ways to indicate the dimension.
accordance with EN 1452. The pipes One is the DN size (nominal diame-
are manufactured from unplasticized Wavin, material, nominal size, nomi- ter), which is used for iron pipes. The
PVC and are subject to the technical nal pressure, date of manufacture (day, second one is used for the plastics
delivery conditions for PVC-U pipes of week, year), quality mark, standard num- industry which is OD (outside diameter).
the Gtegemeinschaft Kunststoffrohre ber, machine number. The next table indicates the OD sizes
e.V., Bonn. against the DN size for PVC pipes.
Example:
Colour: Wavin, PVC, DN100, PN 10, 1.14.06, DN OD
Dark grey in accordance with RAL
EN 1542, 57 40 50
7011.
50 63
In accordance with the DVGW (=DIN) 65 75
agrment certificate Wavin pipes bear 70 -
the following register numbers: 80 90
100 110
125 125
K 026 up to DN 40 PN 10 and PN 16 125 140
K 027 from DN 50 up to DN 150 PN 10 and PN 16 150 160
K 028 from DN 200 up to DN 400 PN 10 and PN 16 (up to DN 300) 150 180
200 200
Technical data for PVC pipes: Typical Values 200 225
Designation: PVC Unit Test Method: 250 250
Density 1410 kg/m 3
ISO 1183 250 280
Modulus of elasticity 300 315
(1 mm/min.) 3000 MPa ISO 527 350 355
Melt index g/10 min ISO 1133 cond. 18 400 400
Linear coefficient of 400 450
thermal expansion 0.7x10
-4
K
-1
VDE 0304 500 500
Specific heat 1.0 J/g K Calorimetric at 23 C 500 560
Thermal conductivity 0.15 W/m K DIN 52 612 at 23 C 600 630
Min. radius of curvature 300 x dy * at 20C
Environmental technical properties Wavins pressure pipes and fittings are tested
and approved according to The Environmental
Agencys demands and found suitable for con-
ducting potable water in water supply systems.
Chemical resistance Refer to DS/ISO DATA 7 Unplasticized

polyvinyl chloride pipes and fittings. Chemical
resistance with respect to fluids.
*dy = outside diameter of plastic pipe

2.4 Features & Benefits Features and benefits Meeting all requirements
Wavin PVC-U pipes and fittings meet
PVC-U pressure pipes and fittings are High
reliability and proven service all the major European standards like
manufactured from unplasticised poly- performance DIN8061/62, ISO4422, EN1452, etc.
vinyl chloride polymer which is a ther- PVC-U pipes and fittings are the Product and material certificates offer
moplastic material commonly used for preferred piping material world-wide the customer the highest level of qua-
potable water distribution, irrigation for potable water supply and lity and reliability. (See 5. Standards
systems and sewer mains. distribution pipes. &Regulations.)
Complete
plastic system
The high strength to weight ratio, toge- Extensive range of pipes and fit- Special projects
ther with exceptional resistance to cor- tings. A specialised team within Wavin is dedi-
rosion makes these pipes ideal for major Smooth
bore, free from cated to supplying all required pro-
infrastructure applications. incrustations ducts for large-scale pipe projects;
Maintaining a smooth internal Wavins own products can be com-
Range surface, preventing the build-up of bined with those of other manufacturers
The lightweight pipes and fittings are deposits. Minimum maintenance to supply a complete package to the
available in diameters from 16 mm - required. customer. This team is experienced
630 mm and in pressure classes ran- Corrosion
resistant in arranging very large quantities of
ging from PN 6 to PN 16. Also unique Durable and complete plastic product right on time to complex
tensile resistant couplers are available system with smooth internal bore. construction projects. Upon request
(up to 630 mm). The PVC-U pressure Light
weight technical advice and training can be
pipes are available in socketed and plain Which makes it easy to handle and offered by Wavin experts to assist in
ended lengths. They can be jointed in install, resulting in reduced laying these projects.
various ways. (See installation). costs.
Reliable
and durable
Both, the easy rubber ring push-fit
system and solvent cement ensure
a tight and durable connection.
Safe
for potable water supply
PVC-U is proven to be one of the
most reliable and safe piping
materials for potable water.
Effective
rubber ring seal joint
Reduced jointing effort and
improved reliability.
High
chemical resistance
Fields of application Wavin PVC-U pressure pipes and
The PVC-U pressure pipes and fittings fittings are resistant to a great
from Wavin are suitable for the following number of chemical agents.
applications:

potable water distribution systems
industrial
process pipelines

pressure sewer
effluent
pipelines

slurry pipelines
irrigation
and watering systems
3. Apollo bi-axial PVC-O
Features and benefits Meeting all requirements

High
burst strength Published standards on Bi-axially
Increased material strength allows oriented PVC-U are:
reduced wall thickness and therefo-
re a reduced pipe weight per metre. - British specification WIS 4-31-08
High
impact strength (1991)
Provides better protection against - Dutch water industry specification
damage during storage, handling BRL-K 565/01 (1998)
The Apollo pressure pipe is the result and installation than conventional - ISO Standard ISO 16422
of several years of research by Wavin PVC-U pipes. - ASTM F1483
to develop a fully Bi-axial oriented PVC esistance to low temperatures
R - Draft AZ/NZS 4441
pipe based on the proven properties of The increased toughness allows
PVC-U. Apollo not only offers a pipe- pipe installation at temperatures Absolutely superior!
line material with increased strength down The Apollo pipe from Wavin is produced
and increased toughness over standard to -20 C. by an unique patented in-line process.
PVC-U and polyethylene, but also a Resistance
to point loading Apollo is the first pipe to be successfully
much-improved ductility and therefore The layered wall structure of Apollo oriented in line, in both the hoop and the
pipe performance. This new material reduces the chance of premature axial direction manufactured by a conti-
provides a water distribution pipe that failure under point loading conditi- nuous process.
is substantially tougher and lighter in ons.
weight. Apollo has been developed spe- Light
weight The orientation process is based on the
cifically for potable water pressure distri- As less material is used, Apollo concept of stretching molecules to pro-
bution systems. pipes are not only lighter than the duce a true laminated wall structure, sig-
equivalent PVC-U pipes but are nificantly increasing mechanical strength
Range seven times lighter than ductile iron. and material toughness. (See figure 1).
Apollo is available in 10 bar, 12.5 bar and Thus an absolute winner in ease of
16 bar from 110 mm to 400 mm in diame- handling and installation.
ter. The pipes are coloured blue or cream Improved
flow performance
and Apollo is also available in black for The reduced wall thickness of
buried non-potable applications. Apollo Apollo pipes results in a larger bore
pipes are produced plain ended or compared to an equivalent PVC-U
with integral sockets. The Apollo pipes pipe.
have an effective length of 6 metres. The flow capacity is improved by Figure 1. Mono-axial and Bi-axial
Other lengths are available on request. approximately 5%. Orientation
Joint
integrity
A full range of standard PVC-U and The Apollo on-line consistent The increased strenght of Apollo is a
ductile iron fittings is available to com- socketing process with factory fit- direct result of the fact that oriented
plement the Apollo pipes. ted ring seal, eliminates the risk of molecules can take more load.
ring
Fields of application displacement during jointing.
Apollo is applicable for potable water Excellent
hydraulic characteristics
pressure distribution systems. Apollo The non-corrosive smooth bore
can also be used for buried non-potable maintains the excellent flow
applications such as grey water, irriga- properties.
tion and sewer pumping mains. Improved properties against
surge and fatigue Figure 2. Increased Strenght of Apollo

Product details
Apollo has been designed as a 10 bar
pressure pipe system operating with a
safety factor of 1.6 and a 16 bar pres-
sure pipe system operating with a safety
factor of 1.4.
As a thin walled pipe system, pipe stiff

ness is an important design considera-
tion. Plastic pressure pipes must have
a minimum stiffness of 4kPa. Stiffness is
calculated using the following information:
Et3
S=
12D3
E modulus
t wall thickness
D mean diameter Apollo socket Apollo ring
Apollo sockets are manufactured on- The Apollo ring seal, shown below, has
Therefore to achieve 4kPa, a minimum line by a process which supports the been specifically designed for use with
wall thickness equivalent to SDR41 is socket internally, preserving hoop as molecular oriented PVC-O, providing
required. well as axial orientation in the socket. a combined lip and compression seal
This method ensures the consistency of which is firmly locked inside the pipe
PRODUCT SPECIFICATION socket size and eliminates the risk of ring socket (see below).
Diameter Wall Thickness SDR displacement during pipe jointing.
(mm) (mm) When two pipes are pushed together,
110 2,7 37 The Apollo process allows optimum the rubber sealing element is designed
160 3.9 41 balance between hoop and axial to deform, creating a sealing pressure
200 4.9 41 stretching to maintain wall thickness acting on both the socket and spigot.
250 6.1 41 throughout the socket.
315 7.7 41
400 9,8 41
Figure 3: Product specifications.
Sealing Element Reinforcement Element

The flexible EPDM section acts The polypropylene rein-
on both spigot and socket for forcement bonded to the
maximum joint security. EPDM section holds the
seal firmly in place.
Figure 4: The Apollo ring seal.

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

The harmonisation of European standards
is one of the key achievements of the
common European market. Technical
regulations and national standards are
no longer allowed to restrict the free
exchange of goods and services.
In the CEN (Comit Europen de Nor

malisation) committees, users national
associations/ organisations and manu-
facturers have come together to create
uniform European standards. These CEN
Standards will become imperative for all
members of the European Community as
well as for the EFTA States who voted in
its favour. They may then not be overruled
by a national standard.

List of relevant standards PVC-U pressure pipe systems
ISO 2045 Minimum insertion depth for push-fit sockets

ISO 2536 Flange dimensions
ISO 3460 PVC adapter for backing flange
ISO 3603 Leak test under internal pressure
ISO/DIN 4422 PVC pipes and fittings for water supply
EN 1452 Plastic pipelines for water supply (PVC-U)
EN 1456 Buried pressure drainage and sewage pressure lines (PVC-U)
EN 1295-1 Structural design of burried pipelines undervarious conditions of loading
DIN 2501 Part 1 Flange, connection dimensions
DIN 3441 Part 1 PVC valves; requirements and testing
DIN 3543 PVC tapping valves, dimensions
DIN 4279 Part 7 Internal pressure test of PVC pressure pipelines for water
DIN 8061 Part I PVC pipes; general quality requirements
DIN 8062 PVC pipes; dimensions
DIN 8063 Part 4 Pipe joints and piping components for PVC pressure pipelines; adapters, flanges,
seals, dimensions
DIN 8063 Part 5 Pipe joints and piping components for PVC pressure pipes; general quality
requirements, tests
DIN 16450 Fittings for PVC pressure pipes; designations, symbols
DIN 16929 Chemical resistance of PVC
DIN 19532 PVC pipelines for drinking water supply
KRV A 1.1.2 Push-fit joints on PVC pressure pipes and fittings, dimensions, requirements, test
KIWA BRL K 603 Plastic gate valves of nominal sizes from 25 mm through 150 mm
KIWA Quality Specification No. 53 Couplings and fittings of unplasticized polyvinylchlorid for water pipes
KIWA Criteria Nr. 23 Injection moulded PVC-fittings with flange connections
KIWA BRLK 2013 Rubber rings and flange gaskets for potable and foul water pipe connections
EN 681 Seals (water)
WIS 4-31-07 Specification for emplasticized PVC pressure fittings and assemblies for
cold potable water (underground use)
5. Product range
PVC-U pipes PN 10 - PN 16 (EN 1452)
Nominal (minimum wall thickness)

Pipe series S
S 12,5 S 10 S 8 S 6,3
(SDR 26) (SDR 21) (SDR 17) (SDR 13,6) PVC-U solvent cement
Nominal pressure PN based on service (design) coefficient C=2,5

DN PN 10 PN 12,5 PN 16
12 x x x x
16 x x x x
20 x x x 1,5
25 x x 1,5 1,9
32 x 1,6 1,9 2,4 PVC-U rubber-ring joint
40 x 1,9 2,4 3
50 x 2,4 3 3,7
63 x 3 3,8 4,7
75 x 3,6 4,5 5,6
90 x 4,3 5,4 6,7

Nominal pressure PN based on service (design) coefficient C=2,0
DN PN 10 PN 12,5 PN 16 PN 20
110 4,2 5,3 6,6 8,1
125 4,8 6 7,4 9,2
140 5,4 6,7 8,3 10,3
160 6,2 7,7 9,5 11,8
180 6,9 8,6 10,7 13,3
200 7,7 9,6 11,9 14,7
225 8,6 10,8 13,4 16,6
250 9,6 11,9 14,8 18,4
280 10,7 13,4 16,6 20,6
315 12,1 15 18,7 23,2
355 13,6 16,9 21,1 26,1
400 15,3 19,1 23,7 29,4
450 17,2 21,5 26,7 33,1
500 19,1 23,9 29,7 36,8
560 21,4 26,7 x x
630 24,1 30 x x

Note 1: The nominal wall thicknesses conform to ISO 4065:1996 / EN 1452-2
Note 2: To apply an overall service (design) coefficient of 2,5 (instead of 2,0)
for pipes with nominal diameters above 90 mm, the next higher
pressure rating, PN, shall be chosen.

Note 3: The dimensions are in millimetres
Note 4: DN = Nominal Diameter

Note 5: Other pipe sizes are available on request.


APOLLO Pipe Range
Nominal Bore Pressure Weight per Pipes per Bundles
Size (mm) (mm) Rating (Bar) Metre (Kg) Bundle per Load
90 84.0 10 1.28 116 12
110 104.0 10 1.57 77 12
160 152.0 10 3.05 30 12
200 190.2 10 4.7 20 12
250 237.6 10 7.5 12 12
315 299.6 10 11.84 9 12
Note: All Apollo pipe has an effective length of 6 metres.
Wavin is able to provide you with a full range of PVC-U and/or ductile iron fittings like tees,
bends and all other assecories which can be requested in PN 10 and PN 16.
6. Installation
The jointing possibilities of Wavin PVC-U long service life with unchanging pro- Insert the spigot end into the socket pipe
pressure pipes and fittings are various. perties. The push-fit connection is not end. Chamfering is not necessary with
The possible assembly solutions are: longitudinal force-connected. It enables the sealing system. Jointing is easy as
connecting PVC pipes and fittings. the rubber ring is of the low-compression
Rubber
ring / push-fit jointing Installation is above ground and only type.
Solvent
cement jointing possible without pressure. Buried pres-
Mechanical
jointing sure pipelines should be installed with
Flanged
connections abutment (for instance, according to
DVGW GW 310) or with appropriate
protection against longitudinal
movement.
PVC push-fit connections are used in the

following applications:
Water
distribution
Service
water systems Figure 6.
Irrigation

Pressure
and vacuum Remove the protective sealing cap both
Drainage
from the socket end of the pipe already
laid and from the spigot end of the next
All sizes of Wavin PVC pressure pipes pipe.
and fittings are supplied with a rubber-
ring sealing system in order to make
jointing as easy and secure as possible.
The system is based on factory fitted,
fixed rubber rings.
The rubber rings on the pipes are pre-
Iubricated at the factory with a special
long lasting silicone lubricant, which
offers the following advantages:
For underground applications the solvent
cement joint is NOT recommended! The Correct
consistency, both at high and
rubber ring seal joint is by far the prefer- low temperatures
red jointing technique for underground Waterproof
Figure 7.
applications. No
noxious substances
Approved
for usage in drinking water The factory fitted rubber ring is pre-lubri-
Selection of the appropriate installation lines cated with long lasting silicone lubricant.
method must be based on local circum- NB: When jointing to fittings do not forget
stances. To ensure that the pipes remain internally to apply lubricant to the rubber ring.
clean - even in the pipe trench - both pipe
6.1 Rubber ring jointing ends are sealed by special tightly fitting
plastic caps. The sealing system makes
The rubber ring push-fit connection for jointing of both pipes and fittings easier.
PVC piping systems is distinguished by
its simple and quick installation and a

In case of pipes laid in pits the expan-
sion and the support regulations must
be taken into account.
Bends, elbows, end pieces, valves,

hydrants, branches etc. installed in
non-positive axial pipelines must be
adequately supported and anchored.
The figures below indicate the necessa-
ry support. See chapter 10 Anchorage.
Figure 8. Figure 11.
Centre pipe and socket end. Ensure or a jack, with the bucket of the
that the spigot end is inserted in the excavator as back bracing.
socket at the correct angle. Chamfering
is unnecessary. If pipes need to be cut, NB:
the pipe ends must be chamfered and Never use the bucket of the excavator to
be de-burred using a rasp or scraper. push the pipes together.
The integral rubber ring joint is a non-

positive axial joint. Pipe component
parts incorporating integral rubber ring
joints may be laid into any soil - with the
exception of not bearing soil to ground
category 2.22 of DIN 18300.
If the pipeline is to carry liquids of a

temperature exceeding 15C, ensure
Figure 9. there is free thermal movement of the
Push the spigot into the socket until it pipe within the socket.
reaches the depth of entry mark, do not
over insert. This must be done manually.
Use a steel crowbar if necessary. Protect
the pipe end with a block of wood. D1) R A in meters for pipe A in meters for pipe
DN mm M lengths of 6 m lengths of 12 m
Figure 10. 50 63 18,9 0,94 3,69
65 75 22,5 0,80 3,13
80 90 27,0 0,66 2,63
100 110 33,0 0,54 2,16
125 140 42,0 0,43 1,70
150 160 48,0 0,38 1,49
200 225 67,5 0,27 1,07
250 280 84,0 0,22 0,86
300 315 94,5 0,19 0,76
400 450 135,0 0,13 0,54
1) Outside pipe diameter
If a crowbar does not give sufficient
leverage, special jointing tackle (straps
and hoist) can be used
6.2 Solvent cement jointing Tools and accessories
Solvent cement jointing calls for ade- The following materials and tools are required for connecting pipes and fittings:
quate technical knowledge that can be
acquired from appropriate training cour- THF adhesive Basis tetrahydrofurane
ses. We will gladly provide information Cleaner Basis methylene chloride
about our training sessions.
Adhesive and cleaner consumption for 100 joints:
The dimensions of Wavin fittings and DN Adhesive kg Cleaner Litres
pipes generally correspond to the most 25 ca. 0,7 ca. 0,35
diverse national standards as well as 32 ca. 1,0 ca. 0,50
to the ISO 727. These fittings can be 40 ca. 1,3 ca. 0,65
connected with all PVC-U pipes whose 50 ca. 1,5 ca. 0,75
outer diameter tolerances conform to 65 ca. 2,0 ca. 1,00
ISO 11922-1. 80 4,0 5,0 2,0 2,50
100 6,0 8,0 3,00 4,00
The solvent cement joint is a positive 125 12,0 13,0 6,0 6,50
axial joint. 150 16,0 19,0 8,0 9,50
It is particularly recommended for: 200 23,0 26,0 11,5 13,0
250 34,0 37,0 17,0 18,50
Not
bearing soils (ground category
2.22 to DIN 18300). Lubricant consumption Paint brush (unlacquered, natural bristles)
Pipes
laid in ducts and pits. DN Lubricant DN mm brush
Underwater
and bridge pipelines. 50 50 joints 1 kg Up to 25 8 mm round brush
65 + 80 30 joints 1 kg From 32 25/3 mm flat brush
The adhesive employed is on the basis 100 25 joints 1 kg From 65 50/10 mm flat brush
of te-trahydrofurane (THF) to DIN 16970 125 20 joints 1 kg From 200 65/20 mm flat brush
and rule R 1.1.7 of the Gtegemeinschaft 150 15 joints 1 kg
Kunststoffrohre e.V. 200 250 10 joints 1 kg
In case of drinking water pipelines, the Lubricant in tubes of 150 g, 250 g, 500 g, 1000 g.
adhesive must also be in accordance
with DIN 19532. The adhesive supplied Absorbent, non-fibering, uncoloured paper
by Wavin meets these requirements. Brush socket
Plastic pipe cutter or saw
Chamfering device or file
cut 2, medium
Shaver
Soft pencil
Jointing tackle from DN 150 recommendable
from DN 200 required
Note: for larger pipe dimensions, please contact Wavin for the
consumption of adhesive, lubricant and cleaner.

Preparations a perfect seal, should never exceed 0,6
Pipe must be cut off at right angles. mm with a dense-type adhesive and 0,3
Cut by means of a fine toothed saw or a mm with a fluid-type adhesive. In order
suitable plastic pipe cutter. Utilise ade- to obtain a perfect joint, it is recommen-
quate devices to make certain that the ded that the adhesive manufacturers
pipe end is square to the pipe axis. instructions be strictly followed.
Remove any burr or unevenness from Wipe the pipe end and the socket with
the sawn-ends by means of a shaver a clean cloth. Clean the outside of the
or an arm file. Carefully chamfer the cut pipe end and the inside of the soc-
pipe ends prior to jointing, as illustrated Cutting the pipe to length. ket thoroughly with PVC-U cleaner and
in the sketch below. absorbent paper. Use a fresh piece of
paper each time. Cleaned areas must
be dry before the cement is applied.
Remove any condensation, which may
have formed on the parts. The cleaner
should dissolve the pipe surface. Check
if the PVC-U is actually dissolved. If not,
then roughen the surface using abrasive
cloth k 80 and clean again.
Chamfering the pipe.
Storage
Pipe outer diameter mm B Adhesive and cleaner must be stored in
6-16 mm 1-2 mm a cool and dry place. Pay attention to the
20-50 mm 2-4 mm maximum storage time of the adhesive
63 mm <= 4-6 mm (approximately 2 years). THF-adhesive
(solvent cement) is supplied ready to
Important: Well-chamfered and rounded use. The viscous structure is to ensure
pipe ends prevent the layer of solvent perfect cementing, therefore do not dilu-
cement from being removed as the pipe te. Adhesive of the correct consistency
is inserted into the fitting. will run down evenly from a wooden spa- Note: Pipe end and fitting socket must
tula held in an inclined position in form be dry and free from grease and dirt.
Note: If necessary, mark the desired of a flag. Adhesive running off lumpy
position of the fitting on both the pipe is unsuitable and must be disposed of. Stir the adhesive thoroughly prior to
and fitting before cementing. Marking Seal the tin and the brush during the usage. To ensure that both jointing
the jointing length on the pipe end cementing breaks or else the adhesive surfaces are completely covered with
makes it possible to check whether the will dry up and be useless (note protec- a smooth, even layer of cement, the
pipe has been inserted to the full extent tive measures). Prior to every usage, the brush should be generously coated with
of the socket. Close tolerances do not adhesive is to be stirred. Should there solvent cement. Start with applying a
always allow the spigot to be pushed be a film on the adhesive or the brush, it normal layer of cement to the inside of
into a socket in dry condition, but only must be removed prior to stirring. the fitting socket from the inside to the
after the adhesive has been applied. In outside and then a thicker one to the
such cases the depth of entry should Cementing pipe end with firm brush pressure. Work
also be marked. A strong, dense-type glue is recom- in well. The brush strokes over the pipe
mended, especially for coupling large end should always be in an axial direc-
diameters, where the clearance may be tion. Apply the adhesive evenly. Replace
high due to the ovalisation effect: such the lid of the solvent cement tin after use
clearance, anyhow, in order to guarantee
to prevent the solvent from evaporating. Minimum cementing lengths
Close the tin of solvent cement during
work intervals.
As the solvent cement sets quickly, the
parts should be slid together within one
minute starting from the application of
solvent cement. Push the chamfered
pipe end into the socket immediately to
depth of entry mark without twisting and
bring them to correct alignment. Hold
them in this position for a short while, Solvent cement coat at d 110 mm.
until initial bonding has taken place.
In case of temperatures above 20C
Note: Insert the pipe to the full depth of and/or windy conditions the open time tR* t F
*
the socket and ensure that the outlet of of the adhesive is reduced. This applies DN mm mm
the fitting is in the correct position. also to pipe surfaces heated by the sun. 50 63 37.5
Avoid overheating when cementing at 65 70 43.5
The process of applying the adhesive summer temperatures by protecting 80 79 51.0
to the parts and their assembly must the jointing area from direct sunlight. If 100 91 61.0
be effected within 3 minutes. Remove necessary, cool the pipe end with water 125 109 76.0
any surplus cement immediately using before cementing. 150 121 86.0
absorbent paper, otherwise the outer 200 160 -
skin of the pipe would be dissolved too Special protective measures must be 250 193 -
much. taken at temperatures below + 5 C. 300 214 -
Do not move the cemented parts during At temperatures near freezing point pipe * to DIN 19532
the first five minutes. Completed joints ends and fittings should be warmed to
must be held at 20-30 C for approx. 10 bring them to hand temperature. Next, Chamfering
minutes. At temperatures below 10C remove any condensation or ice. Solvent
this time in increased to 15 minutes. cement and cleaner should be stored at
Solvent-cemented pipes must not be room temperature prior to cementing.
lowered into the trench before 10-12
hours have elapsed. Note: Both solvent cement and cleaner
dissolve PVC-U. Therefore pipes and
The solvent cement manufacturers fittings must not be laid on or allowed
instructions concerning how long to wait to come into contact with spilled sol-
before handling, and concerning stic- vent cement or paper containing cement
king and pressure testing the system residues.
should be carefully followed. Generally
speaking, none of these operations Outside pipe diameter b
should take place within the first 24 mm mm
hours after making the joint. 6 16 2
20 50 35
The joints can be made single handed for 63 110 6
pipes with diameters up to 90 mm. For 125 200 11 18
110 mm and larger pipes, two people are 225 315 20 26
needed to apply the solvent cement on
the fitting socket and pipe end simulta-
neously in order to avoid exceeding the
maximum handling time. The pipe pit should not be used as a
A jointing tackle eases the assembly of garbage dump.
pipes above DN 125.

or for the removal of surplus cement Do not close the cement pipelines during
in closed containers to minimise the the drying process. This is particularly
amount of solvent fumes in the air. important at temperatures below + 5C,
where there is a danger of damaging the
Solvent cement and cleaner are inflam- material.
mable. Thus all open fires and any
sparking must be avoided, before com- Because of the danger of explosion,
mencing work. Switch off unprotected do not perform any welding near pipes,
electrical equipment, electric heaters, which have been cemented but are not
etc. Smoking is prohibited! Furthermore, yet filled. Danger of explosion!
observe all instructions issued by the
solvent cement manufacturers (for Remove the solvent vapours from pipe-
Outside pipe diameter R example, on the tin label and in any lines, working rooms and pits prior to
mm mm supplementary documentation). welding.
6-16 2
20-50 3 Just before welding fill water into the
63-315 5 pipeline, flush and blow through in order
to remove flammable mixtures. Fill water
Drying time and pressure test into finished pipelines even if they are not
The drying time, before the joint may be put into operation immediately.
subjected to testing or operating pres-
sures, depends on the ambient tempe- Always obey the safety regulations
rature and the tolerances. issued by the authorities responsible.
As a general rule, allow at least: No naked flames when cementing Application limits
1 hour waiting time per bar operating No smoking. For the chemical resistance of solvent
pressure cement joints and other technical tips,
Protect pipes and fittings from spilled please refer the appropriate specificati-
solvent cement, cleaner and absorbent ons of the solvent cement manufacturer.
Nominal Test pressure* Waiting time paper, which has been used to wipe
PN 10 15 bar 15 h off solvent cement. Do not dispose of
PN 16 21 bar 24 h surplus solvent cement or cleaner in
*1,5 x PN, max (PN + 5) bar drainage systems.
Cleaning of the tools Use hand gloves for protection to avoid

Clean the brush with dry absorbent the skin from coming into contact with
paper after use. Brushes must be dry the solvent cement and cleaner. Rub
before being re-used. Cleaner that has protective cream on the hands before
been used for washing the brush must commencing work. Use a skin protective
not be applied to the mating surfaces. cream after cleaning and after comple-
tion of work.
Safety precautions
Solvent cement and cleaner contain Wash eyes with water thoroughly, if the
highly volatile solvents. This makes good solvent cement comes in contact with
ventilation or adequate fume extrac- the eye. Visit the doctor! Immediately
tion essential in closed spaces. Since change clothes soiled with solvent
the solvent fumes are heavier than air, cement.
extraction must occur at floor level, or at
least below the working level. Dispose of
paper, which has been used for cleaning
6.3 Connections Welding torches and soldering
lamps are unsuitable. Then tigh-
The following connections can be utilised ten the screws evenly and crosswise.
for connecting PVC-U-piping systems to
metal pipes or fittings:
- Flanged sockets and flanged spigots
to DIN 16451 sheets 6 and 7, to con-
nect integral rubber ring joint pipes to
flanges.
Support the pipe as shown below by
means of stonefree, tampered soil in
order to prevent the spigot from being
angled in the socket when bending the
pipe.
- A special union rubber ring with green

edge to connect to union sockets. It
compensates for the diameter diffe-
rence of PVC-U and cast-iron pipes.
Use unions to DIN 8063, sheet 3, to con-

nect to male and female threaded parts.
Support cast-iron and heavy fittings so

that their weight does not affect the
- Flanged connections (conical flanged pipeline.
bush or special flanged sockets or
spigots) for solvent weld socket pipes. Pipe bends are used for changing the
direction of the pipeline. To a limited
The screws must not be tightened for extent advantage can be taken of the
30 minutes, at ambient temperatures elasticity of the pipe material and the
near the freezing point for 45 minutes, pipe bent without being warmed. The a
after the last joint has been made. figures of the table are not to be excee-
ded.
If pipe component parts are misaligned
then warm the pipe over a length of
approximately 50 cm at a distance of
approximately 1 m from the flanged joint
prior to tightening these screws. Use a
warm air device or a propane gas flame
to apply even gentle heat to the pipe,
warming it to approximately 120-140
C. Take care not to overheat the pipe.
Heat marks are brown and/or bubbles.

House service connections Corrosion proofing of metallic 6.4 Flange type connection
For taking service connections from the accessories
mains, branches or tapping fittings can If it is necessary to protect metallic com- Pipes can be connected by means of
be used. ponent parts or fittings against corrosion the following detachable or rigid types
then hot or solvent masses must not of joints:
For tapping only crown drills incorpora- come into contact with the PVC-U pipe. Flange adaptors to DIN 8063, sheet 4
ting sufficiently dimensioned flutes may Prevent the pipe from coming into
be utilised. direct contact with sealing or protec- Plastic material or metal.
ting materials attacking PVC-U (see
The drill must be designed in such way DIN 16929). Normally joints should
that the cut disk cannot fall into the only be protected after the hydraulic
pipe. The drilling diameters and the bow test.
widths of the tapping fittings are to be in
accordance with the following table.
Outside Minimum Maximum

pipe bow tapping Or conical flange type bushes to DIN
diameter width diameter 8063, sheet 4
d b
DN mm mm mm Cast iron.
80 90 62 32
100 110 70 40
125 140 70 40
150 160 70 40
200 225 80 50
250 280 80 50
300 315 80 50
400 450 80 50
Flange adaptors to DIN 8063, sheet 4,
Install a protection sleeve into the wall are utilised for connections to metal
duct in case of drinking water pipes in flanges.
accordance with DIN 1988.
Hydraulic testing
In order to prevent the pipeline from
moving back, fill the line to a height of
approximately 80 cm prior to pressure
testing, leaving joints exposed. Use a
test pressure gauge of quality 1.0 having
a measuring range of 0-16 and 0-25 bars Or conical flange type bushes to
respectively and a minimum diameter of DIN 8063, sheet 4.
160 mm.
It is recommended to utilise additionally

a recording pressure gauge having an
adequate measuring range.
DIN 4279, sheets 1and 7, describe how

to carry out the hydraulic tests.
Maximum test pressure 1.5 x PN
6.5 Threaded or adapter joints Wall disk according to DIN 8063, sheet 6.6 Fixing
10. PVC-U pipe and wall disk represent
Adaptor joints must be detachable but a rigid joint. Type of pipe bracket
when fitted rigid. Use metal joints only The inside diameter of the pipe brac-
when connecting to metal pipes or kets (plastic material or metal) must be
fittings. bigger than the outside pipe diameter
when fixed. Smooth off the inside edges
in order to prevent the pipe from being
damaged. If pipe brackets incorporating
a tape are utilised then this tape should
be of the PE-profile type.
Tapes made from plasticized PVC are
unsuitable. Characteristic features when
fire-testing: PE smells of wax, PVC-U
has a sharp odour.
Composite union to DIN 8063, sheet 3. Connections to PVC-U Take care not to use pipe hooks.
Male or female type of union fabricated threaded fittings
from malleable cast-iron or brass in For the connection of PVC-U pipes to
appliances or fittings made of plastic
material which have a male or female
thread, PVC-U threaded fittings accor-
ding to DIN 8063, sheets 6 to 9, can be
utilised. For sealing the thread use only
PTFE tape. Customary sealing material
can contain substances detrimental to
PVC-U. Therefore usage is not allowed.
Changes of direction
accordance with DIN 8063, sheet 3. In case of changes of direction, as for Pendulous brackets, suspension arran-
Male or female thread type of adaptor instance minor centre locations (swan- gements or pipe brackets with welded
socket to DIN 8063, sheet 11. PVC-U neck bends), the changes may not guide shoes are recommended if it is
pipe and adaptor socket represent a be carried out in a cold condition but necessary to accommodate important
rigid joint. only after warming the pipe section to expansion or contraction. Take care that
approximately 100 C. For supplying loose brackets do not interfere with the
gentle heat to the pipe use a warm air linear expansion of the pipes.
device or a propane gas flame. Take
care not to overheat the pipe.
Heat marks are brown and/or bubbles.
Welding torches and soldering lamps are
unsuitable and may not be utilised.

Fixed points Installing and fixing fittings Discharge and flush fittings
Fixed brackets can be obtained by Utilise adapter sockets to DIN 8063,
cementing limit stops on one or both General sheet 11, for the connection of discharge
sides of the pipe. Install those fittings only which do not and flush fittings. Connect discharge
increase the flow pressure by more than valves by means of wall disks to DIN
The limit collars can be manufactured 2 bar after quick action closing (see also 8063, sheet 10. Take care to fix the wall
from a pipe of the same dimension. Their DIN 1988). disks well.
length is 20-30 mm. Cut out approxi-
mately 1/3 of the circumference (see The fluid contact gasket must be fabri-
drawing). cated from a material suitable for this
fluid. Generally loose joints should be
selected for installing fittings into a pipe
system.
A limit stop is also obtained by fixing If possible the fittings should be installed Hydraulic testing
the pipe brackets near a fitting. A fixed directly so that the actuation forces do Leave the system unconvered and expel
point can only be operative if the pipe not affect the pipe system. Special fitting all air in it. For the purpose of a leak test
bracket is well fitted in a sturdy way. A supports or those supports already fixed subject the system to a water test pres-
pendulous bracket is unable to serve as to the fitting are very suitable. Generally sure of 1.5 times the highest operating
a fixed point. brackets must be placed on both sides pressure, measured at the distributing
of metal fittings. Flanged fittings can also main, during one hour.
be supported at the flange.
Hydraulic testing may only be carried out
Take care to support heavy fittings by after joints have been allowed to dry for
means of a special support or a console. at least 15 hours.
Provide elastic pipe joints. Insert for
instance a rubber bellow in order to Painting
prevent vibrations or distortions from Painting the line is unnecessary and is to
being transmitted to the system when be avoided. In case it is absolutely neces-
connecting pipes to booster, circulation sary to change the line appearance,
or similar plants. take care to utilise only those colouring
matters which do not contain agents to
which PVC-U is not resistant (see DIN
16929). Nitro dyes are therefore not
allowed. Lime, oil or latex paints are
however generally recognised as safe.
Colour tapes may be utilised for marking
different lines.
Subsequent installation of pipe One or two flanged connections or split Repair of a damaged line
component parts couplings if the line is hardly or not axi- If the pipe has been damaged on one
In case it is necessary to install fittings ally moveable. side and in a non-splintered way, e.g.
or mountings into an existing system or by a nail or by in-advertent boring,
to replace a pipe section, this can be the damaged section can be repaired
effected by means of couplers, unions without removing the pipe. First debur
or flanged connections. using a shaver or a bastard file. For
the repair, a pipe of the same diame-
Two solvent cement sockets if the line is ter and of a length I=3 x d is required.
axially moveable. Approximately one third of the circumfe-
Branches up to DN 50 can also be made rence is cut out of the pipe section lon-
by means of PVC-U or metal tapping or gitudinally. Debur all cut edges. Solvent
adaptor brackets. weld the new section to the pipe and
secure with two hose clamps. At least
one hour drying time must be allowed
before applying working pressure. Take
One or two unions if the line is hardly or care that the hose clamps are not remo-
not axially moveable. ved before 24 hours have elapsed after
solvent welding.

Connection of Combiflange - Standard for PVC -
Non-tensile resistant
Combiflanges are used to connect two pipes or one pipe

to valves and fittings with flanges drilled to take
PN 10 (or PN 16).
The Combiflange consists of two parts: a cast-iron flange
and a rubber gasket. Its area of application is water and
neutral liquids at temperatures not exceeding 70C. The
tolerance is 1 mm.
1) Cut the PVC pipe at right angles using

a fine-toothed saw.
2) Remove swarf, soil and other impurities from the pipe

end. Do not chamfer.
3) Place the cast-iron flange on the pipe with the small end
facing away from the pipe end.
4) Locate the rubber gasket on the pipe so that the large

end is flush with the PVC pipe end, i.e. with small end of
rubber gasket facing inwards.
5) Apply a thin layer of lubricant to the outer surface of

the rubber gasket. Place the pipe end with the flange
and rubber gasket in position against the valve or fitting
flange.
6) Push the cast-iron flange by hand over the rubber gasket

as far as it will go.
7) Locate the bolts and tighten by hand until the parts con-
nect.
8) Ensure that the assembly is correctly aligned.
9) Tighten the bolts using a spanner. Cross-tighten to

ensure that the bolts are evenly tightened.
Figure 12: Diagram showing connection of non-tensile resistant

Combiflange for PVC.
Connection of Combiflange - Tensile
resistant for PVC
Tensile resistant Combiflanges are used to connect two

PVC pipes or one PVC pipe to valves and fittings with flan-
ges drilled to take PN 10 (or PN 16).
The Combiflange consists of three parts: a cast-iron flange,

a red brass grip ring and a rubber gasket.
Its area of application is water and neutral liquids at tempe-

ratures not exceeding 70C. The tolerance is 1 mm.
1) Cut the PVC pipe at right angles using a fine-toothed

saw.
2) Remove swarf, soil and other impurities from the pipe

end. Do not chamfer.
3) Place the cast-iron flange on the pipe with the small end
facing away from the pipe end.
4) Place the red brass grip ring on the pipe with the small
end facing away from the pipe end.
5) Locate the rubber gasket on the pipe so that the large

end is flush with the PVC pipe end, i.e. with small end of
rubber gasket facing inwards.
6) Slide the red brass grip ring back until it connects with
the rubber gasket.
7) Apply a thin layer of lubricant to the outer surface of the

rubber gasket. Place the pipe end with the flange and
rubber gasket in position against the valve or fitting
flange.
8) Push the cast-iron flange by hand over the grip ring and
rubber gasket as far as it will go.
9) Locate the bolts and tighten by hand until the parts

connect.
10) Ensure that the assembly is correctly aligned.
11) Tighten the bolts using a spanner. Cross-tighten to

ensure that the bolts are evenly tightened.
NB: The same procedure should be followed when Figure 13: Diagram showing connection of tensile resistant flange
connecting two tensile-resistant Combiflanges. When for PVC.
tightening, two extra-Iong auxiliary bolts will be needed.

6.7 Installation of Apollo 1. Clearly mark the cutting position on
the pipe, ensuring the cut will be
Pipe Cutting & Chamfering square to the axis of the pipe. A
All pipe installation work will involve pipe piece of paper with square edges
cutting at some stage. Apollo pipe is can be used for this.
simple and easy to cut following a few
straightforward guidelines. It is impor-
tant that a square cut is made to ensure 1
jointing is successful.
2. Use a fine toothed wood saw to cut
the pipe in an even and gradual cut.
The cut waste pipe should be sup-
ported at all times.
3. Remove all swarf and burs from the

cut end and chamfer the pipe with
a fine to medium file, providing a
chamfer of minimum 15 for half of
the pipe wall thickness.
Figure 14: Cutting and Chamfering.

Pipe Jointing
1 2 3
Figure 15: Pipe Jointing.
1. Remove the protective cap and lubri- 2. Note the depth of entry mark. Align 3. Using a crowbar with a piece of
cate the sealing ring with an appro- the spigot and socket. wood across the mouth of the oppo-
priate lubricant (Wavin Medlube). sing socket push the spigot home,
Check the pipe spigot is chamfered leaving the depth of entry mark just
and clean. visible.
NB: The natural flexibility of Apollo PVC-O allows Apollo to be jointed above ground and snaked into a narrow trench.
Water mains are generally laid with a A full concrete surround should be The usual method of accommodating
minimum 900 mm cover and installed avoided. If it is unavoidable the pipe thrust in a buried pipeline is by pla-
with a granular bed and backfill. should be wrapped a number of times cing concrete between the pipe and
with polythene sheeting for protection. the undisturbed trench wall. The pipe
Pea gravel is the ideal bedding mate- should preferably be cradled in con-
rial as it is free flowing and self-com- Cyclic Fatigue crete rather than surrounded and the
pacting. Washed sand, crushed stone, Apollo has been successfully tested pipe should be protected by using poly-
sintered pulverised fly ash or air-dried against cyclic fatigue. However, field ethylene sheeting or a compressible
furnace slag are suitable alternatives. conditions vary for applications involving membrane. This will allow a degree
continuous cyclic loading. For speci- of movement due to creep and pre-
Backfill material above the initial 100 fic installation recommendations under vent abrasion and stress concentrations.
mm of granular material can be either these conditions please contact Wavin.
selected as-dug material, providing it can Thrust block design has to take
be compacted or, if in the case of a road Water Mains in the UK should be laid in account of factors such as the pipe
situation, imported granular material. accordance with BS CP 312 Parts 1 & 2 diameter and maximum internal pres-
Alternatively foamed concrete can be used. and also the WRc PVC-U Manual (1994). sure to calculate the maximum thrust
generated. The bearing capacity of
No mechanical compaction should Anchorage the surrounding soil has also to be
be undertaken until there is at least The Apollo joint is not designed to resist accounted for in design calculations.
300 mm cover to the pipe, sub- axial loads and therefore any such load
sequent layers can be compac- needs to be transferred to the surroun- For further information on design and
ted in layers not exceeding 300 mm. ding undisturbed ground by means of a anchorage of PVC-O pipeline structure
thrust block. Thrust blocks are required please contact Wavin.
If the depth of cover to the pipe crown is at all:
less than 600 mm and the pipe is to be 01. 02. 03.
subjected to traffic loading, protection Changes
of direction
can be provided by a concrete raft which Reduction
of diameters
bridges the trench. A 300 mm thick Tees

cushion of granular fill should be placed Blank
Ends
04.
between the pipe and concrete raft. Closed
Valves
05.
05.
06.
Anchor Blocks Placed at:

01. Gate Valve Using Puddle
Flange
02. Equal Tee
03. Blank End
04. Reducer
05 & 06. Bends
Figure 16: Recommended Trench Construction Figure 17.

Please note: If narrow trenching, a minimum 50 mm either side of the pipe.

Pipe Flexibility Under Pressure Service Connection
The maximum permissible joint deflec- The standard service connection is made Do
not overtighten the ferrule
tion is 5. Bending should only be carried using a gunmetal mechanical ferrule strap on the main.
out manually and not attempted below which is simply bolted around the main. Do
not try and cut the hole in the
5C. Where greater bending is required, The ferrule has an integral cutter which main too quickly.
the appropriate pre-formed bend should is used to drill through the Apollo main Do
not fit a service connection
always be used. pipe system whilst under pressure. The on a main that is under significant
construction of the ferrule strap system bending.
Pressure Testing is designed to minimise the stress on Take
extra care at a low ambient
The recommended test pressure is 1.5 the pipe, however, it is important to take temperature.
times the actual working pressure of account of the following factors:
the pipeline at the lowest point. Higher
test pressures are unnecessary and
necessitate more expensive anchorage.
Ideally all joints and fittings should be left

exposed for examination during testing,
and the bulk of the pipe should be back-
filled to prevent movement of the pipe
lines during testing. The basic procedure
requires pressuring the main at the test
pressure for one hour followed by a
further period of one hour with all valves
closed and the test pump disconnected.
The success of the test is determined by

the amount of water required to restore
the original test procedure, dependent
on the diameter and length of pipeline.
Full testing details are available from
Wavin. Figure 19: Under Pressure Service Connection.
Figure 18: Pipe Flexibility.
7. D
esign of water
supply pipelines
For fewer than 200 housing units For a normal single-family house with Calculations
Here the design water flow (q ) is deter- d
tour occupants this gives a design water
mined using DS 439, the DIF (Danish flow qmax of: Water consumption/house:
Association of Engineers) code of prac- qmax = 167l / hour = 0,046 l/s
tice for water installations. DS 439 states 400 l/24 hours/pe x 4 (pe) x 2.5
that the sum of the predicted water flows q max
= 24 Water quantity is calculated for each
can be set at 1.6 I/s per housing unit, = 167 l/hour = 0.046 l/s pipe section for instance:
which gives a (qd) of 0.36 I/s per unit.
A - B: (10 + 15 + 8) houses x
For more than 200 housing units Example of design of water 0,046 l/s = 1,52 l/s
Here the design water flow (qmax) is deter- supply pipeline
mined using DS 442, the DIF code of Pressure loss is found by means of the
practice for public water supply systems. The example is based upon the follo- water flow diagram for PE 80 pressure
DS 442 states that qmax can be deter- wing data: pipes PN 10, diagram on the next page.
mined from the following formula:
Pressure
at station A is measured at Using the pipe dimensions below the
Formula 1 3.5 bars (35 m Wat.Col.) following pressure will be available at
PE
80 pipes PN 10 are used as the consumer in station D:
Qmax x ft max
pipeline material
qmax = Maximum
daily water consumption 35 m Wat.Col. 13 m Wat.Col. = 22 m
24 (Qmax )= 400 l/24 hours/pe Wat.Col. > 20 m Wat.Col. OK
Maximum
consumption per hour =
where Qmax = avarage daily consumption 2,5 x Qmax
[Qm] x 24-hour Necessary
pressure at consumer: 2
factor [fd] bars (20 m Wat.Col.)
ft max
= hour factor 4
persons per household
Where normal types of housing are

involved, Qmax can be set at 200 I/24 8
10 houses
C
Main line
hours/pe and fd at 2. This gives a Q max

of
A houses
200 x 2 = 400 l / 24 hours/pe. For normal 50 m
D
types of housing ft max
is set at 2.5.
15
B houses
500 m 650 m 200 m
Figure 20: Diagram of pipeline in example.
Section Quantity of water (l/s) Length (m) Pipe-dimension (mm) Pressure loss Pressure loss of
M Wat.Col./km) section (m Wat.Col.)
A-B 1,52 500 63 15 7,5
B-C 1,06 650 63 7 4,6
C-D 0,37 250 63 3,7 0,9

Sum 13
Table: Example of dimensioning diagram for calculation of pressure loss.

7.1 Piping design, pipe Determination of the required spring Because of the pipe elasticity the linear
arrangement, linear leg length in case of a linear expansion I can be cushioned by sprin-
expansion calculation expansion of I. ging of pipe section a.
When laying PVC-U pipes, the following Base your determination of the spring The values given in the table for the
have to be taken into account: leg length (a) on the higher figure, in this springing resulting from the linear expan-
instance 4 mm. The required spring leg sion I must not be exceeded.
- linear expansion length (a) de-pends on the outside pipe
- pipe clip or bracket arrangement diameter (d) and on the linear expansion
- wall and ceiling transition I.
- installed pipe protection
- connection of water heaters If in our example the outside pipe dia-
meter (d) is 50 mm, the required spring
Linear expansion leg length (a) is 500 mm in case of the
When calculating linear expansion consi- maximum linear expansion of I = 4 mm
der the following conditions: as can be seen from the table below.
1. The ambient temperature
2. The lowest and highest pipe wall
temperature to be expected
Linear expansion is 0.08 mm per m and

per K (Kelvin) change in temperature and
can be calculated as follows: Springing pipeline Linear expansion
Linear expansion (mm) = pipe length (m) DN I (mm)
x temperature difference (K) x coefficient 10 16 14 31 55 86
of linear expansion (0.08). 15 20 11 25 44 69
I = L x T x 0.08 20 25 9 20 35 55
25 32 7 15 28 43 62
Example of calculation: 32 40 5 12 22 34 50
40 50 4 10 18 27 40 70
Pipe length: 5m 50 63 8 14 22 32 55
Lowest pipe wall temperature 65 75 6 12 18 27 47
to be expected: +5C 80 90 5 10 15 22 40
100 110 4 8 12 18 32
Ambient temperature 125 140 6 9 14 25
whilst 150 160 5 8 12 22
installing: + 10C 200 225 4 6 9 15
Temperature difference = 5 K Spring leg length
a (mm) 500 750 1000 1250 1500 2000
Highest wall temperature
to be expected: + 20C
Temperature difference = 10 K
Maximum shortening to be expected:

I1 = 5 m x 5 K x 0.08 mm/mK = 2 mm
Maximum elongation to be expected:
I2= 5 m x 10 K x 0.08 mm/mK = 4 mm

Intermediate data can be seen from the Between two fixed points linear expan- the following table in order to prevent
following diagram. sion can be absorbed by changes of the pipeline comprising bellow expan-
direction, expansion bends or bellow sion joints from buckling.
expansion joints.
It may be necessary to provide conti-
Clip or bracket arrangement in case of nuos pipe support if the ambient tempe-
changes of direction. ratures or the temperatures of the liquids
Pipe installation between two fixed are high.
points.
Steel or aluminium angles or U-profiles
as well as sheet metal semi-shells are
suitable.
Clip and bracket Splitting up the linear expansion

arrangement By providing fixed points in case of
Fix the pipeline in such a way that linear Use only bellow expansion joints the longer pipe sections linear expansion
expansion is not interfered with. Arrange inherent resistance of which is low. can be split up and thus - related to the
the pipe clips, brackets and fittings in single sections - better absorbed.
such a way that it is possible for the pipe
to spring.
Clip or bracket arrangement in case of

branches.
Arrangement of fittings in case of To give an example: rubber bellow
branches. expansion joints are suitable. The bellow
expansion joint position is dependent
on the linear expansion worked out.
Observe the clip and bracket centres of
Clip and bracket centres in cm for horizontal and vertical installations at

temperatures of 20 to 60 C.
Horizontal
DN d 20 C 30 C 40 C 50 C 60 C vertical
10 16 75 60 40 Continuous 80
15 20 85 70 50 support 90
20 25 90 75 55 45 30 100
25 32 100 85 65 50 35 120
32 40 110 100 80 60 40 140
40 50 125 115 95 70 45 160
50 63 140 130 110 85 55 180
65 75 150 140 120 95 60 200
80 90 165 155 135 105 70 220
100 110 185 175 155 120 80 240
125 140 215 205 185 160 110 250
150 160 225 215 200 170 130 250
200 225 250 240 225 200 160 250
Wall and ceiling ducts Not upholstered pipes 7.2 Longitudinal expansion and
Pay attention to DIN 1988. Immediate bedding of the pipe is allo- contraction of plastic pipes
wed if the change of temperature during
Well laying service does not exceed 10 K. Plastics have a comparatively high coef-
In case of rising mains passing through ficient of linear heat expansion, which
wells take care to allow for the branch Take care that the pipe is well bedded should be taken into account when lay-
pipe of floor branches to spring suffi- and that hollow spaces are avoided. The ing plastic pipes.
ciently. This can be ensured by suitably mortar must not be too lean (cement
placing the rising mains in the well (1), mortar mixture 1:3 to 1:4) so that forces Pipe with socket joints do not normally
by providing a sufficiently di-mensioned occurring due to temperature changes require special measures to be taken
branch liner (2) or by installing a spring can be led off into the wall without regarding expansion caused by tempe-
leg (3). causing plaster gaps. The people in rature changes, as each socket acts as
charge of the bedding should be instruc- an expansion piece.
ted accordingly. Examine whether this
method of installation is feasible within However, in the case of a long section of
housing spaces for reasons of noise adhesive-jointed PVC pipes, the whole
control (DIN 4109). section will behave as a single long pipe.
Expansion or contraction will thus be
Installed pipe protection concentrated and the whole section will
Protect exposed pipes from impact and expand or contract.
shocks. When installing potable water
pipes ensure that the pipe wall tempe- Formula 2
rature does not exceed 30 C. This is
particularly important if there are parallel L = t x L x
or crossing warm water or heating pipes. where L = longitudinal expansion/con-
Industrial pipes are to be protected from traction [m]
out-side heat. If welding, burning or sol-
dering works are being carried out near t = T1 - T2 [C]
the pipe system, protect it by means of
asbestos sheet, for example. T1 = stable soil temperature
T2 = temperature of pipe when laid
Connection to water heaters L = length of section [m]
A thermal resistant pipe of a minimum = coefficient of linear heat
length of 0.5 m must be fitted to the expansion
water heater safety group.
Installation of buried floor pipes
Upholstered pipes
Wrap a felt or similar strip around the
entire pipe length. Put elastic materials
(glass wool, rock wool, cellular or simi-
lar materials) around fittings and spring
legs at tees, angles and other changes
of direction in order to allow free linear
expansion.

Use of plastic pipes at 7.3 Hydraulic Flow: Q = water discharge [m3/s ]
temperatures exceeding 20C Frictional Losses Di = internal pipe diameter [m]
I = frictional loss [m/m] [number]
Where circumstances require that the Formula k = frictional resistance [m]
normal maximum operating temperature Water flow diagrams are calcula- for diameter 200 mm
of a pipe be exceeded, the reduction in ted according to the Colebrook-White k = 0.00001 m
pressure necessary to obtain the same formula: for diameter > 200 mm
service life as at a 20C operating tem- k = 0.00005 m
perature can be calculated from the Formula 4
diagram below. The curves are designated by trade
0.74 k name (external diameter) but calculated
Formula 3 Q = -6.95 x log ( + ) x Di 2 x Di x I according to the internal pipe diameter
Di x Di x I x 106 making it possible to read the capa-
PNt = PN x Ct 3.71 x Di city of the pipes direct without having to
interpolate between the curves.
From the diagrams the frictional loss of

the plastic pipe itself appears. Individual
resistances such as bends, valves, redu-
cers, tees, inlet and outlet taps etc. are
not taken into account.
For most water supply projects the dif-

ferent individual resistances will normally
not be calculated. In such a case 2 - 5%
is added to the frictional loss of the
pipeline.
High Water Velocity

For projects with much higher water
velocity or projects for which a detailed
calculation of different individual resi-
stances is desirable the following for-
mula can be used:
Formula 5
v2
H = x
2g
where H = pressure head loss(m)

= resistance (number)
v = velocity (m/s)
g = gravity = (9.81 m/s2)
If the -values of our products are

Diagram Permissible operating pressure at temperatures exceeding 20C required please contact Wavin.
7.4 Water Flow Diagram for Wavin PVC Pressure Pipes PN10
The curves are calculated according to the inside diameter of the PVC pipes.

7.5 Pressure Variations Rapid filling of a pressure pipe line and Where pressure rises occur infrequently,
variations between trapped air masses e.g. pressure testing, power failure etc.,
Water Hammer may also cause sharp rises in pressure. the permissible maximum pressure may
Each time the rate of flow in a pipe Pipe lines should therefore be designed exceed the nominal pressure by 50%.
system changes, a pressure wave is to allow bleeding wherever required and
created. This can result in such large filling speeds should be kept low. For PVC pipes it furthermore applies that
variations in pressure as to cause a where pressure rises occur frequently
water hammer, which may exceed the The speed of the pressure wave depends (maximum 106 instances in a 50-year
permissible load on the pipes (force on the pipe material, wall thickness and period) the permissible maximum pres-
acting upon it). the substance carried by the pipe. sure may exceed the nominal pressure
by 25%, but such pressure rises must
In pump systems changes in the rate of Pressure class PVC not result in a pressure amplitude higher
flow can occur in the case of e.g. power PN a [m/s] than 30%.
cut, sudden blockages, rapid closing of 16 444
valves etc. If this takes place at one end 10 362 In case of doubt please contact Wavin.
of a long pipe line, the pressure waves 8 327
will rebound from the other end and 6.3 -
may cause damage when they return to 6 288
their point of origin - particularly if this 5 263
end is completely shut off and the incre- 4 237
ased pressure cannot escape. The risk
of water hammer may necessitate the The following pressure wave speed
installation of devices to minimize values a [m/s] apply for water carrying
the effect of the pressure waves and (incl. waste water) Wavin pipes:
will often require special operating
nstructions. All known materials show to a varying
degree a tendency to suffer fatigue when Figure 21: Example of variation in
There is ample technical literature subjected to dynamic forces. Incidences pressure.
available on the subject. Comprehen of water hammer will therefore reduce
sive guidance is given on calculation the service life of the pipes - the extent
methods but these are both complica- of such reduction depending upon the
ted and time-consuming. However, data composition of the dynamic forces i.e.:
programs have been produced which
are able to solve even the most com- The
duration of the pressure rise
plicated problems. In compiling these The maximum value of the above
programs, information concerning the compared with the level of the static
special characteristics of the pump, mean stress
pressure head and torque, the valve clo- The
time interval between rises in
sure, the air valves and various designs pressure (frequency) etc.
of the longitudinal profile etc. has been
included. As a result there is a risk of The following permissible pressure rises
pressure variations, rates of flow, vibra- apply for pressure pipes used in water
tion frequencies, volumes of air valve supply systems:
and pressure changes along the pipe
line as a function of time.
8. L
aying instructions
European standard EN 1452-6 Plastic The back fill must conform with the In case of descending gradients the
piping systems for water supplygui- requirements placed upon it by the type stonefree layer must be prevented from
dance for installation applies for the lay- of construction (road, pavement or the being washed away by concrete or clay
ing of pressure pipes. like) above the pipeline. stoppers. Drainage might also be advi-
sable.
The standard lays down that a pipeline The standard states that the soil cove-
should be located at such a distance ring (hd) must not be less than 0.6 m Concrete stoppers
from other pipelines and installations that where the pipeline will be exposed to
it causes no damage to these and allows traffic load, unless special measures
the repair of other installations. Reference are taken. In view of the requirement
should be made to the standard for the that pipelines are laid in frost-free soil,
distances in question. Requirements are pipelines carrying, e.g. potable water,
also attached to the design of the pipe are normally laid with a 1.1 m soil cover.
trench. The levelling layer must be laid or
loosened and subsequently levelled so Pipe trench
that the pipes are evenly supported. The depth of pipe trench should be such In case of changing layers and conse-
that all pipe component parts can be quently changing soil bearing capacity of
The side fill layer must provide ade- perfectly laid below the frost line (mini- the trench bottom, provide an adequate
quate side support for the pipes and it is mum depth of cover 1.0-1.8 m accor- fine gravel or sand filling (approximately
therefore important that this layer is ding to climate and soil conditions). It 10xd) at the points of transition. Should
compacted, e.g. by stamping with the the ground is rocky or stony the trench there be parallel or crossing other pipe
foot. bottom should be lowered by at least conveying warm liquids, then care must
0.15 m and the excavated earth replaced be taken that the PVC-U pipes surface
The materials employed for the levelling by a stonefree layer (sand, fine gravel). temperature does not rise above 20C.
layer and the side tilt must meet the
following criteria: The pipe trench is to be in accordance Back-filling
with DIN 18300, DIN 18303, DIN 4124 Filling of the trench is to be done in lay-
The
particle size must not exceed sheet 1 and DIN 19630. ers up to a depth of approximately 0.30
16 mm In case of stony or rocky ground: provide m above the top of the pipe, utilising
T
he content of particles of between a stonefree layer of 0.15m. stonefree soil and stamping carefully by
8 and 16 mm must not exceed 10% hand. If necessary, suitable soil must be
The
material must not be frozen procured.
Sharp flints or other crushed
material must not be employed a in m for pipe
D1) R lengths of
DN (mm) M 6 m 12 m
50 63 18,9 0,94 3,69
65 75 22,5 0,80 3,13
80 90 27,0 0,66 2,63
100 110 33,0 0,54 2,16
125 140 42,0 0,43 1,70
150 160 48,0 0,38 1,49
200 225 67,5 0,27 1,07
250 280 84,0 0,22 0,86
300 315 94,5 0,19 0,76
400 450 135,0 0,13 0,54
Figure 22. Diagram of trench design 1) Outside pipe diameter.

If the pipe temperature is considerably 4) It should be possible to connect a Procedure for Pressure Testing of
higher than the trench temperature due filter socket in the lowest point and Pipe Systems
to solar radiation, then put first a thin ventilation (air escape) in the summit Below is the procedure for pressure tes-
layer of stonefree soil on to the pipe prior to the starting and end points of the ting of pipe systems. The procedure is
to final back-filling in order to achieve line respectively. in accordance with the standard of the
stressfree laying. Pay attention to pipe 5) Bends, tees, reducers, valves, end Danish Engineers Union: Tightness of
movement resulting from temperature caps etc. should be anchored for the underground sewer systems DS 455,
differences. increased testing pressure. 1st edition, January 1985.
6) The demands placed by the owner on
Final back-filling is then to be effected. possible pressure testing should Before pressure testing the following
Mechanical rammers can be used after appear from the project description must be observed:
the prescribed dumping height has been enabling the contractor to take the 1) End caps are mounted on all ends of
reached. necessary measures for pressure the system. The end cap can be an
testing. end socket or a blank flange. A 90C
Special measures 7) Choice of pipe and fitting material bend, a ball valve and a 32 mm
If district heating pipelines are crossed, should be made under reference to tensile resistant coupler are mounted
the PVC-U pipes must be protected from EN1555/12201/1452 on the end cap, for mounting of a
heat. DIN 19630 refers. 32 mm PE pipe.
When the above conditions have been 2) AII end caps must be anchored.
8.1 Pressure Testing fulfilled the next step is the practical 3) The system must be filled with water
accomplishment of the job, and here at least 24 hours prior to the start
Pressure Testing of PVC-U the following points may contribute to of the pressure test. Ensure that the
Pressure Lines problem-free pressure testing: system is entirely ventilated.
It is possible to pressure test a PVC-U 4) During the first 6 hours the pres-
pressure line, before it is put into service Correct
transport, storage and sure in the system must be 1.3 x the
(taken over by the client). handling of pipes and fittings nominal pressure class. This is very
Correct
excavation, laying, filling important in order that the result of
Pressure testing is carried out accor- and compaction the test is not misleading. This part of
ding to DS 455. It pressure testing is Correctly
used jointing components the test must be documentable to the
requested, it should form part of the pro- and methods inspection authorities.
ject, and here the following conditions 5) There must be access to water on
should be observed: It is highly important that above men- the testing site.
tioned rules are observed as they will 6) Pressure testing against a valve is at
1) The longitudinal profile should be influence the final result of the project. your own risk.
projected with a slight upward incline
for ventilation purposes. During pressure testing the following is
2) A form of ventilation (manual to be observed:
- automatic) should be installed in 1) The actual pressure is measured and
all summits - correct installation of water is added to the system if
ventilation: In the direction of flow a required.
little below exact summit. 2) The system is exposed to a pressure
3) Barring procedures should be corresponding to 1.3 x the nominal
established enabling pressure testing pressure class (testing pressure).
of the line by stages. 3) This pressure is maintained for 2
hours. Supplementary filling of water
is allowed.
4) During the following 60 minutes water The following table takes into account the test pressure of 1.5x nominal pressure.
must not be added. Axial forces P and resultant forces R for 10 bar working pressure pipelines.
5) After 60 minutes the pressure is
measured and water is added until D1) P R(N)
the pressure is again 1.3 x the DN (mm) (N) 11 22 30 45 90
nominal pressure class 50 63 4579 882 1765 2353 3530 6472
(testing pressure). 65 75 6492 1225 2500 3383 4952 9218
6) The fall in pressure and the amount 80 90 9365 1765 3579 4854 7207 13238
of water added must not exceed the 100 110 13974 2696 5393 7256 10787 19809
following limits: 125 140 22653 4364 8678 11767 17455 31969
150 160 29518 5687 11277 15396 22653 41776
Formula 6 200 225 58447 11179 22359 30302 44718 82375
250 280 90515 17357 34617 46973 69627 128467
a) pressure drop in percentage of initial 300 315 114541 21966 43737 59428 87769 162790
pressure = 2% 400 450 233888 45895 91201 121602 179461 331464
b) water quantity in litres/metres = 1) Outside pipe diameter
0.02di - 0.001 + V
Axial forces P and resultant forces R for 16 bar working pressure pipelines.
V = 0.05 x d2 for PVC pipes
V = 0.08 X d2 for PE pipes D1) P R(N)
di = inside diameter DN (mm) (N) 11 22 30 45 90
50 63 7325 1412 2824 3765 5648 10355
After pressure testing the end caps are 65 75 10385 1961 4001 5413 7923 14749
demounted. 80 90 14984 2824 5727 7766 11532 21182
100 110 22359 4314 8629 11611 17259 31695
125 140 36245 6982 13886 18828 27929 51151
150 160 47228 9100 18044 24634 36245 66842
200 225 93516 17887 35774 48484 71549 131801
250 280 144824 27772 55387 75158 111403 205547
300 315 183266 35147 69980 95085 140431 260464
400 450 374221 73432 145922 194563 287138 530343
1) Outside pipe diameter
Figure 23. Diagram of pressure testing of pipeline.

9. Anchorage
The size of the axial force depends on Formula 8 Anchorage of bends

the dimension and working pressure The resulting force for bends can be
(testing pressure) of the pipe line and is N = p x N1 calculated as follows:
calculated as follows:
where N1 = axial force at 1 bar [kN] Formula 9
Formula 7
R = 2 x N1 x p x sin
x dy2 x p p = max. pressure occurring
N = in pipeline [bar] possibly 2
104 x 4 testing pressure
where N1 = axial force at 1 bar [kN]
where N = axial force [kN] (table 7)
dy = external pipe diameter [mm]
p = max. pressure occurring in p = max. pressure occurring
pipeline [bar] possibly testing in pipeline [bar] possibly
pressure testing pressure

PE
Anchorage of tees, end caps and = angle of bend [degrees]
valves R = resulting force [kN]
Fittings exposed to shearing forces

caused by internal water pressure, e.g.
bands, tees, end caps, reducers and Figure 24: Diagram showing Angle 11 22 30 45 60 90
k 0.19 0.38 0.52 0.77 1.00 1.41
valves must be anchored. The shearing anchorage of tee.
force which the anchorage is intended
to withstand can be easily calculated by Table of angle constants.
using the figures in the below table in the
following simplified formula: The resulting shearing force which the
anchorage is intended to withstand can
Outside Axial force at 1 be easily calculated by using the figures
diameter [mm] bar N1 [kN] in the tables in the following simplified
40 0.13 formula:
50 0.20
63 0.32 Formula 10
75 0.45 Figure 25: Diagram showing anchorage
90 0.64 of tee. R = k x p x N1
110 0.95
125 1.23 Where k = constant for resulting force
140 1.54 (see table of angle
160 2.00 constants)
200 3.15
225 4.00 p = max. pressure occurring in
250 4.90 pipeline [bar] possibly
280 6.16 testing pressure
315 7.80
400 12.60 N1 = axial force at 1 bar [kN]
500 19.60
630 31.20
Anchorage block Formula 11 Now the size of the concrete block can
R be calculated by using formula 11:
b= R
h/ earth b=
hx earth
where b = width of anchorage [m]

h = height of anchorage [m] earth is estimated at [kN/m ] 2
The height is estimated at:

R = resulting force [kN] h = 0.2 (height of pipe)
earth = permissible earth The minimum width must then be:

Figure 26: Diagram of anchorage of pressure [200 kN/m2]
bend. 21.83
It is a condition for the strength of the b = = 0.55 m
anchorage that the concrete is cast
against a solid wall of the pipe trench. It 0.2 x 200
may, however, sometimes be necessary
to cast against carefully compacted fill. Anchorage of reducer
In such case account should be taken
in the calculations of the lower strength The axial force for reducer is found by
of the fill. The fitting in question must means of formula 12:
be protected from the damage by the
concrete by an intermediate layer of e.g. Formula 12
Figure 27: Diagram of anchorage of plastic film before casting takes place. x (dy21 x dy22) x p
bend. N=
Example of anchorage of bend 104 x 4
When calculating the area necessary
for the determination of the size of the Conditions: where dy21 = the outside diameter [mm]
anchorage, due consideration has to be of the largest pipe
paid to the permissible earth pressure, - 200 x 45 PVC pressure pipe bend
which in each individual case has to be - Testing pressure (maximum pressure) dy22 = the outside diameter
determined by geotechnical surveys. In 9 bar [mm] of the smallest pipe
most cases it is sufficient to use the
following formula: Formula 10 is applied as follows:
earth = 200 (kN/m2) R = k x p x N1

The person in charge of the project
should always make an appraisal of the where k = 0.77 according to table of
relevance of this value. angle constants
p = 9 bar
This width of an anchorage can then be
calculated by means of the following N1 = 3.15 according to table of Figure 28: Diagram of anchorage of
formula: the previous page reducer.
The resulting force will then be:

R = 0.77 x 9 x 3.15 = 21.83 kN

Example of anchorage of reducer
Conditions:
- 200/110 PVC reducer

- Testing pressure (maximum pressure)
9 bar
which is inserted in formula 12:
x (2002 - 1102) x 9
N=
104 x 4
N = 19.72 kN
The anchorage (concrete block) is

calculated as follows:
h = (is estimated at) 0.2m

earth = (is estimated at) 200kN/m2

N
b=
hx earth
19.72
b=
0.2 x 200
b = 0.49 m
Figure 29. Diagram of anchorage of

reducer.
10. Handling and Storage
Handling plastic piping Figure 31

systems Bearers must be placed on the truck
body.
Wavin pressure pipes are supplied in Support the full length of the load.
pre-packed bundles to ensure adequate Always load and unload properly.
protection during transport and storage. Do not tip or throw the pipes from
The pipes are supplied with end caps the carrier.
protecting the pipes effectively from dirt
entering the pipes.
Handling on site
Figure 32
Small-diameter pipes can easily be
carried without the use of auxiliary
equipment.
Figure 33
Figure 30: Pipes should be handled and Do not drag the pipes across the
stored in bundles as delive- ground and avoid sharp edges.
red from Wavin for as long as
possible.
Transport
Vehicles for transporting pipes should Figure 34

be selected in such a way that the Small-diameter pipes can be
pipes lie completely on the floor of manually placed in the trench.
the vehicle, without jutting out of the
vehicle. Sagging is to be prevented.
Impacts are to be avoided under all
circumstances, particularly at tempera-
tures near the freezing point. To protect
the pipes and fittings from damage, Figure 35
they should not grind against the load Pipes in larger diameter may
area of the vehicle or against the floor necessitate slings. Always use at
of the vehicle during transportation. least 2 slings.
Pipes and fittings should be loaded
and unloaded with extreme caution and
care. If hoists are used, then pipe com-
ponents may not be thrown from the
vehicle into the storage area.
Figure 36
Larger diameters may necessitate a
special lifting bar.

Storage pletely protected from the effects of oil,
Storage areas for pipes should be solvents and other chemical substances
without gravel and plain. Storage and during the storage period. The area
stock heights should be selected in where the pipes are to be placed should
such a way, as to avoid damages or be covered with sheeting or cardboard
permanent deformations. Pipes with (including the side supports) in order
large diameters and small wall thickness to avoid damage caused by protruding
should be equipped with circular stif- rivets and nails.
feners. Point and line supports for the
pipes should be avoided. The influence of weather on stored pipe
components should be kept to a mini-
The recommendation for the permitted mum, i.e. the pipe components should
stacking height for PE pipes not stored be kept in a warehouse. If the pipes
on pallets is 1 m. Pipes should be are stored in the open (construction
stacked in layers with sockets placed sites), then they should be covered with
at alternate ends of the stack to ensure coloured or black sheeting to protect
their support along the entire length. them from the influence of weather (for
example, UV rays). Wavin PE fittings and
valves are packed in PE plastic bags to
protect them from ultraviolet radiation
and dust. We recommend removing the
pipes from the packing only shortly
before installation.
Moreover, one-sided heat exposure

caused by sunshine can lead to
Figure 37. Loose pipes with sockets deformations in the pipes.
must be stored socket end/
spigot end alternately to Maximum permitted storage periods
prevent pipes from resting on should be adhered to (for example,
the sockets. DVGW). The pipe components should
be used in the order of their manufacture
If the pipes are stacked on pallets and delivery to ensure appropriate stock
and are secured against lateral move- turnover.
ments, the stacking height can be
increased to 1.5 m. When spacing the
pipes the bearing width of the sup-
ports and timbers respectively must be
at least 7.5 cm. The distance between
the supports and timbers respective- Note 1: PE pipes should read PVC pipes.
ly should be 1-2 m. The outer sup-
Note 2: Rubber rings will be supplied in plastic bags
ports and timbers respectively are to be
arranged 0.5-1.0 m from the stack end.
1,50 m
The area where pipe components are

stored should provide as much protec-
tion as possible. Pipes should be com-
11. Notes
This document gives units of the interna- Dimensions and units

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

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

87,08 6 0,6 600
91,44 6,3 0,63 630
108,85 7,5 0,75 750
116,11 8 0,8 800
145,14 10 1 1000
181,42 12,5 1,25 1250
232,22 16 1,6 1600
290,28 20 2 2000
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Technical Guide Wavin PVC Pressure Pipe Systems

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Technical Guide Wavin PVC Pressure Pipe Systems

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Waste water drainage

Wavin PVC Pressure

PVC Pressure Pipe systems Product and Technical Guide 1

1. Materials for water distribution page 4

1.1 Classification of plastics for piping systems page 4

2. General material properties page 6

2.1 Polyvinylchloride PVC-U page 6

3. Apollo bi-axial PVC-O page 9

4. Standards & Regulations page 11

5. Product range page 13

6.1 Rubber ring jointing page 15

7.1 Piping design, pipe arrangement, linear expansion calculation page 33

8. Laying instructions page 39

8.1 Pressure testing page 40

10. Handling & Storage page 45

11. Notes page 47

PVC Pressure Pipe systems Product and Technical Guide 3

1.1 Classification of plastics for Procedure example, common PE pipe materials.

PVC 355 1.6 SDR = d / e SDR = 20 x (zul./p) + 1

PVC Pressure Pipe systems Product and Technical Guide 5

Chemical resistance Refer to DS/ISO DATA 7 Unplasticized

*dy = outside diameter of plastic pipe

PVC Pressure Pipe systems Product and Technical Guide 7

Features and benefits Meeting all requirements

PVC Pressure Pipe systems Product and Technical Guide 9

As a thin walled pipe system, pipe stiff

Figure 3: Product specifications.

Sealing Element Reinforcement Element

Figure 4: The Apollo ring seal.

European product standards

In the CEN (Comit Europen de Nor

PVC Pressure Pipe systems Product and Technical Guide 11

ISO 2045 Minimum insertion depth for push-fit sockets

PVC-U pipes PN 10 - PN 16 (EN 1452)

Nominal (minimum wall thickness)

Nominal pressure PN based on service (design) coefficient C=2,5

PVC Pressure Pipe systems Product and Technical Guide 13

Note: All Apollo pipe has an effective length of 6 metres.

PVC push-fit connections are used in the

PVC Pressure Pipe systems Product and Technical Guide 15

Bends, elbows, end pieces, valves,

The integral rubber ring joint is a non-

If the pipeline is to carry liquids of a

PVC Pressure Pipe systems Product and Technical Guide 17

Chamfering the pipe.

PVC Pressure Pipe systems Product and Technical Guide 19

Cleaning of the tools Use hand gloves for protection to avoid

- A special union rubber ring with green

Use unions to DIN 8063, sheet 3, to con-

Support cast-iron and heavy fittings so

PVC Pressure Pipe systems Product and Technical Guide 21

Outside Minimum Maximum

It is recommended to utilise additionally

DIN 4279, sheets 1and 7, describe how

PVC Pressure Pipe systems Product and Technical Guide 23

PVC Pressure Pipe systems Product and Technical Guide 25

Combiflanges are used to connect two pipes or one pipe

1) Cut the PVC pipe at right angles using

2) Remove swarf, soil and other impurities from the pipe

4) Locate the rubber gasket on the pipe so that the large

5) Apply a thin layer of lubricant to the outer surface of

6) Push the cast-iron flange by hand over the rubber gasket

8) Ensure that the assembly is correctly aligned.

9) Tighten the bolts using a spanner. Cross-tighten to

1.1 Classification of plastics for Procedure example, common PE pipe materials.

Chemical resistance Refer to DS/ISO DATA 7 Unplasticized

- A special union rubber ring with green

1) Cut the PVC pipe at right angles using

2) Remove swarf, soil and other impurities from the pipe

4) Locate the rubber gasket on the pipe so that the large

5) Apply a thin layer of lubricant to the outer surface of

6) Push the cast-iron flange by hand over the rubber gasket

8) Ensure that the assembly is correctly aligned.

9) Tighten the bolts using a spanner. Cross-tighten to

Figure 12: Diagram showing connection of non-tensile resistant

1) Cut the PVC pipe at right angles using a fine-toothed

2) Remove swarf, soil and other impurities from the pipe

5) Locate the rubber gasket on the pipe so that the large

7) Apply a thin layer of lubricant to the outer surface of the

9) Locate the bolts and tighten by hand until the parts

3. Remove all swarf and burs from the

Figure 16: Recommended Trench Construction Figure 17.

Clip and bracket centres in cm for horizontal and vertical installations at

earth = permissible earth The minimum width must then be:

Figure 29. Diagram of anchorage of