HYPRO PVC-O Pipes

Installation Guide

Molecor (SEA) Sdn Bhd

A member of the FITTERS Group
T : +603-62767155 | F : +603-62751378
Wisma FITTERS, No. 1, Jalan Tembaga SD 5/2,
Bandar Sri Damansara, 52200 Kuala Lumpur,
Malaysia

Molecor (SEA) Sdn Bhd August 2014

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TABLE OF CONTENTS
1. Introduction

Page | 3

2. Handling and Storage

Page | 4

3. Trench Preparation

Page | 4

4. Assembly of HYPRO PVC-O pipes

Page | 5

5. Assembling Pipes to Fittings

Page | 6

6. Cutting and Chamfering

Page | 7

7. Tapping and Service Connections

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8. Repairs and Cut-ins

Page | 8

9. Contact information

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1. Introduction
1.1 The revolutionary HYPRO PVC-O pipes developed by
Molecor offers the benefits of the most advanced and ecofriendly technology for water transport, and are the best
choice for high pressured fluid transport. HYPRO PVC-O
pipes comply with international standard ISO 16422:2006
and are certified by SIRIM QAS International.
1.2 This guide provides general recommendations with
regards to the installation of HYPRO PVC-O pipes.
Extraordinary conditions not included in this guide should be referred to the Engineer or
field inspectors to provide on-site solutions. Nevertheless, technical advice from Molecor
would always be available. The objective here is to encourage the use of preferred and
recommended methods that lead to proper and professional installation, which
consequently ensures the maximum efficiency and service life of the pipes.
1.3 Ultimately, the Engineer who designs the pipeline will determine how it is to be
installed. It is not our intention that this guide should assume that responsibility unless the
Engineer so directs.
1.4 This guide is based on Molecors experience and on an array of published reports from
other industry resources. Users may also find additional helpful advice in technical
guidelines published by the governing water authorities in each respective jurisdiction.

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2. Handling and Storage

2.1 While HYPRO PVC-O pipes are light-weight and easy to handle, careful handling of the
pipes should be practiced to avoid causing unnecessary damage to them.
2.2 Pipes are delivered to the installation site in
standard pallet size units. Unload the pipes in the units
as shipped and use equipment such as fork lifts or front
end loaders with forks. Avoid sliding the forks against
the underside of the pipes in the pallet which may cause
unnecessary abrasions to the pipes. Unloaded pipes
should be situated on level ground.
2.3 HYPRO PVC-O pipes are manufactured with integrated sockets. To avoid uneven
stacks, these pipes should be stacked in layers with sockets placed at alternative ends. Avoid
applying loads on the sockets.
2.4 HYPRO PVC-O has unbeatable impact resistance; however, unsightly surface scratches
may be caused by coming into contact with sharp objects or sharp edges. Storage areas
should be clear of surface irregularities such as stones, branches or other sharp projections.
2.5 Pipes at the installation site which are positioned along the trench should be located as
close as possible to the line of the trench where they can be lowered with the least amount
of additional handling.

3. Trench Preparation
3.1 Safety first. The contractor or installer bears the responsibility of ensuring that all
regulations have been complied with, and that safety procedures for the protection of
workers and the public have been adhered to.
3.2 The width of the top of the trench is determined by parameters set by the governing
water authority of the installation site and also best practice adhered to by the installer.
Take note that the trench width at the pipe zone should be kept to a practical minimum.
3.3 Although other types of applications are possible, HYPRO PVC-O pipes are particularly
recommended for underground installation. The minimum width of the trench can be
calculated using the following tables:

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4. Assembly of Hypro PVC-O pipes

4.1 HYPRO PVC-O pipes are manufactured with integrated sockets including the rubber
rings of each socket. This eliminates the rubber ring insertion procedure at the installation
site.
4.2 Lay the pipes with sockets forward, assembly will consist of concentrically pushing the
spigot of one pipe into the socket of another.
4.3 Steps for assembly:
4.3.1 In preparation for assembly, ensure that the socket and spigot end of each pipe is
cleaned. Avoid further contamination after cleaning.
4.3.2 Apply lubricant on the chamfer of the spigot end and in the
rubber ring joint.

4.3.3 Align the pipe and place the spigot end inside the socket.

4.3.4 Firmly push the free end into the other pipe. Introduce until the end
mark on the spigot end is no longer visible.

4.4 Other methods for assembly of HYPRO PVC-O include:

4.4.1 Trench Excavator method: After preparing trench using excavator, the excavator could
be utilized for pushing the pipe spigot into the socket. This is most commonly used for large
diameter pipes. Use timber at the edge of the pipe so that the excavator bucket is not in
direct contact with the pipe.

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4.4.2 Crowbar method: Entry of spigot into the socket by pushing with crowbar.

4.4.3 Fork Tool method: For is placed over and behind the socket of the last pipe that was
laid. Join the pipes by wrapping a wire rope sling around the spigot.

5. Assembling Pipes to Fittings

5.1 Fittings are connected directly with the pipe to allow deviations or reductions. It is very
important to fix the fitting to the ground in order to guaranty the net structural resistance.
5.2 HYPRO PVC-O pipes allow connecting the spigot ends to all kinds of fittings with
connection to a flange.
5.3 HYPRO PVC-O pipes are compatible to fittings used in the water industry. Our technical
service will provide you advice in case you need it.

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6. Cutting and Chamfering

6.1 Cutting methods and techniques include band saw cutting, cold sawing, laser cutting and
lathe cutting. The most common method in cutting, is band saw cutting.
6.2 Pipes can be cut to length on-site by using hand saw or power cutting tool. Select a flat
ground and roll the pipe across the ground while scribing a cutting line on the pipe wall with
a felt pen. This line should be placed carefully to ensure accurate cutting.
6.3 Chamfering the pipe involves filing, scraping or grinding on the end of the pipe by
removing 25% of the wall thickness at an angle of 10 to 15 degrees. Ensure that there are no
sharp edges at the spigot end. Such sharp edges will damage the rubber rings when the
spigot is pushed into the socket.
6.4 A new witness mark should be made on the pipe spigot to match the socket depth.

7. Tapping and Service Connections.

7.1 A new connection to existing piping without
interruption of emptying that section of pipe is
possible by using hot tapping method. Typical
connections consist of tapping fitting, isolation valve,
and hot tapping machine. Fine tooth shell cutters or
hole saws are most recommended to avoid any risk
of spalling of the internal pipe surface.
7.2 The hole saw is used to make an opening in the pipe so that a line plugging head can be
inserted.

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8. Repair and Cut-ins

8.1. Mechanical joints or couplings can be used where a section of pipe has to be removed
to insert another fitting or where the section of pipe is damaged. Care should be taken to
avoid excessive bolt torques which may result in distortion of the pipe wall.
8.2 Steps for repairs and cut-ins:
8.2.1 Determine the length of the replacement section, cut the pipe to the proper length.
8.2.2 Bevel the length of the replacement section; locate the reference marks on all ends.
8.2.3 Mount the couplings.
8.2.4 Insert the replacement section into pipeline and slide the couplings into position.

9. Contact Information
9.1 For further technical advice or to arrange for a technical presentation or seminar, please
contact our business headquarters in Kuala Lumpur, Malaysia:

Molecor (SEA) Sdn Bhd

A member of the FITTERS Group

Wisma FITTERS, No. 1, Jalan Tembaga SD 5/2, Bandar Sri Damansara,

52200 Kuala Lumpur, Malaysia
Tel: +603-62767155
Fax: +603-62751378
Email: inquiry@molecorsea.com