Fibrelogic Flowtite Engineering Guidelines DES M-004

Quality
ISO 9001
Engineering Design and

Installation Guidelines
for Flowtite GRP Pressure and
Non Pressure Pipes
Important Disclaimer
The information, opinions, advice and recommendations contained in this
publication are offered only with the object of providing a better understanding of
technical matters associated with pipeline design etc, with Fibrelogic Pipe
Systems Pty Ltd assuring no duty of care in respect of them. This publication
should not be used as the sole source of information. As it does not refer to all
relevant sources of information, reference should also be made to established
textbooks, and other published material. Readers should not act or rely upon any
information contained in this publication without taking appropriate professional
advice, which relates to their particular circumstances. Pipes and fittings are
shown as typical configurations, however, in some cases, product dimensions
may vary or be changed without notice. If a dimension is critical please contact
Fibrelogic Pipe Systems Pty Ltd for clarification.
Document # DES M-004
Fibrelogic Pipe Systems Pty Ltd
th
4 August 2009
Contents
1
INTRODUCTION TO FIBRELOGIC FLOWTITE PIPES .................................................. 4

1.1 Product Benefits ........................................................................................................... 5
1.2 Manufacture .................................................................................................................. 6
1.3 Applications .................................................................................................................. 9
2 MATERIAL PROPERTIES ................................................................................................. 12
2.1 Physical Properties ..................................................................................................... 12
2.1.1
Embodied Energy ................................................................................................ 12
2.1.2
Ring stiffness ....................................................................................................... 13
2.1.3
Abrasion Resistance............................................................................................ 15
2.1.4
Ultraviolet solar radiation resistance.................................................................... 15
2.1.5
Weather Resistance ............................................................................................ 15
2.2 Chemical Properties ................................................................................................... 16
2.2.1
Potable water approvals ...................................................................................... 16
2.2.2
Maximum service conditions ............................................................................... 16
2.2.3
Performance in exceptional chemical environments ........................................... 16
3 SPECIFICATIONS AND TESTING .................................................................................... 17
3.1 Manufacturing Standards............................................................................................ 17
3.2 Standards for Fittings.................................................................................................. 19
3.3 Test requirements for pipes ........................................................................................ 21
3.3.1
Raw Materials ...................................................................................................... 21
3.3.2
Production testing ................................................................................................ 22
3.3.3
Long Term Type Testing ..................................................................................... 27
4 PRODUCT RANGE ........................................................................................................... 29
4.1 Description and classification ..................................................................................... 29
4.2 Dimensions - pipes ..................................................................................................... 30
4.3 Dimensions - fittings ................................................................................................... 35
5 HYDRAULIC DESIGN ....................................................................................................... 55
5.1 Flow and pressure capacity calculations .................................................................... 55
5.2 Economic considerations ............................................................................................ 58
5.3 Air Valves, anti-vacuum valves and scour valves ....................................................... 59
5.4 Surge Capacity ........................................................................................................... 64
5.5 Water hammer surge celerities ................................................................................... 64
5.6 Fatigue under cyclical pressure regimes .................................................................... 65
5.7 Thermal effects on pressure ratings ........................................................................... 65
5.8 Non pressure pipeline design ..................................................................................... 66
6 STRUCTURAL DESIGN .................................................................................................... 69
6.1 Allowable cover heights .............................................................................................. 69
6.2 Thrust block design for pressure pipelines ................................................................. 82
6.3 Angular deflection of Flowtite coupling joint ............................................................ 85
6.4 Design of GRP flanges ............................................................................................... 86
6.5 Above Ground Installation .......................................................................................... 90
7 INSTALLATION ................................................................................................................. 94
7.1 Transportation and Storage ........................................................................................ 94
7.2 Excavation and associated works............................................................................... 95
7.3 Pipe laying .................................................................................................................. 97
7.4 Side support and overlay .......................................................................................... 104
7.5 Trench and embankment fill (i.e. above embedment / overlay) ................................ 105
7.6 Grouting .................................................................................................................... 105
7.7 Joints subject to differential settlement ..................................................................... 106
7.8 Cutting into or repairing installed GRP pipelines ...................................................... 109
FIELD TESTING .............................................................................................................. 112

8.1 Leakage testing pressure pipelines ....................................................................... 112
8.2 Leakage testing non-pressure pipelines ................................................................ 114
8.3 Structural assessment on installation ....................................................................... 117
8.4 High pressure water cleaning ................................................................................... 120
INTRODUCTION TO FIBRELOGIC FLOWTITE PIPES
Fibrelogic Pipe Systems Pty Ltd is a company excelling in providing the ultimate in piping
solutions to its clients.
We are a private, wholly Australian owned company, manufacturing in Australia.
We are able to deliver the highest standard of product by incorporating our:
World class facilities including Flowtite GRP Pipe continuous winding machines,
Extensive QA and testing laboratories
Product Engineering and Development service
Global knowledge-base through the Flowtite Group (largest GRP Pipe group in the
world)
Experienced, professional staff
...and strong ethical business principles.
Globally, demand for Glass Reinforced Plastic (GRP) Pipe manufacturing is growing
dramatically. Due to its high strength, low weight and corrosion resistance, clients are
choosing GRP over traditional coated metallic piping. Flowtite GRP Piping has been the
leading GRP Pipe manufacturing method for nearly 40 years. The technology is now being
used worldwide on all continents with more than forty winding machines located in twenty
licensed pipe factories.
Fibrelogic Pipe Systems has licensed the Flowtite GRP Pipe manufacturing technology from
Flowtite in Norway. Flowtite is a progressive organisation which supports the engineering,
production and development of Flowtite GRP Pipe worldwide.
Corporately, we are a leading company in Australia in growth and technology, but also in
supporting the globally underprivileged through child sponsorship programs. It is a core
aspect of why Fibrelogic Pipe Systems exists to help those in need, globally.
We have a strong, passionate team of executives, management and staff that, when combined
with our world class technology and manufacturing equipment provides a great platform for
optimum product and service.
1.1
Product Benefits
Features
Corrosion-resistant materials
Electrically non-conductive
Light weight(1/4 weight of

ductile iron1/10 weight of
concrete)
Long standard lengths
Dimensions compatible with

existing piping products
Standard and custom fittings
available
Extremely smooth bore
Precision Flowtite coupling

with elastomeric REKA
gaskets
Flexible manufacturing
process
High technology pipe design
High technology pipe

manufacturing system
Benefits
Long, effective service life
No need for linings, coatings, cathodic
protection, wraps or other forms of corrosion
protection
Low maintenance costs
Hydraulic characteristics essentially constant
over time
Unaffected by stray (earth) or induced currents.
Cathodic protection systems do not need to be
considered for either Flowtite pipes or
surrounding structures.
Low transport costs
Eliminates need for expensive pipe handling
equipment
Standard lengths up to 12 metres with longer
lengths available on request
Fewer joints reduce installation time
Compatible with Hobas GRP, Series 2 PVCU,
PVCM and PVCO, ductile iron and most
existing AC pipeline applications
Fittings are available or can be designed to suit
individual requirements
Low friction loss means less pumping energy
needed and lower operating costs
Minimum slime build-up can help lower cleaning
costs.
Tight, efficient joints designed to eliminate
infiltration and exfiltration
Ease of joining, reducing installation time
Accommodates small changes in line direction
without fittings and can accommodate
differential settlement
Custom diameters can be manufactured to
provide maximum flow volumes with ease of
installation
Lower wave celerity than other piping materials
can mean less cost when designing for surge
and water hammer pressures
High and consistent product quality worldwide
which ensures reliable product performance
1.2
Manufacture
Fibrelogic Pipe Systems manufactures the Flowtite GRP Pipe at their purpose built facility in
Lonsdale, South Australia. Flowtite pipes can be manufactured in a number of standard
diameters ranging from DN300 up to DN3000.
Flowtite pipe is manufactured using the continuous advancing mandrel process which
represents the state of the art in GRP pipe production. This process allows the use of
continuous glass fibre reinforcements in the circumferential direction. For a pressure pipe or
buried conduit the principle stress is in the circumferential direction. Incorporating continuous
reinforcements in this direction and not just chopped discontinuous roving, such as in a
centrifugal casting process, yields a higher performing product at lower cost.
Using the technology developed by Flowtite, a very dense laminate is created that
maximizes the contribution from the three basic raw materials, namely glass fibre, silica sand
aggregate and thermosetting resin.
Both continuous glass fibre rovings and chopped roving are incorporated for high hoop
strength and axial reinforcement. A silica sand aggregate is used to provide increased
stiffness with placement near the neutral axis in the core. Thermosetting resin, delivered
through a dual resin delivery system gives the equipment the capability of applying a special
inner resin liner for severe corrosive applications while utilizing a less costly resin for the
structural and outer portion of the laminate.
The raw materials are applied on the continuously advancing mandrel in specific locations to
ensure the optimum strength with minimum weight. The materials are applied to produce a
series of layers which give both pressure resistance as well as pipe stiffness.
The diagram below shows the typical wall construction of a Flowtite pipe and the table
explains the layers construction and purpose. Note that all layers contain thermosetting resin.
Layer
Interior Liner
Barrier Layer
Inner Structural Layer
Core
Outer Structural Layer
Exterior Surface
Construction
C Glass tissue
Chopped glass fibres
Continuous glass fibres and
Silica sand aggregate and chopped
glass fibres
Continuous glass fibres and
Chopped glass and C glass tissue
or polyester veil
Purpose
Protection
Protection
High modulus structural
reinforcement
Solid separating core
High modulus structural
reinforcement
Protection
After all materials have been applied the laminate is cured completely using a number of
strictly controlled mechanisms including heating the mandrel as well as infrared heating of the
external surface.
The cured laminate is cut to length as required. Standard lengths are 12 metre, 6 metre and
3 metre. Intermediate lengths can also be manufactured at 1 metre increments. Longer
lengths are possible but can not be pressure tested.
All pipes are quality inspected after manufacture. Once inspected the pipe spigots are
chamfered and calibrated where necessary for fitment of couplings.
Each pipe is pressure tested to twice its nominal pressure class to verify performance.
Couplings are cut from specially made coupling pipes of an appropriate diameter to allow
internal boring to create grooves for the rubber seals and central register. They are also proof
tested at 2 x PN pressure on a hydrostatic testing machine.
1.3
Applications
With the aging of the worlds infrastructure there are millions of kilometres of water and sewer
pipelines needing rehabilitation. A major concern is that that the deterioration is premature and
design lives predicted at the conceptual stage are not being realised. The prime cause of this
problem is corrosion, typically for the following reasons:
Internal attack on unprotected concrete gravity flow sewer pipes, which deteriorate
rapidly in the presence of sulphuric acid as a result of the hydrogen sulphide cycle. In
water supply installations, high levels of carbon dioxide in soft water from underground
sources can rapidly degrade cementitious liner materials
External attack can be caused by aggressive soil / ground water conditions or stray
electrical currents affecting ferrous and cementitious materials. Unlike GRP, these
pipes are vulnerable when buried in poorly aerated and poorly drained soils of low
resistivity. Saline soils, the presence of chlorides, or sulphate-reducing bacteria also
accelerate corrosion.
GRP pipes are not subject to any of these problems and with the latest advances in
manufacturing technology giving much higher production rates, there has been a widespread
increase in their use for both new infrastructure and as replacements for corrosion prone
materials. The unique properties of Flowtite pipes with high strength, combined with
corrosion resistance and easier laying make them very attractive for use in many of the major
infrastructure applications listed below:
Water supply transmission and distribution mains

Irrigation
Gravity and rising main sewers
Slip lining
Submarine pipelines
Hydro-electric power station penstocks
Water and sewerage treatment plants
Desalination plants
Thermal power station supply and cooling systems
Chemical and industrial process pipelines
Storage tanks
A range of case studies can be found on the international Flowtite website www.flowtite.com
DN 250 Flowtite pipes for a corrosive bore water

supply pipeline for Kogan Creek power station in
Queensland.
DN1000 PN16 SN 10000 Flowtite pressure

pipes and special long length GRP fittings
being installed on a major recycled water
pipeline near Wivenhoe Dam in SE
Queensland.
10
DN1000 PN16 SN10,000

Flowtite pressure pipe
strung out along the alignment
near Wivenhoe Dam in SE
Queensland
11
2
2.1
MATERIAL PROPERTIES
Physical Properties
As the wall construction of Flowtite pipes vary according to pipe class and stiffness, only
indicative material parameter values have been given below. More specific information for any
particular pipe design should be obtained by contacting Fibrelogics engineers.
Property
Density
Thermal coefficient of expansion (axial)
Typical Value
1800 kg/m3 2100 kg/m3
24 - 30 x10-6 m/m.K.
Thermal conductivity
0.14 to 0.22 W/m.K
Tensile Strength
- Circumferential (hoop)
Tensile Strength
- Longitudinal (axial)
Elastic Modulus
- Circumferential tensile and flexural
Elastic Modulus
- Longitudinal tensile and flexural
Circumferential bending creep / relaxation
ratio
Minimum ultimate circumferential tensile
strain
Minimum ultimate circumferential bending
strain
Poissons ratio
Combustibility characteristics (AS 1530.31989)
150 700 MPa

25-60 MPa
17,000 MPa (low pressure pipe)
24,000 MPa (high pressure pipe)
6000 MPa 12,500 MPa
60% retention after 50 years
1.52% initial; 0.65% long term (at 50 years)
2.30% initial; 1.30% long term (at 50 years)
0.22 to 0.29
Ignitability Index (0-20)
Spread of flame Index (0-10)
Heat evolved Index (0-10)
Smoke developed Index (0-10)
10
0
2
6
2.1.1 Embodied Energy

The embodied energy of Flowtite GRP pipes is generally lower than that of equivalent nonpolymer pipe materials. For detailed information, contact Fibrelogic Pipe Systems.
12
2.1.2
Ring stiffness
The stiffness of a pipe indicates the ability of the pipe to resist external soil, hydrostatic and
traffic loads together with negative internal pressures.
It is a measure of resistance of a pipe to ring deflection determined by testing and is the value
obtained by dividing the force per unit length of a specimen by the resulting deflection at 3
percent deflection.
S=
Ff
Ld v
Where:
S=
F=
dv =
Dm =
f=
Equation 2.1
stiffness (Newtons / metre per metre length of pipe)

force (N)
deflection (m)
mean diameter (m)
a deflection coefficient including a correction factor for ovality of the
deformed specimen obtained as follows:
f = 10 5 (1860 + 2500
dv
)
Dm
Equation 2.2
According to the Australian and ISO Standards, stiffness is expressed as follows:
S=
EI
Dm
Equation 2.3
Where S = the pipe stiffness as determined by testing in N/m per metre length of pipe
E = the apparent modulus of elasticity, in Pascals.
I = the second moment of area per unit length of the pipe wall section in m4 per m.
Dm = mean diameter (m)
i.e.
Where t
I=
t3
12
= wall thickness in m.
The initial stiffness is determined using a specific test method and cannot be obtained through
calculations using nominal values of E and t as Flowtite is a GRP composite.
13
There are also other terms in common use internationally describing pipe stiffness.
For example according to German DIN Standards and the ATV code the ring stiffness is
defined as:
SR =
EI
3
Rm
Equation 2.4
Where Rm = mean radius (m).

This stiffness value is 8 times greater than that given by the Australian and ISO Standards, so
that in order to avoid mistakes E and SR are expressed as N/mm2 (MPa) when using this
formula.
According to American ASTM Standards the ring stiffness measured at 5% deflection, is
expressed as:
F
dv
(Pounds per square inch)
Equation 2.5
Where F = load per unit length (pounds per inch)

dv = vertical pipe deflection (inches)
GRP pipes are classified by the nominal stiffness value determined from the standard initial
stiffness test i.e.:
Table 1
Nominal
Stiffness
Nominal Stiffness / Comparison of Units

Unit
SN 2500
SN 5000
Sp (ISO & Aust.)

SR (DIN ATV)
F
dv
(ASTM)
N/m2
N/mm
psi
SN 10000
2500
5000
10000
0.02
0.04
0.08
20
40
80
14
2.1.3
Abrasion Resistance
Flowtite pipes are manufactured with an external layer of reinforced resin to provide scuff
resistance during the handling and installation process.
The potential for bore abrasion wear can be determined using the Darmstadt method. The test
used was developed at the Institute of Hydraulics and Hydrology of Darmstadt, Germany and
the procedure involves axially rocking a half section of pipe through 22 degrees, so that a
calibrated load of abrasive slurry slides back and forth along the invert of the pipe.
When tested a Flowtite pipe specimen showed a wear rate of 0.84mm loss per 100,000
cycles.
2.1.4
Ultraviolet solar radiation resistance
Flowtite pipes have a non-structural external layer of reinforced resin to provide a

weathering layer when stored or installed above ground. This layer protects the structural
layers from UV radiation but may discolour over time. If this is not acceptable, pipes may be
coated with an acrylic (water based) paint.
2.1.5
Weather Resistance
Standard Flowtite pipes can be permanently stored in the open without any detrimental
effects on the structure of the pipe due to UV radiation although some superficial roughening
and discolouration of the external and internal surfaces may occur. For periods over 6 months
in open areas it is recommended that the rubber rings should be stored indoors.
15
2.2
2.2.1
Chemical Properties
Potable water approvals
Flowtite pipes and fittings meet the requirements of AS 4020.

Flowtite pipe has been tested and approved for the conveyance of potable water meeting
many of the worlds leading authorities and testing institutes criteria, including:
NSF (Standard No. 61) United States
DVGW Germany
Lyonnaise des Eaux France
Water Byelaws Scheme (WBS) United Kingdom
Russia (Cert. No. 07700 03515I04521A8)
Oficina Tcnia De Estudios Y Controles Spain
Pnstwowy Zaklad Higieny (National Institute of Hygiene) Poland
OVGW Austria
NBN.S. 29001 Belgium
Copies of Flowtite Technology qualification test reports are available on the web site
www.flowtite.com
2.2.2
Maximum service conditions
Normal Flowtite pipes are intended for use with water, sewage and controlled industrial
wastes at temperatures of up to 35C in the pH range 3 to 9. For temperature and chemical
conditions in excess of these values Fibrelogics engineers should be consulted for advice on
re-rating and chemical suitability.
With the exception of chlorinated or aromatic solvents, Flowtite pipes have a high resistance
to chemical attack. Furthermore, special resin systems can be used to improve the chemical
resistance at elevated temperatures. In the case of some solvents, the use of a vinyl ester
resin system may be recommended.
2.2.3
Performance in exceptional chemical environments
Flowtite pipes selected for use in severe environments, such as the processing industry,
especially at elevated temperatures, may require special resins systems such as vinyl esters.
Because of the range of factors involved, the final determination of the suitability of Flowtite
for a given environment becomes the sole responsibility of the specifier. General guidance
can be provided by Fibrelogic Pipe Systems as to suitable applications based on information
provided by resin suppliuers. However, this advice is not intended to imply approval for any
given application, as neither the resin suppliers nor Fibrelogic has any control over the
conditions of usage or the means of identifying all environmental conditions that may affect the
selected pipes and fittings.
16
3
3.1
SPECIFICATIONS AND TESTING

Manufacturing Standards
Fibrelogic Pipe Systems complies with the requirements of AS/NZS ISO 9001:2000 Quality
Management Systems and has been officially certified by a 3rd party certification body.
Standards developed internationally apply to glass reinforced polyester (GRP) pipes,
sometimes referred to as fibreglass or fibre reinforced polyester (FRP), when used for
infrastructure, including the conveyance of potable water, irrigation water, sewage and
industrial waste. Common to all modern pipe product standards is the fact that they are
performance-based documents, that is, the required performance and testing of the pipe is
specified rather than prescriptive requirements on the manufacturing process.
Flowtite pipes have been appraised by the Water Association of Australia refer to Product
Appraisal 04/06 Flowtite GRP Pipe System for Fibrelogic Pipe Systems Pty. Ltd.
The following list includes standards commonly used for the manufacture and testing of GRP
pipes and fittings.
ISO Standards
The International Standards Organization (ISO) has published a suite of GRP product
standards and corresponding test methods. Flowtite Technology in Europe participated in
the development of these standards; thereby ensuring performance requirements will result in
reliable products. The ISO Standards for GRP pipes and fittings manufacture relevant to
infrastructure works include:
ISO 10467 Plastics piping systems for pressure and non-pressure drainage and sewerage Glass-reinforced thermosetting plastics (GRP) systems based on unsaturated polyester (UP)
resin
ISO 10639 Plastics piping systems for pressure and non-pressure water supply -Glassreinforced thermosetting plastics (GRP) systems based on unsaturated polyester (UP) resin
These Standards are essentially the same except that the sewer pipes must comply with the
strain corrosion type test and water supply pipes with the requirements of AS 4020 for potable
(drinking quality) water. All Flowtite pipes currently manufactured in Australia meet both
standards.
Australian Standards
Australian practice is to use ISO based standards for GRP pipes and fittings and the following
documents are in the process of being revised to meet the latest ISO Standards. Flowtite is
already manufactured to the ISO equivalent. Existing standards are:
GRP Pipes: Australian Standard AS 3571 Glass Filament (GRP) Pipes Polyester Based
Water Supply, Sewerage and Drainage Applications*.
Australian Standard AS 3572 1989 Plastics Glass Filament Reinforced Plastics
(GRP) Methods of Test*.
17
United States of America Standards

Flowtite pipes manufactured in Australia are designed to meet United States Standards in
addition to the ISO and AS Standards.
Currently, there are several ASTM Product Standards in use that apply to a variety of GRP
pipe applications. All product standards apply to pipes with diameter ranges of 200mm to
3600mm and require the flexible joints to withstand hydrostatic testing in configurations (per
ASTM D4161) that simulate exaggerated in-use conditions. These standards include various
qualification and quality control tests.
ASTM D3262 Standard Specification for Fibreglass (Glass-Fibre-Reinforced ThermosettingResin) Sewer Pipe
ASTM D3517 Standard Specification for Fibreglass (Glass-Fibre-Reinforced ThermosettingResin) Pressure Pipe
ASTM D3754 Standard Specification for Fibreglass (Glass-Fibre-Reinforced ThermosettingResin) Sewer and Industrial Pressure Pipe
ANSI/AWWA C950 AWWA Standard for Fibreglass Pressure Pipe is one of the most
comprehensive product standards in existence for GRP pipe. This standard for pressure water
applications has extensive requirements for pipe and joints, concentrating on quality assurance
and prototype qualification testing. Like ASTM standards, this is a product performance
standard. Flowtite pipe is designed to meet the performance requirements of this standard.
AWWA has recently issued a new Fibreglass Pipe Design manual M-45, which includes
chapters on the design of GRP pipelines for buried and aboveground installations.
AWWA C950 Fiberglass Pressure Pipe
AWWA M-45 Fiberglass Pipe Design Manual
Other Standards
Standardisation organisations such as BSI and DIN have also published performance
specifications for GRP pipes to which Flowtite complies where nominated.
DIN 16868 Glass Fibre-Reinforced Polyester Resin Pipes
BS 5480 Pipes and Fittings for Water and Sewage
Associated fittings
Fittings used with Flowtite pipes may be of GRP or metallic materials. The following
documents may be relevant:
International Standards ISO 10639 & 10467.

Ductile Iron Pressure Fittings Australian Standard 2280 Ductile Iron Pressure Pipes
and Fittings.
Mild Steel Cement Lined Fittings Australian Standard 1579 Arc Welded Steel Pipes
for Water and Gas and Australian Standard 1281 The Cement Mortar Lining of Steel
Pipes and Fittings.
Flanged joints, specifically drilling patterns in both GRP and metal Australian
Standards AS 4087 Metallic flanges for waterworks purposes , AS 2129 Flanges
for pipes, valves and fittings and AS 4331.1 (ISO 7005) Metallic flanges - Steel
flanges may be applicable. Note that flange thicknesses for GRP will depend on the
design but will be greater than for metal flanges.
18
3.2
Standards for Fittings
For water supply, sewerage rising-mains, and other pressure applications a full range of GRP
fittings is available. These fittings can be custom made to specific customer requirements.
In addition to GRP pressure fittings, standard ductile iron fittings, valves and hydrants are
suitable for use with Flowtite pipe. The outside diameters of Flowtite GRP pipes are
compatible with Australian Standard PVC-U, PVC-M, PVC-O, ductile iron, and some AC pipes
and fittings of the same nominal diameter.
Where pipe tapping Flowtite pipe is a flexible pipe, flexible tapping bands manufactured from
gunmetal or stainless steel should be used for service connections.
GRP Fittings
Flowtite GRP pressure fittings are manufactured in Classes PN 6, 10, 16, 20, 25 and 32 for
use with Flowtite pipes of the corresponding class. These fittings are fabricated from
Flowtite pipes using proprietary wrapped laminate designs.
Fittings are normally supplied spigot ended suitable for Flowtite couplings. Flanged fittings
are available and can be full-faced or, for higher operating pressures, stub flanges with steel
backing plates may be the preferred option.
Non pressure (i.e. PN 1) fittings are also fabricated from Flowtite pipes and comply with the
requirements ISO 10639 and ISO 10467. Fittings are normally supplied spigot ended suitable
for Flowtite couplings. Branches for sidelines can be attached to the Flowtite mainline
using saddle fittings attached with epoxy adhesive applied in-situ. Adaptor couplings for saddle
branches for joining to PVC DWV
19
Ductile Iron Fittings

Ductile iron fittings socket joints can be used on selected Flowtite pipes of the same nominal
size. Conventional socketed fittings complying with AS 2280 Ductile Iron Pressure Pipes
and Fittings in sizes DN100 to DN750 are suitable. A complete range of bends, tees, reducers
and flange-spigot pieces is available with Griptite* or Tyton# rubber ring sockets in sizes
DN100 to DN750. Other joint designs may also be acceptable. Fibrelogic should be contacted
to confirm the suitability of any particular range of fittings.
These fittings may be protected from corrosion using various alternatives.
Fusion bonded polymer (polyamide or epoxy)
Cement lining and polyethylene wrap.
*Registered Trademark of Northern Iron and Brass Foundry.
#
Registered Trademark of Tyco Water.
Examples of fusion bonded nylon coated ductile iron fittings with Griptite seals suitable for use
with Flowtite
Steel fittings
Fabricated steel (and stainless steel) fittings fabricated from steel plate can be used with
Flowtite pressure pipes. Normally, steel fittings are protected from corrosion externally by
ultra high build epoxy and internally by cement lining. Where possible these fittings are
manufactured with spigots especially sized to match Flowtite outside diameters, including
tolerances so that the joint can be made using standard Flowtite GRP couplings.
Relevant Standards are
AS 1594 Hot-rolled steel flat products
AS 3678 Hot-rolled structural steel plates, floor plates and slabs
AS 1579 Arc welded steel pipes and fittings for water and waste water
AS 1281 Cement mortar lining of steel pipes and fittings
AS 4321 Fusion bonded medium density polyethylene coatings and linings for pipes
fittings
AS 2312 Guide to protection of iron and steel from atmospheric corrosion
and
20
3.3
Test requirements for pipes
A common element shared by all standards is the need for a pipe manufacturer to demonstrate
compliance with the standards minimum performance requirements. In the case of GRP pipe,
these minimum performance requirements fall into both short-term and long-term
requirements.
The short-term tests are conducted at manufacturing sites as part of daily quality control, while
the latter have been conducted at Flowtite Technologys laboratory or by a certified third
party. Results from quality control tests are part of a Flowtite factorys record and retained by
the factory, while the type tests are carried out and archived by Flowtite Technology, which
is the international parent organisation.
3.3.1
Raw Materials
Flowtite Purchase Acceptance Standards (PAS) are common to the worldwide organisation
and each factory maintains Technical Data Sheets and test reports for the raw material
supplied.
Raw materials are delivered with vendor certification demonstrating their compliance with
Flowtite quality requirements. In addition, all raw materials are sample tested prior to their
use. These tests ensure that the pipe materials comply with the stated specifications.
Resins
Flowtite pipes are normally manufactured using orthophthalic polyester resins. However
where unusual environmental conditions exist, isophthalic polyester or vinyl ester can be
specified.
Aggregate and fillers
The quartz sand used in Flowtite pipes is required to meet the specific grading curve particle
sizing of the Flowtite Purchase Acceptance Standard.
Elastomeric seals
The elastomeric sealing rings comply with the requirements of EN 681-1: 1996,Type WA and
WC and AS 1646. Unless otherwise requested EPDM rings will be supplied. However in
special circumstances rings may be supplied, manufactured from other polymers - see
Table 2.
Table 2
Elastomers for Flowtite seals
Polymer
Ethylene propylene-diene*
Nitrile-butadiene
Styrene-butadiene rubber
Abbreviation
EPDM
NBR
SBR
* The standard polymer supplied. Other types are rarely needed and can only
obtained as a special order.
21
3.3.2
Production testing
Every pipe is subjected to the following control checks:

Outside diameter
Wall thickness
Pipe length
Visual inspection of all surfaces
Hydrostatic leak tightness test (for PN6 or higher)
On a sampling basis, the following control checks are performed:
Pipe stiffness
Deflection without liner cracking or structural failure
Axial and circumferential tensile load capacity
Barcol hardness
Composition
Outside diameter
Flowtite pipes are externally controlled in accordance with Table 3 External Diameter Series
of AS 3571. Normal tolerances are given in Table 3
Table 3
Tolerances on spigot outside diameters
DN
300
375
450
525
600
675
750
900
1000
1200
1400
1600
1800
2000
2200
2400
3000
Outside diameter
(PN1 to PN16)
(mm)
Min
Max
344.0
425.0
506.0
586.0
666.0
746.0
825.0
922.0
1024.0
1228.0
1432.0
1636.0
1840.0
2044.0
2248.0
2452.0
3064.0
345.0
426.0
507.0
587.0
667.0
747.0
826.0
923.0
1025.0
1229.0
1433.0
1637.0
1841.0
2045.0
2249.0
2453.0
3065.0
Outside diameter
(PN20 to PN32)
(mm)
Min
Max
345.0
426.0
507.0
587.0
667.0
747.0
826.0
923.0
1025.0
1229.0
1433.0
1637.0
1841.0
2045.0
2249.0
2453.0
3065.0
345.5
426.5
507.5
587.5
667.5
747.5
826.5
923.5
1025.5
1229.5
1433.5
1637.5
1841.5
2045.5
2249.5
2453.5
3065.5
Pipe lengths
The actual length of each pipe is equal to the nominal length with a tolerance of 25 mm. The
effective (i.e. laying) length is equal to the pipe length plus 10 mm (an allowance for the centre
register in the coupling).
Surface quality
The surface of the pipe shall be relatively smooth and free of exposed fibre or sharp
projections. Refer to Appendix B of AS 3571 for guidance with respect to surface defects.
22
Hydrostatic Leak Tightness Testing
Every pipe PN6 or greater is pressure tested to 2 times the nominal pressure class of the pipe.
The pipe is held at this pressure for 2 minutes allowing for inspection of the pipe.
23
Specific ring stiffness
A test specimen from each batch is tested in accordance with ISO 7685 and the calculated
initial stiffness shall be not less than the nominal branded stiffness. A 300mm long test piece
is taken once per shift of pipes manufactured in a single batch. A diametral load is applied
with the pipe bearing top and bottom on flat plates. The load to achieve a 3% deflection is
recorded and used to calculate the initial stiffness.
Specific ring deflection
When tested in accordance with ISO 10466, a test specimen from each production batch of
pipes must satisfy the requirements of Table 4 at the nominated deflections. The stiffness test
specimen is also used for this test.
Table 4
Minimum test deflections

Nominal Stiffness SN
No visible damage to
inside layer at %
deflection of: No structural damage
at % deflection of: -
2500
5000
10000
15
12
25
20
15
24
Initial specific longitudinal tensile test

When an axially oriented test specimen cut from each pipe batch is tested in accordance with
ISO 8513, the longitudinal tensile strength indicated for the pipe shall not be less than the
value given in Table 5. The mean elongation at rupture shall not be less than 0.4 percent for
pipe Class 6 and above and 0.3 for lower classes and non-pressure pipes (i.e. PN 1).
Table 5
Minimum axial tensile strengths (N/mm) of external circumference

Nominal
Diameter
DN
80
100
150
200
250
300
375
450
525
600
675
750
900
1000
1200
1400
1600
1800
2000
2200
2400
3000
Class
PN 1*
Class
PN 6
Class
PN 10
Class
PN 16
110
133
137
138
146
157
169
182
194
219
245
270
296
321
347
372
449
81
96
112
173
173
192
203
213
233
258
284
309
333
383
434
485
537
587
637
687
838
93
111
129
198
181
210
224
239
263
292
324
352
381
440
498
555
614
672
730
789
962
112
133
155
238
206
245
267
284
314
353
389
427
464
538
612
687
761
837
911
985
1208
Class
PN 20
Class
PN 25
Class
PN 32
230
268
288
311
347
389
433
476
518
603
688
253
305
331
356
402
453
504
558
607
711
815
289
354
384
417
471
536
599
664
726
854
981
Note: Tensile strengths shown are for SN 2500 and comply with AS 3571. Flowtite axial strengths will be greater
for higher stiffness pipes.
25
Apparent initial circumferential tensile strength

When a circumferentially oriented test specimen cut from each pipe batch is tested in
accordance with ISO8521, the tensile strength it indicates for the pipe shall not be less than
the value given in Table 6. These values may be calculated from the equation:
Po =
0.02 cu
dm
Where
cu = circumferential strength (N/mm) determined from ISO 8521
Po = initial failure test pressure (MPa) determined by regression testing
dm = mean diameter (m)
Table 6
DN
80
100
125
150
200
250
300
375
450
525
600
675
750
900
1000
1200
1400
1600
1800
2000
2200
2400
3000
Initial (average) circumferential tensile strength

Average apparent initial circumferential tensile strength pipes N/mm
PN6
PN10
PN16
PN20
PN25
PN32
355
422
488
614
735
1001
1061
1092
1125
1223
1405
1587
1761
1927
2290
2654
3036
3389
3760
4124
4488
5580
367
434
506
644
771
1111
1411
1560
1702
1909
2120
2407
2709
3018
3583
4139
4712
5292
5889
6454
7059
8760
421
542
645
843
1024
1614
2027
2358
2483
2852
3290
3763
4167
4614
5491
6367
7253
8112
9015
9900
10759
13389
1913
2508
2715
3005
3474
3991
4560
5077
5646
6733
7766
2251
2922
3238
3573
4148
4806
5482
6114
6790
8088
9413
2755
3602
3980
4396
5096
5933
6743
7589
8372
10010
11648
Barcol Hardness
When tested in general accordance with ASTM Standard D2583 the surface Barcol Hardness
of the pipe shall be greater than 35.
26
3.3.3
Long Term Type Testing
In addition to daily quality control testing, ISO 10467 and ISO 10639 require type testing to
determine long term properties such as hydrostatic failure pressures, stiffness creep (or
relaxation), and strain corrosion. These tests have duration of at least 10,000 hours to enable
extrapolation to establish design values. That is, using the methods of ISO 10928, the physical
parameters required can be determined for the specified nominal 50-year design period.
A statistically significant number of test specimens, generally a minimum of eighteen in
number, are prepared and loaded to various degrees so as to obtain a series of ultimate load
(or strain) values spread over the duration of the test period. A log time log load
regression line of best fit is established using the method of least squares. The 95% lower
confidence limit line can then be constructed based on the 50-year minimum value. In the case
of the hydrostatic design this information is needed to set values for the short-term quality
control tests.
Rigorous joint type tests, which include the combined effect of, draw and shear loading at
normal and maximum angular deflections are also requirements of the Standards.
Long term pressure testing
Flowtite pressure pipe is designed on a strain basis to fulfill the requirements of ISO 10467,
ISO 10639, AWWA C950, ASTM D3517 and ASTM D3754. The 50-year strain value for
Flowtite pipe as determined in report T-95-101R, 50, is 0,65%. Current product designs
comply with this value. For example on particular pipe specimens strain measurements were
made and then using regression analysis the long-term strain of 0,0065 at 23.2 bar pressure
was determined. That is the 50-year burst pressure, p50, equaled 2.32 MPa. The analysis also
provided the corresponding initial value, p0 , of 6.37 MPa.
The minimum design pressure can be computed from equation 24 in ISO 10467 and ISO
10639 i.e.:
C 0.1
p0,d =
PN
t ,PN ,97.5% LCL
RR , p
1 Y 0.01 1.96
The Standards require that the average of the last 20 initial failure pressures during production,
p0, mean to be greater than this value for the product in question.
With C =
p0 , d
p0
p
and RR , p = 50 this equation becomes:
p6
p6
p0
0.1 PN t ,PN ,97.5% LCL
p50
=
1 Y 0.01 1.96
The coefficient of variation Y, for the Flowtite process has been measured over a period of
time and found to be generally within the range of 2.5% to 8%. Assuming a conservative value
of 9% the expression for p0,d becomes:
27
p0 , d =
63.7
0.1 PN t ,PN ,97.5% LCL 1.21 = 3.32 PN t ,PN ,97.5% LCL
23.2
Using the values for safety factors in Table 3.4 of ISO 10467 and ISO 10639 the values for p0,d
are shown in the following Table 7:
Table 7
t,PN,97,5%LCL
applied to to the
Minimum long-term factors of safety
PN32
PN25
PN20
PN16
PN10
PN6
1.3
1.3
1.38
1.45
1.55
1.6
1.6
1.6
1.8
1.83
1.9
2.0
13.8
10.8
9.16
7.70
5.15
3.19
long term
97.5% LCL
t,Pnmean
applied to to the
long term mean
p0,d MPa
Note: As the standards do not provide factors for PN20 this value has been interpolated.
Cyclical internal hydrostatic pressure testing
In accordance with Clause 5.3 of ISO 10467 and ISO 10639 the resistance of Flowtite
pressure pipes to cyclic internal pressure has been verified through testing to ISO. The results
are recorded in TV test report TV MP4/3338-90 and Veroc test report 13-T86. In both cases
pipes were subjected to one million cycles between 0.75 x PN and 1.25 PN without showing
any sign of failure.
Resistance to strain corrosion
The strain corrosion resistance of Flowtite pipes has been measured to a value of 0.66%
(see test report T-99-107). Using the equation in Clause 10.6 of ISO 10952 this value can be
converted to deflections and compared with the requirements. By using the thickest of the
pipes in each stiffness class the following deflections are obtained:
Stiffness class
Deflection %
SN 2500
14.3
SN 5000
11.3
SN 10000
9.0
These values meet the requirements in Table 17 of ISO 10467.

Joint systems
Three methods of jointing Flowtite pipes have been tested i.e. both flexible and rigid joints,
with or without end load resisting capability to meet the requirements of Clause 7 of ISO 10467
and ISO 10639. The following test reports are available:
Flexible non-end-load-bearing joints test report T-93-102

Wrapped non-end-load-bearing joints test report T-2004-127
Bolted non-end-load-bearing joints test report T-2004-129
28
4
4.1
PRODUCT RANGE
Description and classification
Nominal Sizes (DN)

Flowtite pipes are currently manufactured in Australia in the nominal size range 300 mm to
3000 mm.
Flowtite pipes are manufactured with the same outside diameters as ductile iron of the same
nominal diameter; as a result the internal diameters are approximately 10% larger than
nominal size in comparable sizes in the DN300 to DN750 ranges.
Nominal Pressure Classes (PN)
Pressure pipes are classified according to nominal pressure and nominal stiffness; nonpressure pipes by nominal stiffness only.
Table 8
Nominal pressure rating PN
Working Pressure (MPa)
Working Pressure (Bar)
Working Head (Metres)
Max. diameter for specific PN (mm)
1
0.1
1
10
3000
6
0.6
6
61
3000
10
1.0
10
102
3000
16
1.6
16
163
3000
20
2.0
20
204
3000
25
2.5
25
255
2400
32
3.2
32
326
1800
Nominal Stiffness (SN)

Standard nominal stiffness is shown in Table 9.
Table 9
Stiffness (SN)
2500
5000
10000
Other pipe pressure or stiffness classes apart from those listed may be manufactured on
request.
Branding and Marking
All pressure pipes are branded to indicate the nominal diameter, pressure class and stiffness
as shown by the following example:
Couplings for non-pressure pipes are branded to indicate the nominal diameter. Because
couplings are common in the non-pressure and pressure range up to Class 6 they will
generally be branded Class 6, for example DN900 PN6.
29
4.2
Dimensions - pipes
Table 10
Pipe - available sizes and classifications for SN 2500

Pipe stiffness SN 2500
DN
375
450
525
600
675
750
900
1000
1200
1400
1600
1800
2000
2200
2400
3000
Spigot
OD
t
(mm)
426
5.5
507
6.6
587
7.7
667
8.7
747
9.6
826 10.5
923 11.7
1025 12.9
1229 15.3
1433 17.7
1637 20.1
1841 22.7
2045 25.0
2249 27.5
2453 29.9
3065 37.1
PN 1
ID
(mm)
415
494
572
650
728
805
900
999
1198
1398
1597
1796
1995
2194
2393
2991
PN 6
Mass
t
ID
(kg/m) (mm) (mm)
14.4
5.5
415
20.8
6.6
494
28.6
7.7
572
36.7
8.7
650
46.0
9.6
728
55.7
10.5 805
69.4
11.7 900
85.6
12.9 999
122.3 15.3 1198
165.7 17.7 1398
215.5 20.1 1597
274.0 22.7 1796
336.8 25.1 1995
406.6 27.5 2194
483.0 29.9 2393
751.7 37.1 2991
PN 10
Mass
t
ID
(kg/m) (mm) (mm)
14.4
20.8
28.6
36.7
46.0
8.6
730
55.7
9.5
807
69.4
10.5 902
85.6
11.5 1002
122.3 13.6 1202
165.7 15.8 1401
215.5 17.9 1601
274.0 20.0 1801
336.8 22.1 2001
406.6 24.2 2201
483.0 26.3 2400
751.7
PN 16
PN 20
PN 25
PN 32
Mass
t
ID
Mass
t
ID
Mass
t
ID
Mass
t
ID
Mass
(kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m)
39.9
48.9
60.8
74.7
106.5
144.2
187.5
236.3
290.8
350.8
416.3
30
Table 11
DN
300
375
450
525
600
675
750
900
1000
1200
1400
1600
1800
2000
2200
2400
3000
Pipe - available sizes and classifications (SN 5000)
PN 1
PN 6
PN 10
t
ID
Mass
t
ID
Mass
t
ID
(mm) (mm) (kg/m) (mm) (mm) (kg/m) (mm) (mm)
345
See Table for SN 10000
426
6.9
412
18.4
6.9
412
18.4
6.6
413
507
8.3
490
26.5
8.3
490
26.5
7.8
491
587
9.5
568
35.5
9.5
568
35.5
8.9
569
667 10.7 646
45.6
10.7 646
45.6
10.0 647
747 11.9 723
57.1
11.9 723
57.1
11.1 725
826 13.1 800
69.7
13.1 800
69.7
12.2 802
923 14.5 894
86.7
14.5 894
86.7
13.6 896
1025 16.0 993 106.3 16.0 993 106.3 15.0 995
1229 19.0 1191 151.9 19.0 1191 151.9 17.9 1193
1433 22.1 1389 207.1 22.1 1389 207.1 20.7 1392
1637 25.2 1587 269.9 25.2 1587 269.9 23.5 1590
1841 28.2 1785 341.3 28.2 1785 341.3 26.3 1788
2045 31.2 1983 419.4 31.2 1983 419.4 29.2 1987
2249 34.3 2180 507.1 34.3 2180 507.1 32.0 2185
2453 37.2 2379 601.6 37.3 2378 601.6 34.8 2383
3065 46.3 2972 937.6 46.3 2972 937.6
Spigot
OD

PN 16
Mass
t
ID
Mass
t
(kg/m) (mm) (mm) (kg/m) (mm)
5.1
17.4
6.2
414
15.9
6.2
24.6
7.3
492
22.5
7.2
32.7
8.3
570
29.9
8.1
42.1
9.3
648
38.3
9.1
52.6
10.3 726
47.8
10.1
64.2
11.3 803
58.1
11.1
80.6
12.5 898
72.2
12.3
99.1
13.8 997
88.7
13.5
142.0 16.3 1196 126.3 16.0
191.9 18.9 1395 171.1 18.5
250.2 21.4 1594 222.3
315.5 24.0 1793 280.2
388.8 26.5 1992 345.1
469.4
558.3
PN 20
ID
(mm)
335
414
493
571
649
727
804
898
998
1197
1396
PN 25
PN 32
Mass
t
ID
Mass
t
ID
Mass
(kg/m) (mm) (mm) (kg/m) (mm) (mm) (kg/m)
10.4
5.1
335
10.3
15.7
6.1
414
15.3
21.9
7.1
493
21.4
28.9
8.1
571
28.3
37.1
9.1
649
36.2
46.2
10
727
45.1
56.1
11
804
54.7
69.7
12.1
899
67.8
85.5
13.4
998
83.3
121.9
15.8 1197 118.7
164.9
18.3 1396 160.4
31
Table 12
Pipe available sizes and classifications (SN 10000)
Spigot
OD
2000
2045
38.9
1967
522.6
38.9
1967
522.6
38.9
1967
522.6
2200
2400
2249
2453
42.7
46.5
2164
2360
631.9
749.8
42.7
46.5
2164
2360
631.9
749.8
42.7
46.5
2164
2360
631.9
749.8
3000
3065
57.9
2949 1169.7
57.9
2949 1169.7
Mass
(kg/m)
16.4
22.2
32.0
43.2
56.0
70.9
86.5
107.3
132.7
190.5
258.5
336.7
424.8
Mass
(kg/m)
16.4
22.2
32.0
43.2
56.0
70.9
86.5
107.3
132.7
190.5
258.5
336.7
424.8

PN 16
Mass
t
ID
Mass
(kg/m) (mm) (mm) (kg/m)
16.3
8.3
328
16.2
22.2
7.9
410
20.7
32.0
9.2
489
28.9
43.2
10.6 566
39.0
56.0
11.9 643
50.1
70.6
13.2 721
62.5
86.5
14.5 797
76.2
107.3 16.2 891
94.9
132.7 17.8 989 116.6
190.5 21.2 1187 166.9
258.5 24.6 1384 226.1
336.7 27.9 1581 294.3
424.8 31.3 1778 371.7
300
375
450
525
600
675
750
900
1000
1200
1400
1600
1800
DN
PN 6
t
ID
(mm) (mm)
8.3
328
8.3
409
10.0 487
11.5 564
13.1 641
14.7 718
16.2 794
17.9 887
19.9 985
23.8 1181
27.6 1378
31.4 1574
35.2 1771
PN 10
t
ID
(mm) (mm)
8.3
328
8.3
409
10.0 487
11.5 564
13.1 641
14.7 718
16.2 794
17.9 887
19.9 985
23.8 1181
27.6 1378
31.4 1574
35.2 1771
PN 1
t
ID
(mm) (mm)
345
8.3
328
426
8.3
409
507 10.0 487
587 11.5 564
667 13.1 641
747 14.7 718
826 16.2 794
923 17.9 887
1025 19.9 985
1229 23.8 1181
1433 27.6 1378
1637 31.4 1574
1841 35.2 1771
34.7
PN 20
t
ID
(mm) (mm)
6.3
332
7.7
411
9.0
489
10.2 567
11.5 644
12.8 721
14
798
15.6 892
17.2 991
20.4 1188
23.7 1386
PN 25
Mass
t
ID
(kg/m) (mm) (mm)
13.2
6.3
332
20.0
7.5
411
28.2
8.8
489
37.3
10
567
47.9
11.3 644
59.7
12.5 722
72.8
13.7 799
90.5
15.2 893
111.1 16.8 991
158.8 19.9 1189
215.3 23.1 1387
g
g
g
g
g
g
g
g
1976
457.5
PN 32
Mass
t
ID
(kg/m) (mm) (mm)
12.9
6.2
333
19.4
7.5
411
27.2
8.7
490
36.1
9.9
567
46.2
11.1 645
57.6
12.3 722
70.2
13.5 799
87.2
15
893
107.1 16.5 992
153.0 19.6 1190
207.0 22.7 1388
Mass
(kg/m)
12.6
18.9
26.3
35.0
44.8
55.9
68.0
84.4
103.7
148.0
200.2
g
g
32
Table 13
Couplings - available sizes and classifications

Coupling dimensions & Masses
DN
300
375
450
525
600
675
750
900
1000
1200
1400
1600
1800
2000
2200
2400
3000
Length
270
270
270
270
330
330
330
330
330
330
330
330
330
330
330
330
360
(mm)
PN 1
Cplg
Cplg
OD
mass
388
11.5
469
14.0
550
16.6
630
19.1
716
30.8
796
34.1
875
37.6
973
42.8
1076
48.4
1281
59.4
1486
70.5
1691
81.9
1896
93.3
2100
105.2
2305
117.4
2510
129.7
3144
248.4
PN 6
Cplg
Cplg
OD
mass
388
11.5
469
14.0
550
16.6
630
19.1
716
30.8
796
34.1
875
37.6
973
42.8
1076
48.4
1281
59.4
1486
70.5
1691
81.9
1896
93.3
2100
105.2
2305
117.4
2510
129.7
3144
248.4
PN 10
Cplg
Cplg
OD
mass
389
11.7
470
14.5
551
17.3
631
20.0
718
32.2
798
36.3
879
41.2
977
47.1
1080
53.5
1287
66.5
1492
79.4
1698
93.1
1903
107.0
2110
125.3
2317
143.8
2523
162.5
PN 16
Cplg
Cplg
OD
mass
390
12.2
471
15.0
553
17.9
633
21.0
721
34.6
802
38.6
882
43.0
980
49.6
1084
56.6
1291
71.5
1500
89.5
1710
112.5
1918
134.4
2126
156.3
PN 20
Cplg
Cplg
OD
mass
391
12.4
472
15.3
554
18.3
634
21.3
724
36.4
804
40.3
884
44.4
983
51.6
1087
59.4
1300
82.3
1512
107.1
PN 25
Cplg
Cplg
OD
mass
392
12.6
473
15.7
555
18.8
636
22.1
727
38.4
807
42.6
888
48.3
989
57.2
1100
72.7
1315
101.2
1526
128.1
PN 32
Cplg
Cplg
OD
mass
399
14.7
480
18.4
563
22.2
644
26.1
733
43.0
816
50.0
898
57.0
1005
73.4
1116
90.6
1331
121.9
1542
151.0
33
Table 14
Pipe spigot ends - dimensional details
Nominal diameter
(DN)
Witness Mark
P
Calibration Length
CL
Chamfer Length
N
300
130 mm
140 mm
10 mm
375
130mm
140 mm
15 mm
450 -525
130 mm
150mm
20 mm
600 to 3000
160 mm
190 mm
20 mm
34
4.3
Dimensions - fittings
(Note that overall dimensions are subject to change without notice)

11.25, 22.5 & 30 BENDS
Table 15
PN 1, PN 10 & PN 16
Nominal
Radius
Diameter of Bend
DN
R
(mm)
(mm)
300
375
450
525
600
675
750
900
1000
1200
1400
1600
1800
2000
2200
2400
450
600
675
750
900
1050
1200
1350
1500
1800
2100
2400
2700
3000
3300
3600
11.25
22.50
300
Length
BL
(mm)
Approx
Mass
(kg)
Length
BL
(mm)
Approx
Mass
(kg)
Length
BL
(mm)
Approx
Mass
(kg)
400
450
450
450
400
400
450
450
450
500
600
650
700
700
700
700
10
18
29
39
51
57
70
97
120
191
311
439
554
734
887
1053
400
450
500
500
400
450
450
500
500
600
650
750
800
800
800
800
13
20
32
43
45
64
78
108
133
229
337
506
681
838
1014
1203
400
450
500
500
450
450
500
550
550
600
700
800
850
900
900
1000
13
20
32
43
51
64
87
119
147
229
363
540
724
943
1140
1503
35
45 & 60 BEND
90 BEND
Table 16
PN 1, PN 10 & PN 16
Nominal
Diameter of Bend
DN
R
(mm)
(mm)
300
375
450
525
600
675
750
900
1000
1200
1400
1600
1800
2000
2200
2400
450
Radius
450
600
675
750
900
1050
1200
1350
1500
1800
2100
2400
2700
3000
3300
3600
600
900
Length
BL
(mm)
Approx
Mass
(kg)
Length
BL
(mm)
Approx
Mass
(kg)
Length
BL
(mm)
Approx
Mass
(kg)
500
600
600
650
600
650
700
800
850
950
1100
1250
1350
1450
1550
1550
16
26
38
55
66
90
118
168
220
352
553
818
1113
1469
1896
2242
550
650
700
750
700
800
850
950
1000
1200
1350
1550
1700
1800
1950
2100
17
28
43
62
75
107
139
193
250
430
655
979
1353
1755
2296
2932
750
900
1000
1050
1100
1200
1350
1500
1650
1950
2250
2550
2850
3100
3350
3600
22
35
56
78
104
141
194
266
362
611
953
1404
1977
2631
3423
4349
36
TEES sp, sp & sp
Table 17
PN 1
PN 6 & PN 10
PN 16
Nom Dia Nom Dia Body Branch Approx Body Branch Approx Body Branch Approx
Body Branch Length Length Mass Length Length Mass Length Length Mass
DN
DN
L
H
L
H
L
H
(mm)
(mm)
(mm)
(mm)
(kg)
(mm)
(mm)
(kg)
(mm)
(mm)
(kg)
300
375
100
700
400
12
1000
550
18
1300
700
23
150
700
400
13
1200
650
23
1600
850
30
200
800
400
16
1300
650
26
1700
850
34
250
800
400
18
1300
650
29
1700
850
37
300
900
450
21
1400
700
34
1800
900
44
100
700
450
17
1100
650
26
1500
850
33
150
700
450
18
1200
700
30
1600
850
37
200
800
450
21
1500
800
39
2000
1050
49
250
800
450
23
1500
800
42
2100
1100
56
300
900
500
28
1600
850
49
2100
1100
61
375
1000
500
33
1700
850
57
2300
1150
71
37
TEES sp, sp & sp

PN 1
PN 6 & PN 10
PN 16
DN
DN
L
H
L
H
L
H
(mm)
(mm)
(mm)
(mm)
(kg)
(mm)
(mm)
(kg)
(mm)
(mm)
(kg)
450
525
600
675
750
100
700
450
24
1200
700
40
1600
900
48
150
700
450
25
1300
750
45
1700
950
54
200
800
450
29
1500
800
54
1900
1050
63
250
800
450
31
1500
800
57
2000
1050
70
300
900
500
37
1700
900
69
2200
1200
83
375
1000
500
43
1800
900
78
2400
1250
95
450
1100
550
53
1900
1000
93
1500
1300
81
100
700
500
31
1300
800
58
1700
1000
69
150
700
500
33
1400
800
64
1800
1050
75
200
800
500
38
1400
850
67
1900
1050
82
250
800
500
40
1800
950
70
2400
1300
86
300
900
550
43
1800
1000
93
2500
1350
115
375
1000
550
55
1900
1000
104
2600
1350
129
450
1100
550
65
1900
1000
114
2600
1350
140
525
1200
600
78
2000
1000
130
2700
1350
158
300
900
600
60
1100
700
73
1400
800
83
375
1100
600
75
1400
750
95
1700
900
104
450
1100
600
81
1400
750
102
1700
900
111
525
1200
600
93
1500
750
116
1800
900
125
600
1300
650
109
1700
850
143
1900
950
143
300
900
650
74
1200
750
97
1500
900
108
375
1100
650
92
1500
850
125
1800
1000
133
450
1100
650
99
1500
850
133
1800
1000
141
525
1200
700
115
1600
850
150
1900
1000
158
600
1300
700
131
1700
900
170
2000
1050
178
675
1400
700
149
1900
900
198
2100
1050
197
300
900
700
89
1300
850
126
1600
1000
138
375
1100
700
111
1400
850
140
1700
1000
150
450
1100
750
119
1600
900
167
1900
1100
177
525
1200
750
136
1700
950
188
2000
1150
197
600
1400
750
163
1800
1000
212
2100
1150
218
675
1500
800
186
1900
1000
235
2200
1150
239
750
1600
800
208
2100
1050
272
2300
1150
263
38
TEES sp, sp & sp
PN 1
PN 6 & PN 10
PN 16
DN
DN
L
H
L
H
L
H
(mm)
(mm)
(mm)
(mm)
(kg)
(mm)
(mm)
(kg)
(mm) (mm)
(kg)
900
1000
1200
300
900
750
109
1400
950
166
1600
1100
170
375
1100
750
135
1500
950
182
1800
1100
194
450
1100
750
142
1600
950
202
2000
1200
224
525
1200
800
163
1700
1000
226
2100
1250
248
600
1400
850
198
1900
1050
263
2200
1300
274
675
1500
850
221
2000
1050
289
2400
1300
309
750
1600
850
245
2100
1100
321
2500
1300
336
900
1700
850
274
2300
1150
370
2600
1300
370
300
900
800
133
1400
1000
202
1700
1200
218
375
1100
800
164
1500
1000
221
1800
1200
235
450
1100
800
172
1500
1000
231
1900
1200
256
525
1200
850
196
1600
1000
256
2000
1200
280
600
1400
900
236
1900
1150
317
2400
1400
350
675
1500
900
263
2000
1150
347
2500
1400
379
750
1600
900
290
2200
1200
396
2600
1400
410
900
1800
950
341
2300
1200
434
2800
1400
459
1000
1900
950
378
2500
1250
498
2900
1400
501
300
1000
900
205
1500
1200
305
1800
1350
322
375
1100
950
231
1600
1200
331
2000
1350
362
450
1100
950
240
1600
1200
343
2000
1350
373
525
1200
950
270
1700
1200
376
2100
1350
403
600
1400
1000
323
1800
1200
410
2200
1400
437
675
1600
1000
376
2200
1350
514
2700
1600
551
750
1700
1050
415
2300
1350
555
2800
1600
589
900
1800
1050
456
2400
1350
602
2900
1600
636
1000
1900
1100
508
2500
1350
655
3000
1600
687
1200
2200
1100
629
2800
1400
800
3200
1600
801
39
TEES sp, sp & sp

PN 1
Nom Dia
Body
DN
(mm)
1400
1600
1800
PN 6 & PN 10
Nom Dia
Branch
DN
(mm)
Body
Length
L
(mm)
Branch
Length
H
(mm)
Approx
Mass
Branch
Length
H
(mm)
Approx
Mass
(kg)
Body
Length
L
(mm)
300
1000
1000
275
1600
1350
436
375
1100
1050
308
1700
1350
469
450
1200
1050
344
1700
1350
483
525
1300
1050
381
1800
1350
524
600
1400
1100
424
2000
1400
595
675
1500
1100
466
2100
1400
642
750
1700
1150
539
2400
1500
750
900
1900
1150
615
2500
1500
807
1000
2000
1200
676
2600
1500
871
1200
2200
1200
797
2900
1550
1045
1400
2500
1250
969
3200
1600
1241
300
1000
1150
356
1700
1500
597
375
1200
1150
430
1800
1500
639
450
1200
1150
441
1900
1500
688
525
1300
1200
490
2000
1500
738
600
1400
1200
539
2100
1550
794
675
1600
1250
627
2200
1550
850
750
1700
1250
681
2300
1550
908
900
1800
1300
746
2700
1700
1092
1000
2000
1300
846
2800
1700
1168
1200
2300
1350
1032
3100
1750
1377
1400
2500
1350
1191
3400
1800
1610
1600
2800
1400
1414
3600
1800
1818
300
1000
1250
445
375
1200
1250
538
450
1200
1250
550
525
1300
1300
608
600
1400
1300
668
675
1600
1350
775
750
1700
1350
839
900
1800
1350
910
1000
2100
1450
1085
1200
2300
1450
1253
1400
2600
1500
1492
1600
2800
1500
1695
1800
3100
1550
1975
(kg)
40
AIR VALVE TEES sp, sp & fl

(Drilling to AS 4087 Class PN 16)
Table 18
PN 1, PN 6 & PN 10
Nom Dia
Body
DN
(mm)
Nom Dia
Branch
DN
(mm)
Body
Length
L
(mm)
Branch
Length
H
(mm)
Approx
Mass
300
100
1000
375
100
450
525
600
675
750
900
1000
1200
1400
PN 16
Branch
Length
H
(mm)
Approx
Mass
(kg)
Body
Length
L
(mm)
550
21
1300
550
26
1100
650
29
1500
650
36
100
1200
750
43
1600
750
51
150
1200
750
48
1600
750
56
100
1300
800
61
1700
800
71
150
1400
800
70
1800
800
80
100
1100
700
66
1400
700
75
150
1100
700
71
1400
700
80
200
1100
700
75
1400
700
85
100
1200
750
90
1500
750
99
150
1200
750
94
1500
750
104
200
1200
750
99
1500
750
109
100
1300
800
117
1600
800
127
150
1300
800
122
1600
800
132
200
1300
800
127
1600
800
137
250
1300
800
135
1600
800
146
100
1400
800
155
1600
800
157
150
1400
900
160
1600
900
163
200
1400
900
165
1600
900
168
250
1400
900
174
1600
900
177
100
1400
900
191
1700
900
204
150
1400
900
196
1700
900
209
200
1400
900
201
1700
900
214
250
1400
900
209
1700
900
224
100
1500
1000
291
1800
1000
306
150
1500
1000
296
1800
1000
312
200
1500
1000
302
1800
1000
317
250
1500
1000
310
1800
1000
327
100
1600
1100
419
2100
1100
481
150
1600
1100
425
2100
1100
487
200
1600
1100
430
2100
1100
492
250
1600
1100
439
2100
1100
502
(kg)
41
AIR VALVE TEES sp, sp & fl
PN 1, PN 6 & PN 10
Nom Dia
Body
DN
(mm)
1600
1800
2000
2200
2400
PN 16
Nom Dia
Branch
DN
(mm)
Body
Length
L
(mm)
Branch
Length
H
(mm)
Approx
Mass
L
(kg)
Body
Length
H
(mm)
Branch
Length
Approx
Mass
(mm)
(kg)
100
1700
1200
578
2400
1200
713
150
1700
1200
584
2400
1200
719
200
1700
1200
590
2400
1200
725
250
1700
1200
599
2400
1200
735
100
2700
1300
1153
2700
1300
1010
150
2700
1300
1159
2700
1300
1016
200
2700
1300
1165
2700
1300
1023
250
2700
1300
1175
2700
1300
1033
100
3000
1400
1574
3000
1400
1379
150
3000
1400
1580
3000
1400
1386
200
3000
1400
1587
3000
1400
1392
250
3000
1400
1597
3000
1400
1403
100
3300
1500
2092
150
3300
1500
2098
200
3300
1500
2105
250
3300
1500
2116
100
3600
1600
2706
150
3600
1600
2713
200
3600
1600
2720
250
3600
1600
2731
42
SCOUR TEES sp, sp & fl

(Drilling to AS 4087 Class PN 16)
Table 19
PN 1, PN 6 & PN 10
Nom Dia
Body
DN
(mm)
Nom Dia
Branch
DN
(mm)
Body
Length
L
(mm)
Branch
Length
H
(mm)
Approx
Mass
300
100
1000
375
100
100
450
525
600
675
750
900
1000
PN 16
Branch
Length
H
(mm)
Approx
Mass
(kg)
Body
Length
L
(mm)
550
21
1300
550
26
1100
650
29
1500
650
36
1200
750
43
1600
750
51
(kg)
150
1200
750
48
1600
750
56
100
1300
800
61
1700
800
71
150
1400
800
70
1800
800
80
100
1100
700
66
1400
700
75
150
1100
700
71
1400
700
80
200
1100
700
75
1400
700
85
100
1200
750
90
1500
750
99
150
1200
750
94
1500
750
104
200
1200
750
99
1500
750
109
100
1300
800
117
1600
800
127
150
1300
800
122
1600
800
132
200
1300
800
127
1600
800
137
250
1300
800
135
1600
800
146
100
1400
800
155
1600
800
157
150
1400
900
160
1600
900
163
200
1400
900
165
1600
900
168
250
1400
900
174
1600
900
177
100
1400
900
191
1700
900
204
150
1400
900
196
1700
900
209
200
1400
900
201
1700
900
214
250
1400
900
209
1700
900
224
43
SCOUR TEES sp, sp & fl
PN 1, PN 6 & PN 10
Nom Dia
Body
DN
(mm)
Body
Length
L
(mm)
Branch
Length
H
(mm)
Approx
Mass
100
1500
150
1200
1400
1600
1500
1000
296
1800
1000
200
1500
1000
302
1800
1000
250
1500
1000
310
1800
1000
100
1600
1100
419
2100
1100
150
1600
1100
425
2100
1100
200
1600
1100
430
2100
1100
250
1600
1100
439
2100
1100
100
1700
1200
578
2400
1200
150
1700
1200
584
2400
1200
200
1700
1200
590
2400
1200
250
1700
1200
599
2400
1200
100
2700
1300
1153
2700
1300
150
2700
1300
1159
2700
1300
200
2700
1300
1165
2700
1300
250
2700
1300
1175
2700
1300
100
3000
1400
1574
3000
1400
150
3000
1400
1580
3000
1400
200
3000
1400
1587
3000
1400
250
3000
1400
1597
3000
1400
100
3300
1500
2092
150
3300
1500
2098
200
3300
1500
2105
250
3300
1500
2116
100
3300
1500
2706
150
3300
1500
2713
200
3300
1500
2720
250
3300
1500
2731
3
0
4
1
1000
2
9
3
1
1800
6
8
3
1
2400
291
(kg)
9
7
3
1
2200
1000
Approx
Mass
3
3
0
1
2000
Branch
Length
H
(mm)
3
2
0
1
1800
(kg)
Body
Length
L
(mm)
6
6 2 7 7 1 7 2 2 3 9 5 5 0 1
1
0 1 1 2 8 8 9 0 1 1 2 3 0
0
3 3 3 3 4 4 4 5 7 7 7 7 1
1
Nom Dia
Branch
DN
(mm)
PN 16
44
SLOPE JUNCTIONS
Table 20
Non pressure PN 1 (only)

Nom Dia
Body
DN
(mm)
Nom Dia
Branch
DN
(mm)
Body
Length
L
(mm)
Branch
Length
E
(mm)
Length
F
100
150
100
100
150
100
150
200
100
150
200
250
100
150
200
250
300
100
150
200
250
300
375
100
150
200
250
300
375
450
600
600
700
600
700
800
600
700
800
900
700
800
900
1000
1100
700
800
900
1000
1100
1300
700
800
900
1000
1100
1300
1400
420
420
420
420
500
500
500
500
570
570
500
570
570
640
710
570
640
640
710
780
850
640
710
710
780
850
920
920
200
250
300
375
450
Approx
Mass
(mm)
Branch
Height
H
(mm)
350
375
425
400
450
500
425
475
525
575
500
550
600
650
700
550
600
650
700
750
850
600
650
700
750
800
900
950
300
300
300
300
350
350
350
350
400
400
350
400
400
450
500
400
450
450
500
550
600
200
500
500
550
600
650
650
2.6
4.1
5.6
5.6
7.8
9.8
8.2
10.6
13.5
16.9
12.7
15.9
19.3
23.9
29.5
16.9
20.7
24.8
30.2
36.7
47.7
24.0
29.1
34.1
40.6
48.3
61.6
74.3
(kg)
45
SLOPE JUNCTIONS
Non pressure PN 1 only

Nom Dia
Body
DN
(mm)
Nom Dia
Branch
DN
(mm)
Body
Length
L
(mm)
Branch
Length
E
(mm)
Length
F
525
100
150
200
250
300
375
450
525
300
375
450
525
600
300
375
450
525
600
675
300
375
450
525
600
675
750
700
800
900
1000
1100
1300
1400
1500
1100
1300
1400
1500
1600
1100
1300
1400
1500
1700
1900
1100
1300
1400
1500
1700
1900
2100
710
710
780
780
850
920
990
990
920
990
990
1060
1130
990
1060
1060
1130
1200
1270
1060
1130
1130
1200
1270
1340
1410
600
675
750
Approx
Mass
(mm)
Branch
Height
H
(mm)
600
650
700
750
800
900
950
1000
850
950
1000
1050
1100
900
1000
1050
1100
1200
1300
950
1050
1100
1150
1250
1350
1450
500
500
550
550
600
650
700
700
650
700
700
750
800
700
750
750
800
850
900
750
800
800
850
900
950
1000
32
38
45
52
61
77
91
108
77
95
112
130
153
94
116
134
155
188
225
113
138
158
182
218
259
304
(kg)
46
TAPERS & ECCENTRIC REDUCERS
Table 21
Nominal Diameter
DN
DN
Large
Small
End
End
(DL)
(DS)
(mm)
(mm)
150
200
200
250
250
300
300
375
450
525
525
600
600
675
675
750
750
900
900
1000
1000
1200
1400
1600
1800
2000
2200
2400
100
100
150
150
200
200
250
300
375
375
450
450
525
525
600
600
675
675
750
750
900
1000
1200
1400
1600
1800
2000
2200
Taper
length
(L)
Dimensions
Spigot Overall
lengths Length
(A & B)
(mm)
(mm)
(mm)
125
250
125
250
125
250
125
188
188
375
188
375
188
375
188
375
188
563
375
625
250
500
500
500
500
500
500
500
300
300
300
300
300
400
400
400
400
400
400
400
400
400
400
400
400
400
400
400
400
500
500
600
600
600
600
600
725
850
725
850
725
1050
925
988
988
1175
988
1175
988
1175
988
1175
988
1363
1175
1425
1050
1500
1500
1700
1700
1700
1700
1700
PN1
Approx. Mass
PN6 &
PN16
PN10
(kg)
4
6
6
8
9
15
16
22
29
36
39
50
53
68
67
85
83
106
102
129
125
222
313
473
615
757
927
1108
4
6
7
11
12
17
18
29
39
54
55
71
72
100
95
130
121
167
152
206
188
360
557
820
1078
1347
1641
1928
4
7
8
13
14
23
24
44
59
76
75
89
87
120
106
174
155
242
217
298
265
512
740
1166
1495
1821
47
MANHOLE CONNECTORS
Table 22
Non pressure PN 1 only

Nominal
Diameter
DN
(mm)
Length L
OD
(Maximum)
Approx
Mass
(mm)
(mm)
(kg)
100
600
139
2.4
150
600
162
4.2
200
600
180
6.1
250
600
227
9.3
300
600
282
12.7
375
600
346
17.6
450
600
567
24.3
525
600
667
22.3
600
600
747
42.5
675
750
827
63.1
750
750
906
75.8
900
750
1013
94.2
1000
1000
1115
147.9
1200
1000
1319
208.5
1400
1000
1523
279.4
1600
1000
1737
363.2
1800
1200
1941
539.5
2000
1200
2155
663.4
2200
1200
2359
798.1
2400
1200
2563
943.1
48
FLANGE SPIGOT CONNECTORS
Table 23
PN 10
PN 16
Nom Diameter
DN
(mm)
Flange
OD
(mm)
Length
L
(mm)
Approx
Mass
(kg)
Length
L
(mm)
Approx
Mass
(kg)
100
230
350
2.7
400
3.3
150
305
400
5.4
400
6.4
200
370
400
8.4
400
9.3
250
430
400
13.1
450
15.1
300
490
400
16.1
400
17.1
375
610
450
26.4
450
27.8
450
675
450
35.1
450
36.4
525
785
450
43.1
450
46.9
600
850
500
62.0
500
68.1
675
935
550
85.7
550
88.5
750
1015
550
113.1
550
117.3
900
1185
600
145.1
600
151.1
1000
1275
600
186.2
650
198.9
1200
1530
700
303.7
750
326.0
1400
1750*
750
437.6
800
459.1
1600
1960*
800
605.5
850
729.1
1800
2160*
900
844.4
950
892.4
2000
2395*
950
1101.5
1000
1140.8
2200
2610*
1050
1470.8
2400
2825*
1100
1799.6
49
CLOSED COUPLINGS
Table 24
Non pressure PN 1
Nom Dia
DN
(mm)
Coupling
OD
(mm)
Length
L
(mm)
Approx
Mass
(kg)
80
134
157
1.4
100
157
157
1.7
125
175
157
2.0
150
212
157
2.4
200
278
182
4.6
250
332
182
6.5
300
402
277
13.3
375
483
277
16.4
450
564
277
19.8
525
644
277
23.2
600
732
338
36.7
675
812
338
41.3
750
893
339
47.1
900
993
340
55.8
1000
1098
341
66.0
1200
1307
343
88.6
1400
1516
345
116.0
1600
1725
347
149.0
1800
1934
349
187.0
2000
2144
352
239.9
2200
2353
354
293.4
2400
2562
356
356.3
3000
3208
392
685.1
50
SADDLE JUNCTIONS
Table 25
45 degree
Body
Body Approx
Length Width Mass
L
W
(mm)
(mm)
(kg)
Body
Length
L
(mm)
Body
Width
W
(mm)
Approx
Mass
Nom Dia
Body
DN
(mm)
Nom Dia
Branch
DN
(mm)
300
100
400
400
260
69
260
260
45
150
400
450
315
94
310
315
64
100
400
400
260
62
260
260
40
150
400
450
315
84
310
315
58
225
400
570
410
139
400
410
97
300
400
670
490
195
470
490
137
100
400
400
260
57
260
260
37
150
400
450
315
78
310
315
54
225
400
570
410
129
400
410
90
300
400
670
490
181
470
490
127
100
400
400
260
54
260
260
35
150
400
450
315
73
310
315
50
225
400
570
410
121
400
410
85
300
400
670
490
170
470
490
119
100
400
400
260
37
260
260
24
150
400
450
315
50
310
315
35
375
450
525
600
675
750
900
Branch
Length
H
(mm)
90 degree
(kg)
225
400
570
410
83
400
410
58
300
400
670
490
116
470
490
82
100
400
400
260
36
260
260
23
150
400
450
315
49
310
315
34
225
400
570
410
80
400
410
56
300
400
670
490
113
470
490
79
100
400
400
260
44
260
260
28
150
400
450
315
59
310
315
41
225
400
570
410
98
400
410
69
300
400
670
490
137
470
490
96
100
400
400
260
47
260
260
30
150
400
450
315
63
310
315
44
225
400
570
410
105
400
410
73
300
400
670
490
147
470
490
103
51
SADDLE JUNCTIONS
Nom Dia
Body
DN
(mm)
1000
1200
1400
1600
1800
2000
2200
2400
3000
Nom Dia
Branch
DN
(mm)
Branch
Length
H
(mm)
Body
Body Approx
Length Width Mass
L
W
(mm)
(mm)
(kg)
Body
Length
L
(mm)
Body
Width
W
(mm)
Approx
Mass
100
400
400
260
47
260
260
30
150
400
450
315
63
310
315
44
225
400
570
410
104
400
410
73
300
400
670
490
147
470
490
103
(kg)
100
400
400
260
54
260
260
35
150
400
450
315
73
310
315
51
225
400
570
410
121
400
410
85
300
400
670
490
170
470
490
119
100
400
400
260
54
260
260
35
150
400
450
315
74
310
315
51
225
400
570
410
122
400
410
86
300
400
670
490
172
470
490
121
100
400
400
260
56
260
260
36
150
400
450
315
76
310
315
52
225
400
570
410
125
400
410
88
300
400
670
490
176
470
490
123
100
400
400
260
57
260
260
37
150
400
450
315
77
310
315
53
225
400
570
410
128
400
410
90
300
400
670
490
179
470
490
126
100
400
400
260
59
260
260
38
150
400
450
315
80
310
315
55
225
400
570
410
132
400
410
92
300
400
670
490
185
470
490
130
100
400
400
260
61
260
260
40
150
400
450
315
83
310
315
57
225
400
570
410
137
400
410
96
300
400
670
490
193
470
490
135
100
400
400
260
64
260
260
42
150
400
450
315
87
310
315
60
225
400
570
410
144
400
410
101
300
400
670
490
202
470
490
141
100
400
400
260
71
260
260
46
150
400
450
315
97
310
315
67
225
400
570
410
160
400
410
112
300
400
670
490
225
470
490
158
52
MANHOLE DROP JUNCTIONS
Table 26
Non pressure PN 1
Nom Dia
DN
(mm)
Length
L
(mm)
Offset
B
(mm)
Centreline
Height F
(mm)
Approx
Mass
(kg)
300
1780
890
890
50
375
1939
969
969
73
450
1877
939
939
103
525
2233
1117
1117
164
600
2380
1190
1190
225
675
2784
1392
1392
333
750
3000
1500
1500
439
53
MANHOLE DROP BENDS
Table 27
Non pressure PN 1
Nom Dia
DN
(mm)
Offset
B
(mm)
Centreline
Height B
(mm)
Approx
Mass
(kg)
300
890
890
31
375
969
969
44
450
939
939
61
525
1117
1117
96
600
1190
1190
129
675
1392
1392
185
750
1500
1500
240
54
HYDRAULIC DESIGN
5.1
Flow and pressure capacity calculations
Flowtite pipelines have exceptionally good hydraulic performance when new, as

they fall in the smooth polymer pipe category. However, these may in some
instances be affected by various adverse service factors including:
Growth of slime (varies with age of the pipeline and available nutrient in the
water)
Siltation or settlement of suspended particulate matter
Fittings types and configurations
The flow resistance chart has been provided see Figures 5.1. It is based on the
following parameters.
Operating temperature of 20C which corresponds to a kinematic viscosity of

water
= 1.01 x 10-6 m2/s
Equivalent roughness
k= 0.020 0.015 mm
An approximate allowance for the effect of variation in water temperature on the chart
values an be made by increasing the chart value of the head loss by 1% for each 3C
below 20 and by decreasing it by 1% for each 3C in excess of 20 of pressure
rating
The notation used for the equations in this section follows:
d
f
g
HL
H
i
j
k
m
n
N
Q
Qp
Qf
R
Rp
Rf
S
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
V
Vp
Vf
=
=
=
internal diameter (m)

Darcy friction co-efficient
acceleration due to gravity (m/sec2)
friction head loss (m)
Total (pumping) head
annual interest rate
annual interest rate including inflation
equivalent hydraulic roughness (m)
assumed inflation rate
Manning n
planned life of system (years)
flow or discharge (L/s)
most probable peak flow (L/s)
flow or discharge - pipe flowing full (L/s)
hydraulic mean radius i.e. flow area/perimeter (m)
hydraulic mean radius for partly full pipe (m)
hydraulic mean radius for full pipe i.e. d/4 (m)
hydraulic gradient, also slope of gravity flow sewer
(m/m)
mean velocity (m/sec)
mean velocity in part full pipe (m/s)
mean velocity - pipe flowing full (m/s)
T
y
=
=
=
duration of pump operation (hours/year)

depth of flow above pipe invert (m)
fluid density (kg/m3)
55
=
=
kinematic viscosity (m2/sec)

angle (radians) subtended at pipe centre by water
surface in invert - see Figure 3.4
average boundary shear stress (Pa)
The chart is based on calculations using the Colebrook White Transition Equation see equation 5.1. For pipes flowing full this equation takes into account, liquid
viscosity and pipe roughness, and is recognised as being one of the most accurate in
general use but requires iterative solutions. The Colebrook-White transition equation
is as follows:
k
2.51
2 2 gdS log
+
3.7d d 2 gdS
Equation 5.1
When comparing Flowtite with other pipe systems, designers should take into
account both the smooth bore and the anticipated pipeline service. Different
applications may require a variation of the values of roughness coefficients chosen to
conform to accepted practice. In the case of sewerage, it may be considered
necessary to allow for slime development. Generally smooth pipe materials have a
Colebrook White k value equal to less than one fifth of the value used for the
rougher materials such as cement lined, concrete and vitrified clay pipes used for the
same purpose.
Empirical formulae, exponential in form, have been in engineering use over many
years. Being relatively easy to use they are still favoured by some engineers.
For water supply applications, Hazen Williams equation is frequently used i.e.
Q = 278 C d 2.63 S 0.54
Equation 5.2
Using the Norwegian experimental data the derived value of Hazen Williams
Coefficient for Flowtite of C between 152 and 155.
The Manning Equation is the most common for non-pressure gravity flow.
Q
4000 d

4
n
Equation 5.3
For Flowtite n may be taken as 0.01 for a clean pipeline. Again this is
conservative compared with Australian Standard AS 2200 that gives the range of n
for polymeric materials of 0.008 to 0.009.
56
Figure 5.1
57
Design flow velocities

The Water Services Association of Australia Code WSA O3 design recommendations
may be applied to Flowtite pipe installations. In pumped transmission mains capital
cost and discounted running costs should be determined see Section 5.2. However
as a guide the Code suggests that the most economic design is likely to have
velocities in the range 0.8 to 1.4 m/s. In some circumstances it also suggests that 2.0
m/s may be acceptable or 4.0 m/s for short periods with 6.0 m/s as the maximum.
Generally head losses should not exceed 3 m/km (or 5m/km for pipes less than DN
200). Where the water is carrying abrasive material the design velocity should not
exceed 4.0 m/s.
5.2
Economic considerations
Since energy consumption is a significant factor in pumped pipelines an economic

analysis is necessary of optimize the cost of capital involved in building a pipeline
and the present worth of the anticipated energy consumption over the life of the
pipeline
An example of a typical present worth calculation to determine the optimum pipe
diameter for a particular project is shown in Table 28 where 16 km long pipeline is
required to carry a flow of 350 L/s. The overall capital cost is combined with the
present worth of the annual pumping costs over the 25-year life of the system to
determine the least expensive option.
The equations needed for these calculations are:
Annual pumping cost Y
Y=
0.0098 Q H C T
pump efficiency
Equation 5.4
Present value of annuity A can be calculated from:
A=
Y (1 (1 + i ) n )
i
Equation 5.5
Where the rate of inflation is to be included, then
Y (1 (1 + j ) n )
A=
j
Equation 5.6
The adjusted interest rate j is calculated from
j=
(i m)
(1 + m)
Equation 5.7
Note that in the special case where i = m then the value of A = n x Y

Table 5.1 shows the calculations for optimizing the pipe size for a major transmission
main. It can be concluded from the table that for the assumptions made a DN 525
pipeline would be the best option for a minimum present worth cost.
58
Table 28 Example optimizing pipe size on financial basis

Pipe Description:
Flowtite Flowtite Flowtite
DN450
DN525
DN600
10/5000
10/5000
10/5000
Flowtite
DN675
10/5000
Input information
Flow [L/s]
Length [metres]
Static lift [m]
Cost of Pipeline [$/m]
350
16000
30
$232.00
Viscosity [m/s2]
Internal diameter [m]
Roughness "k" [mm]
1.0100E-06
0.487
0.02
350
16000
30
$284.00
350
16000
30
$354.00
350
16000
30
$433.00
1.0100E-06 1.0100E-06 1.0100E-06

0.569
0.647
0.725
0.02
0.02
0.02
Results of calculation
Head loss due to flow resistance [m/m]
Total flow resistance head [m]
Pump efficiency[%]
Power reqd.[kW]
Cost per kWh [$/kWh]
Op. hours/year
Op. cost [$/year]
Return on investment [%/yr]
Life of scheme [years]
Present value pumping
cost [w/o inflation]:Total P V [w/o infl.]
Annual inflation rate [%]
Resulting effective interest rate [%]
Present value of pumping
cost [including inflation]
Total present worth [including inflation]
0.00449
71.82
65.0
537.3
$0.12
7000
$451,347
10.00
25
0.002173
34.77
65.0
341.8
$0.12
7000
$287,092
10.00
25
0.001155
18.48
65.0
255.8
$0.12
7000
$214,893
10.00
25
0.000665
10.64
65.0
214.5
$0.12
7000
$180,141
10.00
25
$4,096,891
$7,808,891
3.00
6.80
$2,605,942 $1,950,594 $1,635,152

$7,149,942 $7,614,594 $8,563,152
3.00
3.00
3.00
6.80
6.80
6.80
$5,357,841
$9,069,841
$3,408,004 $2,550,952 $2,138,422

$7,952,004 $8,214,952 $9,066,422
Table 28 shows that the DN 525 pipeline is likely to be the best option. This may be
subject to a sensitivity analysis to cover the effect of varying some of the less certain
assumptions made.
5.3
Air Valves, anti-vacuum valves and scour valves
Air must be expelled from a pressure pipeline during the filling operation and also
allowed to enter a pipeline if it is being emptied for any reason. Also, because most
water is saturated with air, which will leave solution when the water pressure is
reduced, air will tend to collect at high point in a pipeline system under normal
operating conditions. As air accumulates, it has the effect of lessening the effective
pipe diameter leading to reduced discharge or increase friction head. In extreme
situations the flow may actually cease (see Fig 5.3). Pressure surges of high
magnitude may also result from the unstable flow conditions created.
59
FIG 5.3 There is no flow in this pipeline due to lack of

air valves
An automatic air valve is comprised of a float confined in a chamber with an orifice to
atmosphere on top and connection to the pipeline at the bottom. When the chamber
is full of water the float seals the orifice, but when air from the line enters the
chamber or the pressure drops below atmospheric the float drops. It remains open
until water refills the chamber and air is bled from the line.
Where the hydraulic grade is close to the high point of a pipeline a simple vent tube
extended above the grade line may be used as an AV.
Location of air valves
Air (and gases) periodically released from the liquid in a pipeline due to temperature
changes, water movements etc. will accumulate in the more elevated sections or
peaks. It is good practice in pressure pipelines to grade evenly between these
peaks to ensure that the locations of all potential air traps are known. Air valves are
required at peaks or sharp changes in grade in the pipeline to allow the air to escape
progressively and avoid any reduction of flow capacity or unnecessary pressure
surges. Peaks relative to the hydraulic gradient as well as the horizontal datum
should be considered for AV location.
Generally the large orifice diameter should be at least 0.1 of the pipe diameter. The
volume rate of flow air through an orifice is roughly 40 times that of water under the
same pressure differential. The following is the list of typical conditions where air
valve may be found necessary.
1. Where a section of pipeline
a) Runs parallel to the hydraulic gradient
b) Has a long horizontal run. Double air valves are required at the end of
a run, and single air valves located at every 500-1000 metres of run.
2. Where pipeline peaks above the operating hydraulic gradient but below the higher
(source) level, air can be expelled at this point by installing a manually operated gate
valve (not an air valve) which is opened when the lower (outlet) level valve is closed.
The operation should be carried out at regular intervals. Where the pipeline peak
above the higher (source) level, syphoning will occur and special provision will have
to be made to expel air such as a vacuum pump. It is recommended that peaking
above the hydraulic gradient, and the source level should be avoided.
3. Where abrupt changes the grade occur on both upward and downward slopes, a
small orifice air valve should suffice.
60
4. During long ascents, large orifice air valves are required at 500-1000 metre
intervals.
5. During long descent, double air valves are required at 500-1000 metre intervals.
6. On the downstream side of section valves in trunk mains, or where flow is in both
directions, on both sides.
In large diameter pipelines (e.g. DN600 or greater) consideration should be given to
all likely operating conditions. For example where flow capacities are significantly
below the design maximum, hydraulic jumps may develop due to the pipeline being
partially full or in a channel flow mode.
FIG 5.4 Hydraulic jumps require additional vents
As illustrated in Figure 5.4 a series of unstable hydraulic jumps may cause air to
accumulate downstream from the peak. This air may need to be extracted using a
series of suitably spaced vents. These may be combined using a series of
interconnected tappings to permit air to return to the air space upstream of the jump.
Where air valves are require on mains of major importance it is normal practice to
install a gate valve directly onto the tee branch prior to connecting the air valve.
Alternatively, an air valve incorporated a control valve can be used. This allows
maintenance to be carried out on the air valve without dewatering the pipeline.
Under operating conditions care should be taken to ensure that this valve is always
left in the open position.
Types of automatic air valves
Single air valves
The single air valve, with small orifice (Fig 5.5) is used to release small quantities of
air, which may accumulate in charged water main. Although designated by their inlet
connection, e.g. 25 mm, this has nothing to do with the orifice size, which may be as
small as 3 mm.
FIG 5.5 Single air valves
61
Double air valves

The double air valve, with small and large orifice in separate chambers (Fig 5.6),
performs the dual function of realising small quantity of air as it collects (similar to the
single air valve), and admits or releases large volumes of air when a pipeline is
emptied or filled. They are designated by their inlet connection, which is usually
slightly smaller than the orifice diameter. Sizes range from 50mm to 100mm.
FIG 5.6 Double air valves
Kinetic air valves

A difficulty sometimes experienced with large orifice air valves that the ball blows
shut when a water main is being filled at the high rate. A pressure differential of 100
kPa could lead to air velocities approaching 300 m/sec i.e. the speed of sound.
The kinetic air valve (Fig 5.7) has a float chamber constructed in such a way that air
expelled from a rapidly filled main cannot blow the valve shut, however high the
emergent air velocity.
FIG 5.7 Double kinetic air valves with control valve
Anti-vacuum valves
Anti-vacuum valves have the primary function of preventing the formation of a
vacuum in large diameter water mains or hydro-electric penstocks. They are much
larger in size than conventional air valves with orifice sizes ranging from DN 200 to
DN 500. The corresponding airflows at 50% vacuum will range from 5m3 per second
to 50m3 per second respectively.
62
Scour valves
Scouring points located in depressions along a pressure main are essential so that
the line can be drained for maintenance purposes and sediment removal. Special
flanged scour tees with branches offset to invert level are available.
The discharge from a scouring point is usually piped to a nearby stormwater drain
unless the effluent will cause pollution. In these cases a detention tank has to be
provided so that a tanker can remove foul water.
63
5.4
Surge Capacity
Flowtite pipes are designed to resist surge pressures in excess of the nominal
pressure class. Flowtite pipes are designed in accordance with AWWA M-45
Fiberglass Pipe Design Manual. The maximum surge pressure in accordance with
AWWA M-45 is 1.4 times nominal pressure. AS/NZS 2566.1 Buried flexible pipelines
Part 1: Structural design recommends a lower value of 1.25 times nominal pressure.
5.5
Water hammer surge celerities
Water hammer effects are considerably reduced in polymeric pipeline materials

including GRP when compared with iron steel and concrete due to much lower
moduli of elasticity. Typical values for celerities in Flowtite pipes of different
diameters, stiffness and classes are given in Table 29.
Table 29
Water hammer celerities (m/s) for Flowtite
Description
DN 80
- DN100
DN 150
- DN250
DN 300
- DN 375
DN 450
- DN 750
DN 900
- DN 3000
PN 6 SN 2500
PN 10 SN 2500
PN 16 SN 2500
PN 6 SN 5000
PN 10 SN 5000
PN 16 SN 5000
PN 25 SN 5000
PN 6 SN 10000
PN 10 SN 10000
PN 16 SN 10000
PN 25 SN 10000
PN 32 SN 10000
570
580
630
-
520
540
600
-
365
435
500
405
435
505
575
350
420
490
380
420
495
570
415
425
495
570
615
340
405
480
370
410
480
560
410
415
485
560
615
Figure 5.8 illustrates a typical water hammer pressure envelope. These can be
determined using computer software such as WATHAM, HYTRAN or an equivalent.
In this diagram the maximum surge effect has been generated at the pump
shutdown, a situation that is quite common.
MAX. POSITIVE SURGE
MAX. POSITIVE SURGE
(ON STOPPING)
DESIGN HEAD
(ON STARTING)
HYDRAULIC GR
ADIENT
(OPERATING
)
NO FLOW STATIC HEAD

MIN NEGATIVE SURGE
DISCHARGE M/H
(ON STOPPING)
SUB ATMOSPHERIC PRESSURE

PUMP
Figure 5.8 Typical hydraulic grades and surge envelopes required for design
64
5.6
Fatigue under cyclical pressure regimes
Flowtite pipes when manufactured in accordance with ISO 10467 and ISO 10639
and used in water, drainage and sewerage applications do not require de-rating for
cyclic pressure fatigue.
The standards specify that complying pipes shall be type tested in accordance with
the methods of ISO15306. In the cyclical pressure test the pipe specimen is
subjected to pressure cycles 0.25 times the nominal pressure for at least one
million cycles. For example a PN16 pipe would be subjected to a cyclical pressure
range from 1200 kPa to 2000 kPa at a nominated frequency.
Test reports are available for Flowtite specimens, which show that, after being
subjected to a minimum of one million cycles, they had ultimate, burst strengths and
pressure proof test performances equivalent to those of untested new pipes.
These tests illustrate that there is a considerable difference in the fatigue
characteristics between GRP pipes made from reinforced thermoset plastics when
compared to un-reinforced thermoplastics pipes.
5.7
Thermal effects on pressure ratings
Flowtite pipe resin is classified as a thermoset and is less affected by elevated

temperatures than many thermoplastics. The standard orthophthalic polyester pipe
resin has a heat distortion temperature (HDT) of 750 C and is limited to a maximum
long term operating temperature of 550C. Refer to Table 5.3 for re-rating factors
based on AS 2634 recommendations. Higher operating temperatures are possible
where vinyl ester pipe resins are used.
Table 30
Thermal pressure rating for standard polyester resin
Long term operating temperature 0C
Re-rating factor applied to PN
35
40
45
50
55
1.00
0.95
0.90
0.85
0.80
65
5.8
Non pressure pipeline design
Low head irrigation and stormwater drainage design

The design of drainage pipe networks is discussed in Australian Rainfall and Runoff
published by the Institution of Engineers. There are differences from other
applications owing to the frequency of inlet and junction pits, which significantly affect
the hydraulic capacity of the system. Similar effects are sometimes seen in gravity
flow irrigation systems. In both cases high head losses occur through pits. Pits may
be rectangular, circular, benched and unbenched, with and without sidelines, with
and without entries for surface stormwater from gutters on roadways, and often
involve changes in flow direction. The value for KL in Figure 5.9 can range from 0.2
to 2.5 or more depending on the pit configuration. Appropriate values can be
obtained from ARRB Report No. 34 Stormwater drainage design in small urban
catchments by John Argue.
Another consideration affecting flow capacity is the debris and sediment load which
stormwater flow often carries.
Figure 5.9 Accounting for head losses through low head chambers
Sewerage design
The design of gravity sewers can be complex owing to the assumptions that must be
made to cover wide variations in flows between storm flows and low dry weather
sewage flows. Although the pipes must be sized to carry the high wet weather flows,
the size and grade must also meet self-cleansing criteria under dry weather
conditions.
Acceptable design methods will vary between authorities and the whether the system
is to be designed for sewage flows only or combined sewage and stormwater flows.
In Australia the separated sewage flow is the usual requirement. Even so these
systems often carry considerable stormwater flow in wet weather due to incidental
inflow and infiltration of storm water. For design purposes the normal average
sewage flow of say 0.003 L/s per head of population or equivalent population (EP)
is increased by a series of empirical factors to allow for peak dry and peak wet
weather flows. The resulting maximum design flow is therefore much higher than the
estimated average flow. Sewer pipes are sized to carry the maximum design flow (Qf)
flowing full. In addition a check is made to ensure that in dry weather there will be
sufficient flow to ensure a self-cleansing flow at least once daily.
66
Figure 5.10 Self-cleansing flow - angle of repose of sediment

Historically, the normal design criterion was that a partial flow with a self-cleansing
velocity of 0.6 m/s had to be achieved once a day. Today most design methods are
based on fluid boundary layer shear theory. Research on movement of sand particles
on submerged pipe perimeters at low flows shows that deposition will occur on the
flatter parts of the pipe invert where the slope of the pipe wall is less than = 350 refer to Figure 5.10. Boundary layer design theory builds on this fact.
From open channel theory the following expression can be written in terms of
average boundary shear stress .
= .g.R.S
Equation 5.8
For a circular sewer flowing part full, since Rf =d/4 Equation 5.8 can be rewritten
= .g . d 4 .
Rp
Rf
.S
Equation 5.9
It can be assumed for 1.5 Pa that the pipe invert will be self-cleansing. Therefore
taking this as the value for , the minimum self cleansing slope can be determined
by rearranging Equation 5.9:
S min =
4.
R
.g.d . p R
f
Equation 5.10
Using geometrical relationships and Mannings equation (Equation 5.3), the hydraulic
elements chart Figure 5.11 has been developed to relate the flow, depth and
hydraulic mean radius ratios to each other. With the Qp/Qf ratio known, the depth
ratio y/d can be found and then from this value the Rp/Rf ratio can be determined for
substitution in Equation 5.10
67
1.0
0.9
Depth to diameter ratio (y/d)
0.8
0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1.0
1.1
1.2
1.3
Ratio of hydraulic mean radius, velocity

and flow
Qp/Qf
Vp/Vf
Rp/Rf
Figure 5.11 Proportional velocity and discharge in part-full pipes

Example
Problem:
A DN 1000 Flowtite sewer carrier laid at a 0.068% gradient, with an assumed
Colebrook White roughness k = 0.02 mm, will carry 800 L/s when flowing full (See
Figure 5.2). The probable daily peak dry weather flow is estimated at 320 L/s.
Will this sewer be self-cleansing?
Solution:
From the flow resistance chart Figure 5.2 , it can be seen that a DN 1000 Flowtite
pipe has a hydraulic gradient of 0.36 m/m when flowing at 800 L/s.
The ratio Qp/Qf = 320 / 800= 0.40
From Figure 5.6; y/D = 0.48 and for this depth ratio Rp/Rf = 0.94
Substituting for Rp/Rf in Equation 5.10 (with 1.5 Pa)
= 0.000651 or 0.0.065%.
As this required grade of 0.065% is less than the 0.068% proposed, the pipeline will
be self-cleansing.
68
6
6.1
STRUCTURAL DESIGN
Allowable cover heights
In engineering terminology Flowtite pipes are considered to be flexible pipes. This

means they are designed to deform or deflect diametrically within specified limits
without structural damage.
The external soil and live loadings above flexible pipes may cause a decrease in the
vertical diameter and an increase in the horizontal diameter of the pipe or cause ring
instability. The horizontal movement of the pipe walls in the soil material at the sides
develops a passive resistance within the soil to support the external load. That is,
the pipeline performance at a given cover height is influenced by the native soil type,
its stiffness, the pipe embedment material, its compaction, the height of water table,
vacuum conditions, live loading such as vehicular loads, and hydrostatic operating
pressures. The higher the effective soil modulus at pipe depth, the less the pipe will
deflect and the ring stability will be improved.
Initial deflections of up to 3% are permissible and will not affect the pressure rating of
the pipe. Contact Fibrelogic for further details or refer to AS/NZS 2566.1 Buried
flexible pipelines Part 1 Structural design
To properly assess the effect of site conditions on a proposed installation, specific
information is needed for design including:
Pipe diameter
Cover height
Properties of native soil
Width of embedment
Properties of embedment material
Height of water table
Traffic loading
Special requirements, such as concrete encasement or grouting.
The appropriate value of the effective soil deformation modulus for a particular
installation will depend on the native soil type and condition, the pipe embedment
material, its degree of compaction and its geometry (e.g. trench width / embedment
width). Geotechnical surveys giving soil types and properties, including soil-bearing
capacities, SPT values at pipe depth and embedment compaction, will be relevant to
the design.
The following notation is used in this Section:
a
= the radius of loaded circular plate (m)
b
= embedment width each side of pipe at spring-line (m)
B
= trench width at pipe spring-line (m)
D
= overall outside diameter of pipe (m)
Ee
= embedment soil deformation modulus (MPa)
En
= native soil deformation modulus (MPa)
E/
= combined soil deformation modulus (MPa)
H
= cover height (m)
h
= bedding thickness (m)
k
= overlay thickness (m)
p
= presumptive (allowable) bearing pressure (kPa)
= displacement or settlement (m)

= Leonhardt correction factor.
69
Geotechnical Investigation
The conventional approach to a pipeline route investigation has been to assess the
soil conditions at pipe depth by carrying out a drilling and soil sampling program
along the alignment. While the intention in the past was often to determine the
presence of rock and to estimate trench stability for construction purposes, this
investigation is now used for more detailed geotechnical reporting with additional
information readily obtained from routine surveys. It includes design data such as the
Standard Penetration Test (SPT) blow counts (at pipe depth), identification of native
soil type and density, and depth of water table. The designer will need to assess the
embedment material chosen to surround the pipe and its compaction.
Derivation of soil deformation modulus values
The correct choice of soil moduli will have significant effects on design decisions. An
approximate conversion of SPT blow counts to soil moduli is given in Table 6.1 of
AS/NZS 2566.1. However many designers may have more confidence in basing their
assessment on the widely available data on foundation design. Often this is
contained in records obtained over many years and frequently gives correlations
between SPT and allowable soil bearing pressures.
If SPT values are not known for the soils in the pipe zone and the soil has already
been exposed by excavation, the Clegg impact hammer can be used to obtain
Impact Values (CIVs). These are numerically similar to SPT blow counts and can be
substituted in Table 6.1 to obtain an estimate of En.
The soil deformation moduli stated in AS/NZS 2566.1 were originally derived from
European design practice using soil bearing plate tests. These moduli can be nearly
half the value of deformation moduli measured using standard laboratory triaxial tests
so the two should not be confused. Using allowable foundation bearing pressures it
is possible to derive the plate load or pipe design soil moduli from the Boussinesqs
plate bearing theory for an elastic, homogenous, isotropic solid. That is for a rigid
plate and a soil Poissons ratio of 0.5: -
1 . 18 . p . a
. 10
En
Equation 6.1
For the purposes of obtaining a derivation it can be assumed that the plate is a
standard 750 mm diameter and the allowable settlement is 15mm. Equation 6.1 then
provides a conversion relationship, En = 0.03 x p. Table 6.2 which is partly derived
from on data published by Sowers (1979) relating SPT to bearing pressure has been
extended to show En values obtained by applying this factor.
Values of the soil deformation moduli are needed for both the native and embedment
soils within a distance of 2.5 x pipe diameters each side of the pipe centre-line. The
modulus for a given pipe embedment soil (Ee) is dependent on the compaction as
well as soil type and can be estimated from Table 6.3.
70
Compaction standard dry density ratio

Methods for measurement of compaction are given in AS 1289-E3. The actual dry
density ratio (previously known as Proctor ratio) of a soil is defined as a percentage
of the maximum dry density determined in the laboratory at the optimum moisture
content, which has been determined in the laboratory. Then dry density is derived
from the following equation:
100
Equation 6.2
=
d
100 + w
Where = wet field density

w = percentage moisture content
The dry density ratio is the field dry density divided by the maximum dry density
determined in the laboratory for the soil (expressed as a percentage) when
compacted at the optimum moisture content.
FIG 6.1 Typical dry densities for different soils

Figure 6.1 shows the effect of compacting at different moisture contents on the dry
densities of various soil types. It should be noted that the curve for gravel is relatively
flat as water content has minimal effect on the achievable compaction. Therefore
these materials are preferred for embedment. The curve shown for sand is concave
over the intermediate range of moisture contents. With some fine sands at these
moisture contents the density can be more than 20% less than for the compaction
achievable at higher moisture levels. Because of this property these bulking sands
are highly unsuitable as embedment material. The convex curves for cohesive soils
such as silt and clay are particularly sensitive with respect to moisture and are
difficult to compact adequately in a pipe trench.
The dry density may be determined in the laboratory by either the Standard method
or the Modified test method each giving significantly different results. The
compaction energy for the Modified is 4.5 times higher than for Standard and the
resultant maximum dry density ratio will be lower for a given field test sample. For
71
granular soils the difference is about 5% (less for uniformly graded sand) and about
10% for cohesive soils. AS/NZS 2566.2 refers to standard dry density ratio only.
FIG 6.2
Standard Compaction
2.7 kg rammer is dropped from a
height of 300 mm 25 blows per
layers
Modified Compaction
4.9 kg rammer is dropped from a
height of 450 mm 25 blows per
5 layers
Compaction - density index

An alternative method of evaluating the degree of compaction, which is faster and
less expensive for granular soils, is the density index (or relative density). With this
method the loosest and densest densities are determined in the laboratory as
follows.
A container filled with the soil is vibrated on a vibratory table for 10 minutes or until
the settlement ceases to determine a value for the maximum dry density max. The
minimum dry density min is determined by gently pouring the soil into the container
and measuring the density. Combined with the dry density d, which has been
measured on site, the density index ID for site compaction can then be determined
from equation 6.3.
(
(
max
D
max
min
min
)
)
x100%
Equation 6.3
These two compaction methods give unrelated percentages that are quite different in
magnitude and must not be interchanged. For example in broad terms a compacted
soil with a density index of 65% may have a standard dry density ratio of 90%.
72
Table 31
Standard embedment widths (from AS/NZS 2566)
Nominal diameter
DN
Outside diameter
of pipe D (mm)
Side clearance b Embedment width B

(mm)
300
345
200
745
375
426
200
826
450
507
300
1107
525
587
300
1187
600
667
300
1267
675
747
300
1347
750
826
300
1426
900
923
350
1623
1000
1025
350
1725
1200
1229
350
1929
1400
1433
350
2133
1600
1637
1841
1.5 x D
1.5 x D
2456
1800
2762
2000
2045
1.5 x D
3068
2200
2249
1.5 x D
3374
2400
2453
1.5 x D
3680
3000
3065
1.5 x D
4598
Note that Tables 31 has been compiled with reference to AS/NZS 2566.1. The side
clearances given are conservative to facilitate the compaction of the haunch zone.
Figure 6.3 Critical dimensions for design and installation
73
Table 32 Typical native soil moduli obtained from SPT or allowable bearing
loads
Soil description
Loose sand, dry

Firm sand, dry
Dense sand, dry
Loose sand,
inundated
Firm sand, inundated
Dense sand,
inundated
Soft clay
Firm clay
Stiff clay
Hard clay
Heavily fractured or
partially weathered
rock
*SPT before inundation
Standard
Penetration
Resistance blow
count over 300 mm
5 - 10
11 - 20
31 - 50
5 - 10*
Allowable
foundation bearing
pressures p
(kPa)
70 -140
150 - 300
400 - 600
40 - 80
Derived soil
deformation moduli
En/ (using Eqn. 6.1)
(MPa)
2.1 - 4.2
4.5 - 9.0
12 - 18
1.2 - 2.4
11 - 20*
31 - 50*
80 - 170
240+
2.4 - 5.1
7+
2-4
5-8
9 - 15
30+
50+
30 - 60
70 - 120
150 - 200
400+
500 - 1200
0.9 - 1.8
2.1 - 3.6
4.5 - 6.0
12+
15 - 36
The correlation of SPT to bearing pressure given in Table 32 is from George F

Sowers Introductory soil mechanics and foundations: Geotechnical Engineering
published by Macmillan.
Table 33
Table 6.3 Embedment soil moduli
Soil description
Deformation moduli
Ee/
( MPa)
Aggregate single
Uncompacted
5
size
50
6
60
7
70
10
3
Aggregate - graded
Uncompacted
5
50
7
60
10
70
Crushed rock
uncompacted
1
85
3
90
5
95
7
1
Sand and coarse
uncompacted
3
grained soil with
85
5
less than 12% fines
90
7
95
Coarse grained soil
85
1
with more than 12%
90
3
fines
95
5
Note: These values are given in AS/NZS 2566.1 Buried flexible pipelines Part 1:
Structural design Table 3.2
Standard dry density

ratio (%)
Density Index (%)
74
Effective soil modulus

Knowing the proportion of embedment and native soil in the side support zone that is
trench (or embedment width) to pipe diameter (B/D) together with the ratio of
embedment modulus to native soil modulus (Ee/ En), the Leonhardt factors given in
Table 34 enable an overall effective soil modulus E/ to be determined using the
equation:
E/ = .Ee
Equation 6.2
Assuming a density of 20 kN/m3 for the trench fill over the pipe reference to Tables
35 to 37 will then give an estimate of maximum safe cover heights. (See worked
example).
Normally the embedment widths B should comply with the dimensions in Table 31
and based on these, pre-calculated safe maximum cover heights for a range E
values (i.e. many combinations of native and embedment soils) are given in Tables
35 to 37.
Table 34
Leonhardt Correction Factor *
Ee/En
0.2
2.4
1.7
1.5
1.2
1.0
1.0
B/D
1.5
2
2.5
3.0
4.0
5.0
0.4
1.8
1.5
1.3
1.2
1.0
1.0
0.8
1.2
1.2
1.1
1.0
1.0
1.0
1
1.0
1.0
1.0
1.0
1.0
1.0
2
0.6
0.6
0.7
0.8
1.0
1.0
4
0.3
0.4
0.5
0.6
0.9
1.0
6
0.2
0.3
0.4
0.5
0.8
1.0
*Alternatively see Figure 3.2 of AS/NZS 2566.1
Example 6.1
Problem
What is the maximum cover height for a DN 900 PN 6 SN 5000 Flowtite pipe laid in
a trench 1800mm wide? The native soil is firm clay with a minimum SPT of 7 blows
per 300mm. The embedment material is graded aggregate placed with a Density
Index of 60.
Solution
From Table 32 select En = 3 MPa, and from Table 33 select Ee = 7.0 MPa.
Since B/D = 1800/900 = 2
and Ee/En = 7/3 = 2.33
from, Table 34 by interpolation, the Leonhardt factor = 0.55.
Therefore the combined soil modulus E = 0.55 x 7 = 3.85 MPa.
Referring to Table 35; interpolating for a DN900 SN 5000 and an E of 3.85 MPa it
appears that the maximum cover height under traffic loading and high water table
would be approximately 5.2 metres.
75
Table 35 Permissible maximum cover height (metres) for PN 10 pressure pipe

operating at 80 metres head
Nominal
Stiffness / DN
(all PNs)
Effective (combined) soil modulus E

(Derived from En, Ee, and embedment width B)
1.0
MPa
2.0
MPa
3.0
MPa
4.0
MPa
5.0
MPa
6.0
MPa
7.0
MPa
8.0
MPa
SN 2500
DN300
DN600
DN1200
DN2400
ns
ns
ns
2.90
2.57
1.52
4.17
3.84
3.09
5.52
4.90
4.23
6.29
5.90
5.22
7.21
6.85
6.19
8.12
7.77
7.09
8.92
8.50
7.90
SN 5000
DN300
DN600
DN1200
DN2400
2.00
ns
ns
3.96
3.65
2.90
5.50
5.18
4.47
6.88
6.55
5.81
8.17
7.84
7.15
9.30
9.02
8.30
10.43
10.12
9.40
11.45
11.10
10.40
SN 10000
DN300
DN600
DN1200
DN2400
2.74
2.92
2.57
1.52
4.41
4.85
4.80
4.20
5.88
7.23
6.85
6.18
7.36
8.90
8.60
7.90
8.70
10.82
10.20
9.43
10.00
12.00
11.60
10.90
11.20
13.35
13.05
12.37
12.40
14.65
14.30
13.60
Note: Table 35 is based on the following design parameters

1. Class PN 10 pipes operating at a head of 80 metres
2. No negative pressure (i.e. vacuum)
3. Allowable design deflections
6%,
4. Circumferential flexural strain
0.65%
5. Buckling factors of safety 2.5
6. No water table
7. AUSTROADS dual lane T44 highway loading
8. Fill density of 20 kN/m3
Minimum Cover Height
Cover heights shown in Table 35 may be insufficient to prevent flotation should the
trench become flooded when the pipes are empty. A minimum cover of at least 1.5 x
diameter is necessary to avoid this possibility.
76
Table 36 Permissible maximum cover height (metres) for PN 10 pressure pipe

operating at 100 metre head
Nominal

Stiffness / DN
1.0
MPa
2.0
MPa
3.0
MPa
4.0
MPa
5.0
MPa
6.0
MPa
7.0
MPa
8.0
MPa
SN 2500
DN150
DN300
DN600
DN1200
DN2400
ns
ns
ns
2.91
2.57
1.54
4.17
3.83
3.08
5.25
4.90
4.20
6.29
5.90
5.20
7.23
6.87
6.18
8.12
7.77
7.08
8.92
8.60
7.90
SN 5000
DN150
DN300
DN600
DN1200
DN2400
1.63
1.42
ns
3.44
3.55
2.90
4.77
4.93
4.47
6.05
6.25
5.80
7.20
7.40
7.15
8.22
8.50
8.30
9.25
9.50
9.70
10.20
10.50
10.45
SN 10000
DN150
DN300
DN600
DN1200
DN2400
ns
ns
1.80
1.83
1.54
1.50
2.50
3.25
3.30
3.40
2.56
3.48
4.43
4.50
4.61
3.28
4.40
5.52
5.62
5.75
4.00
5.25
6.59
6.70
6.85
4.60
6.10
7.60
7.72
7.90
5.22
6.82
8.55
8.65
8.85
5.77
7.60
9.45
9.60
9.80

1. Class PN 10 pipes operating at a head of 80 metres
6%,
0.65%
6. No water table
77
Table 37 Permissible maximum cover height (metres) for PN 1 non pressure

applications only
Nominal

Stiffness / DN
1.0
MPa
2.0
MPa
3.0
MPa
4.0
MPa
5.0
MPa
6.0
MPa
7.0
MPa
8.0
MPa
SN 2500
DN150
DN300
DN600
DN1200
DN2400
n/s
n/s
n/s
2.62
2.31
1.50
3.73
3.47
2.88
4.69
4.45
3.88
5.60
5.33
4.75
6.45
6.20
5.60
7.25
7.00
6.40
8.00
7.70
7.18
SN 5000
DN150
DN300
DN600
DN1200
DN2400
1.65
n/s
n/s
3.55
3.27
2.70
4.90
4.65
4.10
6.19
5.85
5.30
7.30
7.05
6.45
8.35
8.10
7.50
9.30
9.05
8.50
10.28
10.00
9.45
SN 10000
DN150
DN300
DN600
DN1200
DN2400
2.85
2.77
2.62
2.29
1.50
4.85
4.85
4.69
4.45
3.87
6.67
6.60
6.45
6.20
5.60
8.20
8.15
8.00
7.70
7.19
9.57
9.50
9.35
9.10
8.55
10.92
10.80
10.70
10.40
9.86
11.20
12.10
12.00
11.66
11.10
12.47
13.30
13.10
12.85
12.35

1. Pipes are Class PN 1 i.e. non pressure
6%,
0.65%
6. Water table at surface
78
Table 38
Minimum cover heights
Location
Minimum height
of cover H (m)*
Minimum value
of E/ (MPa)
Not subject to vehicular loading
0.30
Not applicable
Subject to vehicular loading - not in roadways

- in sealed roadways
- in unsealed roadways
0.45
0.60
0.75
2.0
2.0
1.5
Pipes in embankment conditions or subject to

construction equipment loading
0.75
2.0
* Note these covers may be applied where there is no risk of flotation. Calculations
using the methods of AS/NZS 2566 Part 1 show that these values can be used for
stiffnesses of SN 5000 or greater and diameters up to DN 1400 for the minimum E
shown. The same criteria as for Table 6.5 have been used except for the live load
which is AUSROADS TL 44 dual lane
Under roadways the only pipe embedment material should be used above the pipes
and have a minimum compaction Density Index of 65%. After pipes are laid and
centred in the trench, the embedment material should be compacted in 80-100mm
layers to the specified density. The embedment should continue above the pipe to
provide protection from the back fill. That is a height above the pipe of 100-300 mm
may be required depending on pipe size and site conditions.
79
External hydrostatic pressures

As can be seen when applying buried flexible pipe design principles, soil support
significantly enhances the buckling resistance of pipes under external hydrostatic
pressure which may occur due to a high water table and/or negative internal
pressures.
However where Flowtite pipes are subjected to external hydrostatic pressures
without any significant external soil support, the possibility of buckling due to reduced
structural stability of the pipe wall must be considered. Negative heads such as in
suction delivery pipelines to pumps or as the result of negative water hammer surge
waves may require a minimum stiffness of SN 10000 if the pipes are above ground.
If during installation, pipes are to be grouted externally inside another conduit, the
allowable liquid grout pressure will be limited by the pipe stiffness - see Table 6.6.
Table 6.7 Allowable negative / external fluid pressures on unsupported pipes
(factor of safety = 2.5)
Stiffness SN
2500
5000
10000
External pressure, kPa

For intermittent & short
For continuous long term
term duration (<6 hours)
duration (i.e. 50 years)
22
15
44
31
88
61
Where pipes are encased in concrete, which in turn is subjected to high external
hydrostatic pressures, a further long term buckling possibility exists owing to the
permeability of concrete. This mode of collapse should be checked for pipes serving
as liners in the structural concrete of tunnels at considerable depths below the
standing water table see Table 6.8.
80
Table 6.8 Allowable external fluid pressures on pipes in a rigid encasement( i.e.
concrete encased with a factor of safety 2.5)
Radial gap
as
percentage
of radius
Stiffness
(SN)
N/m.m
0.001%
2500
5000
10000
2500
5000
10000
2500
5000
10000
2500
5000
10000
2500
5000
10000
0.01%
0.1%
1.0%
10.0%
Enhancement
Factor applied to
unsupported
buckling pressure
of Table 6.7
17.3
14.9
13.0
16.8
14.8
12.9
16.2
14.0
12.0
9.5
8
7.7
3.5
3.5
3.5
External hydrostatic
pressure (kPa) for
continuous long term
operation
266
458
799
258
455
793
249
430
737
146
246
473
54
108
215
Values in Table 6.8 have been calculated using the method given by Lo, King and
Zhang Jane Collapse Resistance Modelling of Encased Pipes published in Buried
Plastic Pipe Technology STP 1222 ASTM Philadelphia 1990.
DN250 SN 10000 Flowtite

being inserted into host pipe.
The allowable grouting pressure
can be obtained from Table 6.7
i.e. 88 kPa
81
6.2
Thrust block design for pressure pipelines
Where the pipeline system is rubber ring jointed there will be unbalanced force at
changes of size or direction of the pipeline. That is, at bends tees, reducers, valves
and closed ends. In buried installations, concrete blocks sized according to soil
conditions usually restrain fittings. Where bends are in the vertical plane, convex and
close to surface, the mass of a concrete anchor block alone may have to be used.
Figure 6.4 Typical concrete thrust block arrangement for ductile iron fittings
82
Table 6.9 Hydrostatic forces in kilonewtons on rubber ring jointed fittings per
10 metres hydrostatic head
Pipe DN
Pipe OD
Bend
90 0
Bend
45 0
Bend
22.5 0
Bend
11.25 0
300
375
450
525
600
675
750
900
1000
1200
1400
1600
1800
2000
2200
2400
3000
345
426
507
587
667
747
826
923
1025
1229
1433
1637
1841
2045
2249
2453
3065
13.22
20.16
28.55
38.27
49.41
61.98
75.78
94.63
116.70
167.77
228.09
297.65
376.46
464.51
561.81
668.35
1043
7.15
10.91
15.45
20.71
26.74
33.54
41.01
51.21
63.16
90.80
123.44
161.09
203.74
251.39
304.05
361.71
564.71
3.65
5.56
7.88
10.56
13.63
17.10
20.91
26.11
32.20
46.29
62.93
82.12
103.86
128.16
155.00
184.40
287.88
1.83
2.79
3.96
5.31
6.85
8.59
10.50
13.12
16.18
23.26
31.62
41.26
52.18
64.39
77.88
92.64
144.64
Tee /
Closed end
& Valve
9.35
14.25
20.19
27.06
34.94
43.83
53.59
66.91
82.52
118.63
161.28
210.47
266.19
328.46
397.26
472.59
737.82
Note: For concentric reducers the resultant thrust will be the difference between the
closed end forces for the two pipe sizes.
Table 6.10 Estimated horizontal soil-bearing capacities (kPa) apply minimum
factor of safety of 1.1 for thrust block design
Soil group
description as
per AS 1786
GW, SW
GP, SP
GM, SM
GC, SC
CL
ML
OH
Minimum soil cover above fitting supported by thrust block

0.75 metre
1.0 metre
1.25 metre
1.5 metre
57
48
48
79
74
69
0
76
64
64
92
85
81
0
95
80
80
105
95
93
0
114
97
96
119
106
106
0
Thrust blocks must be formed so as to distribute the hydrostatic force to a plane

surface of undisturbed soil, which is approximately perpendicular to the imposed
load. The equation for this calculation is:
A = T/ b x f
Equation 6.3
Where A = area perpendicular to force (m2)

T = hydrostatic thrust (kN)
b = soil bearing capacity (kPa)
f = factor of safety
83
Example 6.1
Problem
A DN 750 PN10 SN 5000 pipe laid at a cover height of 1000 mm will be subjected to
1100 kPa during the field testing of the pipeline. A design check is required for a
thrust block for 90-degree bend that has been constructed against undisturbed soil
estimated to have a safe horizontal bearing capacity of 100 kPa.
Solution
From Table 6.9; the thrust from a 90-degree bend under 100 kPa pressure equals
75.78 kN.
Therefore the outwards thrust along the axis symmetry of the bend at a test pressure
of 1100 kPa will be T = 11 x 75.78 = 833.6 kN.
Using Equation 6.3 to check the area of concrete/soil interface that is perpendicular
to the line of thrust.
A = 833.6/100 x 1.1
= 7.17 square metres
Example 6.2
Problem
A DN1200 x 1000 PN16 SN 10000 taper is to be installed in a pipeline. What is
required for resisting the unbalanced thrusts on this fitting assuming the maximum
test / operating pressure is 1500 kPa? The fitting will have a cover height of 1200 mm
in native soil with an estimated horizontal bearing capacity of 75 kPa.
Solution
For a pressure of 1500 kPa i.e.150 m head from Table 6.9; the axial thrust on the
DN1200 (closed) end of the fitting will be 118.63 x 15 kN and on the DN1000 end it
will be 82.52 x15 kN. The difference will be the thrust to be supported by a thrust
block i.e. 541.6 kN.
Therefore the area of the thrust block at the concrete / native undisturbed soil
interface which is perpendicular to the line of thrust (i.e. parallel to the axis of the
fitting - refer to Figure 6.2) can be calculated using Equation 6.3.
A = 542/75 x 1.1
= 7.95 square metres
84
6.3
Angular deflection of Flowtite coupling joint
The maximum angular deflection at each coupling joint must not exceed the values
given in Tables 7.2 and 7.3. It will be noted from Table 7.3 that pipe lengths shorter
than standard may be useful were the pipe alignment needs to be curved without the
use of bend fittings.
85
6.4
Design of GRP flanges
GRP flanges may be required for joining to other materials or where external thrust
restraints are not practicable. The unique fabrication methods possible with GRP
frequently provide economic solutions for complicated fitting assemblies.
Flange compatibility
For bolting compatibility flange drillings for GRP fittings manufactured to ISO 10639
and ISO 10467, the bolt PCD, outside diameter, number and diameter of bolt holes
can be determined from the purchasers order, or if not specified, then Class 16 of
AS 4087 Metallic flanges for waterworks purposes would be the default
configuration as given in Table 6.11. This coincides with Tables C & D of AS 2129
Flanges for pipes, valves and fittings. Note that for rated pressures from 1600 to
3500 kPa the Class 35 configuration of AS 4087 should be used which coincides with
Tables F & H of AS 2129.
Table 6.11 Compatible bolting configuration for Class 14 & 16 metallic flanges
DN
80
100
150
200
225
250
300
350
375
400
450
500
600
700
750
800
900
1000
Outside
Dia
185
215
280
335
370
405
455
525
550
580
640
705
825
910
995
1060
1175
1255
Bolting Details
Pitch circle
diameter
146
178
235
292
324
356
406
470
495
521
584
641
756
845
927
984
1092
1175
No. of
holes
4
4
8
8
8
8
12
12
12
12
12
16
16
20
20
20
24
24
Dia. of
holes
18
18
18
18
18
22
22
26
26
26
26
26
30
30
33
36
36
36
Fastener size
and thread
M16
M16
M16
M16
M16
M20
M20
M24
M24
M24
M24
M24
M27
M27
M27
M33
M33
M33
Bolt and gasket materials shall comply with AS 4087 Table 3.2 and WSA 109
Industry standard for flange gaskets and O rings respectively.
86
GRP flange characteristics

The jointing procedures for flanged connections including one or more GRP flanges
as compared with all metal-flanged joints are not significantly different. However the
following points unique to GRP should be observed. These are:
a) Because GRP flanges are pressure rated (e.g. PN 6, PN 12, etc) in the same
way as GRP pipes, the required rating shall be specified by the purchaser.
The flange thicknesses will vary accordingly and typically will be substantially
thicker than metallic flanges of similar pressure rating.
b) GRP flanges may be either flat face and full gasket (includes flanges with
concentric ribbing on flange or gasket surface), flat face and O ring seal or
stub flange and matching flat gasket (with metal backing plate) see Figure 1.
O ring seals and groove dimensions shall comply with AS 4087 Appendix B.
c) At higher pressure/torque values, flat face flanges may require a full metal
backing plate to avoid risk of crushing GRP under washers. Alternatively O
ring seals may be used to reduce torques required at high pressures. i.e.
greater than PN 12 for larger than DN 500. For the maximum allowable
torque values see PN6 and PN12 of Table 6.12.
d) Flat face GRP flanges to be mated with raised face flanges require an
insertion plate to support the GRP flange with minimum thicknesses shown in
Table 6.14. A second gasket and longer bolts will be required. (The
nominated bolt torques are unaffected)
e) GRP stub flanges (with steel backing plate) can be used with raised face
flanges without an insertion plate. The torque values of Table 6.12 apply.
f) Metal washers of similar material to the fasteners shall be used with all GRP
flanges.
g) Fastener bearing surfaces on GRP flanges are machined all over or spot
faced depending on size.
h) Appropriate bolt torques for GRP flange fasteners are listed in Table 6.12.
These vary depending on the operating and rated pressure of the flange
system and values for intermediate pressures may be interpolated.
i) Flat gaskets 3 mm thick complying with WSA 109 for flanges rated up to PN
16 shall be used with hardness within the range 56 to 75 IRHD.
j) If the flange requires an O ring seals it shall comply with WSA 109 with
hardness in the range 36 to 55 IRHD.
k) Grade 4.6 galvanised steel or Grade 316 property Class 50 stainless steel
fasteners are recommended for GRP flanges. Higher strength bolts are
acceptable i.e. Grade 8.8 galvanised steel and Grade 316 Class 80 stainless
steel.
87
Table 6.12 Bolt tightening torques for flat face and stub flanges
PN 6
Torque
N.m
25
80
35
100
35
150
50
200
50
225
50
250
70
300
70
350
70
375
70
400
75
450
75
500
80
600
100
700
120
750
150
800
190
900
200
1000
DN
PN 10
Torque
N.m
35
80
40
100
50
150
60
200
70
225
80
250
90
300
120
350
120
375
120
400
150
450*
150
500*
210
600*
210
700*
200
750*
300
800*
300
900*
400
1000*
DN
PN 16
Torque
N.m
50
80*
75
100*
60
150*
80
200*
90
225*
100
250*
100
300*
150
350*
150
375*
200
400*
250
450*
250
500*
300
600*
350
700*
400
750*
450
800*
475
900*
500
1000*
DN
* NB Full metal backing plate required with flat face flange & gasket. Alternatively use
O ring or ribbed reinforced seals that allow reduced torques.
Table 6.13 Dimensions of washers to AS 1237-1973 required for flange nuts
and bolts
Size of bolt
M16
M20
M22
M27
M33
Galvanised steel
Outside washer
Nominal
diameter (mm)
thickness
(mm)
30
3
37
3
44
4
50
3
60
3
Stainless steel
Outside washer
Nominal
diameter (mm)
thickness
(mm)
30
1.5
37
2.0
44
3
50
3
60
3
88
Table 6.14 Backing plates (for full face and stub flanges) and insertion/spacer
flanges for raised face installations
(Based on AS 4087 Table PN 16 steel flange thicknesses & drilling patterns)
Nominal
diameter
80
100
150
200
225
250
300
375
400
450
500
600
700
750
800
900
1000
Galvanised steel
Thickness (mm)
8
10
10
16
16
16
19
26
26
26
34
43
51
51
51
61
61
Outside dia.
185
215
280
335
370
405
455
550
580
640
705
825
910
995
1060
1175
1255
Stainless steel
Thickness (mm)
10
10
13
13
16
16
19
22
22
25
29
32
Outside dia.
185
215
280
335
370
405
455
550
580
640
705
825
89
6.5
Above Ground Installation
Standard Flowtite pipes with rubber ring couplings or butt strap joints can be used
for permanent above ground pipelines. However when standard Flowtite pipes with
rubber ring jointed couplings are used above ground or in situations without soil
support there is a need for careful consideration to be given to the design and
location of the supporting structures.
Exposure to sunlight and ultra violet radiation does not affect unprotected Flowtite
structurally although the exterior will become weathered, that is roughened and
discoloured with time. If this is not acceptable pipes can be coated with water based
acrylic paint finishes.
Should there be unusually high tensile axial loadings exceeding those allowable for
standard pipe, special biaxial Flowtite can be specified which has enhanced axial
strength up to three times that of standard pipe.
Pressure pipes must be installed on a straight alignment to ensure there are no
unanticipated lateral reaction forces due to the hydrostatic pressure in the pipeline.
Fittings will need special anchorage to withstand thrusts caused by hydrostatic
pressures within the pipe system. In the case of pressure pipes supports are
required each side of the coupling at a centreline distance not exceeding the greater
of 250 mm and 0.5 X DN, to ensure its complete stability - see Fig 6.3. This limitation
can be increased up to 1/6 of the pipe length from the end for low-pressure
applications - see Fig 6.4. When a pipe length is supported on more than two
supports, the alignment should be kept straight to within a tolerance of 0.1% of the
span length.
A typical detail for support cradles and hold-down/ anchor straps is shown in Fig 6.5.
Compressible material such as 5 mm thick insertion rubber should be placed
between the pipe wall, the cradle and/or strap. The cradle should extend to 150
degrees of the circumference and have a radius that allows for the protection. Any
misalignment of the supports across the joints should be limited to the lesser of 0.5%
x DN and 3 mm. Although a hold down straps is not usually required at every support
there should be at least one per pipe, uniformly spaced along the pipeline.
Calculations of the safe span lengths in Table 6.15 have been made on the basis of
applying a factor of safety of 6 to the axial strength of the pipe and limiting the
deflection to span / 500.
90
Figure 6.5: Recommended support locations for pressure pipes
Figure 6.6: Alternative support locations for low pressure pipes
Figure 6.7 Typical support details
91
Table 6.15 Permissible spans for standard Flowtite pipes simply supported
and full of water
Nominal
diameter DN
Pressure
class PN
SN 2500
Nominal Stiffness
SN 5000
SN 10000
80
100
125
150
200
250
300
375
16
16
16
16
16
16
16
1.0
6.0
10.0
16.0
20.0
25.0
32.0
1.0
6.0
10.0
16.0
20.0
25.0
32.0
1.0
6.0
10.0
16.0
20.0
25.0
32.0
1.0
6.0
10.0
16.0
20.0
25.0
32.0
1.0
6.0
10.0
16.0
20.0
25.0
32.0
4.06
4.47
4.47
4.64
4.81
4.96
5.14
4.12
5.02
5.04
5.17
5.37
5.55
5.73
4.14
5.14
5.45
5.69
5.89
6.08
6.28
4.26
5.38
5.71
6.18
6.39
6.61
6.81
4.41
5.66
6.02
6.64
6.88
7.11
7.33
4.06
4.47
4.47
4.64
4.81
4.96
5.14
4.12
5.04
5.04
5.17
5.37
5.55
5.73
4.14
5.54
5.54
5.69
5.89
6.08
6.28
4.26
5.97
6.04
6.18
6.39
6.61
6.81
4.41
6.22
6.40
6.64
6.88
7.11
7.33
2.07
2.25
2.46
2.83
3.24
3.81
4.35
4.06
4.47
4.47
4.64
4.81
4.96
5.14
4.12
5.04
5.04
5.17
5.37
5.55
5.73
4.14
5.54
5.54
5.69
5.89
6.08
6.28
4.26
6.04
6.04
6.18
6.39
6.61
6.81
4.41
6.52
6.52
6.64
6.88
7.11
7.33
1.0
6.0
10.0
16.0
20.0
25.0
32.0
4.58
5.94
6.34
6.98
7.34
7.58
7.82
4.58
6.46
6.64
7.09
7.34
7.58
7.82
4.58
6.96
6.96
7.09
7.34
7.58
7.82
450
525
600
675
750
92
Table 6.15 - continued

Nominal
diameter DN
Pressure
class PN
900
1.0
6.0
10.0
16.0
20.0
25.0
32.0
1.0
6.0
10.0
16.0
20.0
25.0
32.0
1.0
6.0
10.0
16.0
20.0
25.0
32.0
1.0
6.0
10.0
16.0
20.0
25.0
32.0
1.0
6.0
10.0
16.0
1.0
6.0
10.0
16.0
1.0
6.0
10.0
16.0
1.0
6.0
10.0
1.0
6.0
10.0
1.0
6.0
1000
1200
1400
1600
1800
2000
2200
2400
3000
Nominal Stiffness
SN 2500
SN 5000
SN 10000
4.73
6.20
6.61
7.32
7.74
8.15
8.40
4.91
6.43
6.88
7.63
8.07
8.72
8.99
5.22
6.90
7.39
8.22
8.71
9.47
10.11
5.52
7.35
7.87
8.77
9.31
10.14
11.13
5.80
7.77
8.31
9.29
6.07
8.17
8.74
9.78
6.32
8.55
9.15
10.26
6.57
8.91
9.53
6.81
9.25
9.91
7.48
10.22
4.73
6.76
6.95
7.55
7.90
8.15
8.40
4.91
7.03
7.24
7.89
8.29
8.72
8.99
5.22
7.57
7.80
8.52
8.96
9.47
10.11
5.52
7.54
8.31
9.09
9.31
10.14
11.13
5.80
8.57
8.80
9.64
6.07
9.01
9.26
10.16
6.32
9.44
9.70
10.64
6.57
9.85
10.12
6.81
10.25
10.52
7.48
11.34
4.73
7.39
7.39
7.64
7.90
8.15
8.40
4.91
7.73
7.73
8.16
8.45
8.72
8.99
5.22
8.35
8.35
8.90
9.30
9.75
10.11
5.52
8.91
8.91
9.51
9.94
10.45
11.13
5.80
9.46
9.46
10.09
6.07
9.96
9.96
10.64
6.32
10.45
10.45
11.16
6.57
10.92
10.92
6.81
11.36
11.36
7.48
12.60
93
7 INSTALLATION
7.1
Transportation and Storage
Although Flowtite pipes are light and robust, they should not be rolled, dropped,
thrown, or allowed to come into contact with sharp objects likely to cause damage.
Where Flowtite pipes are unloaded to storage they should be kept in their packs if
possible. The storage site should be smooth and level. If pipes are not crated they
should be placed on horizontal supporting timbers (at approximately 2 metre
centres), and these should also be used to separate layers if pipes are stacked.
Stack heights should be limited to prevent excessive ovalisation, The socket and
spigot ends should be placed at alternate ends with sockets protruding so they will
not be subject to load during storage.
Table 7.1 Packing specifications
Nominal
pipe size
(DN)
Quantity of pipes on
table-top truck
Across
High
Number of
12 m lengths
per
semi-trailer
Number of
metres
per
semi-trailer
300
375
450
525
600
675
750
900
1000
6
5
4
4
3
3
2
2
2
5
5
4
4
3
3
3
2
2
30
25
16
16
9
9
6
4
4
360
300
192
192
108
108
72
48
48
1200
48
1400 - 2400
12
94
FLOWTITE pipes are packed for road freight on shaped timber

bearers with couplings already fitted unless otherwise specified
7.2
Excavation and associated works
Flowtite is a flexible pipe and is designed to deflect under vertical soil loads, which
are then transferred to the soil in the side support zone. Australian Standard AS/NZS
2566.2 Buried Flexible Pipelines Part 2 Installation provides extensive guidance
on installation requirements.
Fig 7.1 Buried pipeline terminology
95
Trench excavation
Excavate the trench to the line and grade specified. The trench width must be
sufficient to permit compaction of the pipe embedment materials with suitable
equipment. The minimum pipe trench width required is typically equal to pipe OD +
300 to OD + 0.OD/2 mm depending on pipe diameter see Table 6.2 for widths as
per AS/NZS 2566.2. The trench bottom should be even and free of large clods and
stones.
Foundation
The native soil in the foundation zone should be carefully excavated to grade to
permit the pipeline to be correctly aligned, allowing for bedding material of a
minimum thickness of 75 to 150 mm beneath the pipe, depending on the diameter.
Unstable and wet ground conditions
When wet and/or unstable soil conditions are encountered, precautions must be
taken to maintain firm and permanent side support for the pipes once installed.
Where groundwater is present and there will be a risk of the fine soil particles
migrating across the interface between the native and embedment soils, it is
recommended that the embedment material should be fully enveloped with geotextile
material. Details of soil gradings where this can occur are given in AS/NZS 2566.2.
Pipe installation should be carried out in a trench free of water. Where there is a
possibility of a continuing high rate of ground water inflow it may be necessary to
facilitate drainage of the trench by the use of a porous layer of bedding material in
the foundation zone. Generally this will be a coarse granular material which will need
to be fully encapsulated in a geotextile fabric and is sometimes described as a
drainage mattress.
Trench shields
Where trench shields or soil boxes are required, it is desirable for them to be a close
fit against the excavated trench walls and for the bottom edge to be kept above the
top of the pipe. If for safety reasons they must extend to the bottom of the trench,
compaction of the embedment after the shields are lifted is necessary to eliminate
any voids that may otherwise develop (see Figures 4.2 a and 4.2 b). Soil boxes used
in open excavations are prone to accumulate loose debris between the box and the
trench wall. As this poor quality material can adversely affect the available side
support, it is good practice to place high quality embedment material in this part of
the side support zone as soon as possible to exclude any debris or material which
may slough from the trench wall (see Figure 7.3)
96
Figure 7.2(a) Shields kept above side

zone
Figure 7.2(b) Shields in side support

support zone
Figure 7.3 Shields in wide trench
7.3
Pipe laying
Bedding
The pipe bedding should be comprised of embedment material used to provide
uniform support and load distribution along the pipe barrel as well as supporting the
side support embedment material. A layer of granular material with a maximum
particle size of 20mm placed and compacted to least 100mm clear thickness is
recommended. A slight depression should be formed under each socket to ensure
that the complete length of the pipe barrel is evenly supported. When aligned as
specified the pipes should be on the centreline of the trench. If groundwater is
present, the trench should be de-watered so that the pipes can be installed in a
relatively dry trench. In unstable soils additional bedding may be required to provide
a sound foundation where unsatisfactory native material has been removed from the
foundation zone.
Once the trench and bedding has been prepared, pipes can be lowered into the
trench with suitable lifting equipment (chains should not be used). Generally an
excavator/backhoe can be used with a nylon sling at the midpoint of a pipe. The
following procedure is recommended when installing Flowtite rubber ring jointed
pipes and fittings.
97
Jointing of pipes and fittings (rubber ring types)

Flowtite pipes are delivered to site with a coupling already fitted on each length. It
is normal practice to string pipes so that they can be laid by starting from the downstream end with the coupling or socket end facing in the up-stream direction.
Thoroughly clean the coupling grooves for the rubber seal and central register
stoppers.
Inspecting and cleaning

coupling grooves and ring
before joining DN750
FLOWTITE pressure pipes
Applying an approved jointing fluid to pipe spigot

prior to insertion into coupling
98
Although pipes may show some out-of-roundness due to storage loads, this is
usually quite minimal. Where it is present, it is advantageous to orientate the larger
pipe diameter vertically. This will ease the jointing process and helps to offset any
deflection after backfilling.
If the joint is to be made using a cut pipe length the pipe spigot diameter must first be
checked to ensure it is within tolerance. Cutting with a portable circular saw fitted with
a diamond tipped or abrasive masonry blade can be used. As Flowtite pipes
contain significant amounts of silica precautions against the inhaling the dust
produced are essential. A field lathe could be used to machine pipe spigots but is
generally not required as at least 40% of pipe lengths supplied on a project will be
suitable for cutting and joining without any machining. If the pipe has been cut the
spigot should be chamfered and a new witness mark made with a black marker pen
at a distance from the spigot end equal to the socket depth.
Ensure each pipe is progressively placed on the bedding material at the correct line
and grade. Insert the REKA ring seal in the groove with the tapered side facing
outwards and ribbing exposed. It will help if the ring is allowed to form two loops on
opposite each other while the ring is progressively pushed into the recess as the ring
is being compressed circumferentially during this process. Ensure the ring is
uniformly seated. Only at this stage should a thin layer of jointing fluid be applied to
the exposed rubber seal surface. Also apply jointing fluid liberally to the spigot in the
area where the seal will slide. (Under no circumstances should mineral oils or
greases be used, as these compounds will cause long-term degradation of the
rubber seal. In an emergency common soap can be used).
Joining force being applied to DI

fitting with an excavator bucket
(protected from possible damage
using a timber bolster)
Petrol powered disk cutter
used to cut back pipe spigot
99
The jointing force must be applied in an axial direction without jerking. If mechanical
plant such as an excavator bucket is being used, timber packing must be provided to
protect the GRP surfaces. Alternatively one or two cum-along-winches attached to
nylon slings wrapped around each pipe can be used.
Push (or pull) the joint home using the witness mark on the spigot to determine when
it is fully inserted.
Where a change in alignment is to be made at a joint the offset should be made after
pushing the pipe fully home without any misalignment. The pipe can then be moved
to achieve the required angular deflection limited to the maximum allowable offsets
shown in Table
Angular deflection limits for Flowtite couplings
The normal angular deflection permitted for Flowtite coupling joints is shown in
Table 7.2. However for diameters larger than DN525 where both sides of the
coupling are mobilised the permissible overall joint deflection can be as much as
TWICE that tabulated.
Note that where these deflections result in a convex vertical curve in the pipeline
alignment, the depth of cover should be increased to at least 1.2 m for pipeline if the
operating pressure is more than 1500 kPa.
Table 7.2 Angular deflection (rotation) at a Flowtite coupling joint (for pipe
pressure rating shown)
Nominal pipe diameter DN
< DN525
DN525 - DN900
> DN900 - DN1800
> DN1800 - DN3000
Pipe rating (bar)

PN16
3.00
2.00
1.00
0.50
PN 20
2.50
1.50
0.80
NA
PN 25
2.00
1.30
0.50
NA
PN32
1.50
1.00
0.50
NA
Figure 7.4 Joint geometry - angular deflection includes both sides of coupling
100
Table 7.3 Offset in millimetres for angular joint deflection (for pipe length
shown)
Deflection
angle Y
(degrees)
Offset (mm)
3m
6m
12 m
6.00
5.00
3.00
2.50
2.00
1.50
1.30
1.00
0.80
0.50
157
136
105
78
65
52
39
26
314
261
209
157
120
105
78
52
628
523
419
313
240
209
156
104
Nominal radius of curvature R

(Metres)
3m
6m
12 m
57
69
86
114
132
172
215
344
115
137
172
228
265
344
430
688
230
274
344
456
532
688
860
1376
Cut pipe spigot-end preparation

It is important to select an Adjustment pipe (branded ADJ or ADJUST) for cutting
as this will meet the required spigot tolerances and allow the use of the standard
Flowtite coupling without any machining required. The cut end should be
chamfered at a 20-degree angle (to the pipe axis) for the distance given in Table
4.4(b).
Joint misalignment
The maximum sideways or vertical shear displacement (i.e. misalignment) between
pipe spigots joined with Flowtite couplings is limited to 5 millimetres. Therefore
attention must be given to the possibility of differential settlement between the
pipeline components or associated structures to avoid exceeding this limit over time.
Field closures
(i)
Flowtite couplings can be used as slip collars if the central rubber stops are
removed and the pipe ends to be joined are within the tolerances for
adjustment pipes. This can be checked in the field by removing the rubber
rings and ensuring that the coupling will slide over pipe for the required
distance.
(ii)
Proprietary mechanical joints such as Teekay, Straub, Norma or in the

smaller diameters (< DN900) gibault joints will be required for cut-ins if the
pipe ODs are too large for the Flowtite slip collar procedure of (i) above. In
the larger diameters at higher pressures Klamflex and Viking Johnson
couplings may be necessary. The coupling manufacturers recommendations
with respect to assembly and bolt tightening must be followed.
101
Tapped connections
As with most pipe materials Flowtite pipes cannot be direct tapped but will require
either tapping band or flanged branch sleeve, depending on the diameter of the
branch required. Specialist contractors with equipment for live (under pressure)
tapping should be used when tapping mains under pressure. No tapping should be
closer than 2 x main diameter to the end of a pipe and should be limited to pipes not
subject to significant axial stresses.
For small off-takes for service connections, approved tapping bands such as Taptite
nylon coated ductile iron or Milnes gunmetal full-circle types are available. Holes
should be drilled using tungsten tipped masonry drill or similarly faced hole
trepanning cutter.
Where larger off-takes are required, they should not exceed the following nozzle
diameter to main diameter percentage ratio for different stiffnesses:
SN 2500
SN 5000
SN 10000
20%
25%
30%
Only approved tapped sleeves should be used, that is proprietary types which have
been tested on GRP pipes. The manufacturers instructions must be followed with
particular attention paid to applying the correct bolt torques.
Flanged joints
The procedure for assembling flanged joints is as follows: 1. The mating flanges and gasket must be clean, smooth and properly aligned at the
start of the assembly process. Should an O ring seal be used in lieu of a full face
gasket, it should be correctly seated in the prescribed groove. The mating flange
shall not be grooved.
2. Insert lubricated fasteners (with washers for GRP surfaces) molybdenum
disulphide grease or equivalent nickel based anti-seize compound is
recommended. Ensure that no traces of petroleum oil or grease contaminate the
flange faces or rubber gasket.
3. Tighten fasteners using the usual star sequence pattern See Figure 7.6, with
torque increments per cycle not exceeding the lesser of 25 N.m or 20% of the
final torque requirement.
4. On achieving the recommended torque value given in Table 6.12 allow a onehour rest period and re-check torques. Do not over tighten as this may damage
the joint components, e.g. localised crushing of the GRP under the washers or of
the gasket, leading to potential leakage in service.
5. Where possible leave access to flanged connection for inspection purposes until
after acceptance testing is complete.
6. Should leakage be observed under test it is preferable to eliminate the hydrostatic
pressure before relaxing and retightening the fasteners.
102
Figure 7.5 Flange types
Full Face Flange with

O ring gasket
Figure 7.6 Fastener tightening using star sequence
103
7.4
Side support and overlay
Embedment haunching and side support

Generally material used in the embedment zone should be uniform selected
cohesionless soil. Information regarding selection is given in Appendices G and H of
AS/NZS 2566.2. The most important aspect for the successful installation of
Flowtite pipe is the selection and compaction of the embedment, i.e. the material in
around the pipe. Embedment material should be of a granular nature, which is
readily compactable. Crushed rock, aggregate and graded sand are commonly used
but occasionally native soils, (eg. beach and mallee sand) may also be suitable,
provided they are free flowing and readily compacted.
The embedment must be evenly compacted between the pipe and the surrounding
native soil given that the side support zone extends beyond the pipe horizontally for a
distance of twice the pipe diameter in the pipe zone. Care must be taken not to move
the pipe from its alignment when compacting the embedment material.
Where trench shields or boxes are used special care must be taken to ensure any
voids resulting from their use are completely filled with compacted embedment
material as described in Clause 5.4.4 of AS/NZS 2566.2
If there is a possibility of migration of fines between the embedment and native soil
geotextile fabric should be used at the interface to envelope the embedment
including the bedding completely (See Section 4 of AS/NZS 2566.2 and Appendix J
for further information)
Attention to the quality and degree of compaction of embedment material placed
each side of a Flowtite pipeline is fundamental to its structural integrity. The
following, Table 7.4, shows the default values given in AS/NZS 2566.2 for the
appropriate degrees of relative compaction of the embedment bedding and side
support zone.
Table 7.4 Minimum relative compactions (extract from AS/NZS 2566.2 Table 5.5)
Soil type
Test method
Cohesionless
Density Index
Cohesive
Standard Dry
Density Ratio, or
Half Density
Ratio
Trafficable areas
Embedment
Trench /
material %
embankment
fill material %
70
70
95
95
Non trafficable areas

Embedment
Trench /
material %
embankment fill
material %
60
Compaction to
suit site
requirements
90
Overlay
The embedment material should extend to a cover height of 100 to 300mm above the
pipe (depending on the diameter) to provide protection from placement of fill material
and the operation of compaction equipment.
104
7.5
Trench and embankment fill (i.e. above embedment / overlay)
Backfill over Flowtite pipelines may involve the use of excavated material providing
the thickness of overlay is adequate. Care must be taken to avoid the inclusion of
large stones, rocks or hard clumps that may cause point loading on the pipeline.
Compaction of the final backfill by large vibrating power compactors should be used
until there is an adequate height of fill over the pipes. This will vary depending on the
capacity of the machine but generally a minimum of 0.5 metres is desirable.
Monitoring embedment compaction
After the filling operation is complete, the adequacy of embedment compaction and
the use of correct backfilling techniques may be assessed either by soil
stiffness/density testing during placement or by the measuring the diametral
deflection of the pipe after backfilling is complete.
The deflection check described in Section 8.3 is particularly useful in the early stages
of construction for pipes with more than 2 metres cover. Acceptable deflection values
will vary depending on the elapsed time after installation. AS/NZS 2566.2 gives
factors which can be applied depending on the time intervals after completion of the
backfilling e.g. the maximum recommended allowable deflection at 24 hours is 3% for
Flowtite and at 30 days, 3.5%. Refer to Table 6.2 of AS/NZS 2566.2 for allowable
deflections at other time periods.
Note: During compaction of backfill in the pipe embedment zone, an increase in the
vertical diameter and decrease in the horizontal diameter may occur. This is not
detrimental providing the magnitude of the horizontal diametral deformation does not
exceed the prescribed allowable deflections. See Section 9 for test procedure.
7.6
Grouting
In situations where it is necessary to pressure grout the annulus between Flowtite

pipes and an enveloping conduit, e.g. when using Flowtite to reline a deteriorated
pipeline, it is important to ensure the grout is introduced into the annulus evenly. The
pipe must be adequately chocked to resist flotation and bending. The allowable
hydrostatic grout pressure will depend on its setting time but typically must not
exceed Pallow of Equation 7.1 to ensure an adequate factor of safety (of 2.5) against
buckling instability which may lead to pipe collapse. See also Table 6.8 for more
accurate detail.
Pallow = 24 x SN / 2500 kPa
Equation 7.1
If necessary the effect of grout pressures can be substantially reduced by filling the
pipeline with water. Alternatively it may be possible to stage the grouting process in
two or even three lifts, i.e. to allow grout to solidify in the annulus below the spring
line before the top section is filled.
105
7.7
Joints subject to differential settlement
Relative settlement
Where Flowtite pipes are connected to significant concrete structures it is
recommended that short pipe lengths or rocker pipes be used adjacent to the
structure as described in AS/NZS 2566.2. This will allow the pipes to accommodate
differential settlement through a small amount of rotation of the rocker pipe together
with joint deflection without damage.
Pipe / concrete interface
Flowtite pipes can be directly embedded directly into concrete. However it is
recommended that at the entry and exit points, i.e. at the face of the concrete, the
pipe should be wrapped in a compressible material. Alternatively a Flowtite
coupling should be located and cast into the concrete face so that the rubber ring
joint can accommodate any movement.
Flanged off-takes for air valves and scours.
Auxiliary pipe connections

Scour and air valve structures are often associated with flanged pipe work which in
turn must be connected to small diameter flanged off-takes on the mainline. As there
is potential for differential settlement or movement between these assemblies
provision must be made for this. The usual method is to provide a rocker pipe of
between 2 x DN and 3 x DN in length which is designed to articulate between two
introduced rubber ring joints as illustrated in Figure 7.7.
Alternatively a similar length of a small diameter polyethylene pipe spool with stub
flanges and backing plates can be inserted between the two assemblies. Any
relative movement is then absorbed by the flexibility of the polyethylene. Figure 7.8
shows a scour arrangement using PE pipes and fittings.
106
Figure 7.7 Use of a rocker pipe
Side view of scour valve pit with rocker pipe
Plan view of scour valve pit with rocker pipe
107
Figure 7.8 Use of flexible PE spool pipe
Side view of a PE pipe being used to provide flexibility between the mainline and
scour structure
Plan view of a PE pipe being used to

provide flexibility between the
FLOWTITE mainline and scour
structure
108
7.8
Cutting into or repairing installed GRP pipelines
If it is necessary to remove a section of an installed Flowtite pipeline to insert a

fitting or replace a damaged pipe the following procedure is a guide.
Repair kits
In addition to the replacement item which is assumed to have ends to Flowtite pipe
tolerances (of which at least one is a spigot), the materials required for its insertion
into the pipeline will depend on whether there is an in situ adjustment pipe in the
vicinity of the intended replacement:
(i) If this were the case, the repair kit would comprise of three Flowtite couplings
and a short closure length (say 3m minimum in length) of adjustment pipe.
(ii) a: If it is not the case the repair kit could comprise of two Flowtite couplings, a
mechanical coupling and a short closure length (say 3m minimum in length) of
adjustment pipe, or
(ii) b: Alternatively, if a larger excavation is possible so as to expose another joint
then a full length adjustment pipe (usually 12m) for the closure should be used. This
will enable all joints to be on correctly toleranced ends suitable Flowtite slip collars
Note that jointing lubricant is required for both Flowtite and mechanical couplings.
Procedure
1) Dewater the pipeline.
2) If a pipe, fitting or coupling has to be removed from the installed pipeline
select a position at about 1.5 metres away on one of the GRP pipes located
adjacent to the item to be removed. This will be the location of the initial two
rough cuts. If there is an option of these cuts being made in an adjustment
pipe this should be selected for cutting.
3) This initial opening in the line should be made by making two parallel rough
cuts at least 450mm apart i.e. more than the 330mm coupling width. After
clearing debris from the gap it should be possible to pull the item to be
removed in an axial direction into this gap. Once free it should be possible to
lift it out of the trench.
4) The in-situ rough-cut pipe end must then be prepared for a new joint by
cutting back to allow for the insertion of the replacement plus closure pipe.
The distance from the newly prepared spigot to the spigot end replacement
piece should be calculated so as to allow for 20mm clearance allowance at
between spigots
5) Care must be taken to achieve the required squareness tolerances and it will
need to be sanded smooth and chamfered to the same dimensions as factory
made pipe spigots. If this spigot is an adjustment pipe OR a pipe to
adjustment pipe dimensions, it will be possible to plan for slipping a Flowtite
coupling over the pipe-to-pipe joint.
109
FIG 7.9 shows the

sequence for inserting
the closure pipe using
slip couplings and/or
mechanical couplings on
each end
6) If the spigot is not to the required jointing tolerances for a Flowtite coupling
then a mechanical coupling will be required for the pipe-to-pipe joint.
7) Because the closure pipe is an adjustment pipe, it will be possible to use a
Flowtite coupling on the pipe-to-replacement joint as a slip collar. If the insitu pipe is also to acceptable tolerances (even if not an adjustment pipe), a
slip joint using a Flowtite coupling will also be possible for the pipe-to-pipe
joint.
8) Note that the central stops are removed when using Flowtite couplings as
slip collars.
9) Ensure that new rubber rings for used for any reused couplings.
10) If not already socketed, make up the replacement piece with a single
Flowtite coupling (only) pre-fitted. Prepare bedding material in the trench to
the correct level and lower the replacement into the trench. Once aligned this
replacement-to-pipe joint should be made in the normal way.
11) Where both ends of the closure pipe can be slip jointed with Flowtite
couplings, lubricate each in turn for a distance of 340mm (i.e. double the
normal distance). Place slip couplings on both ends. They must be pushed
clear of the pipe ends. Refer to Figure 7.9. Special attention is needed during
this operation to ensure that the second ring is eased into position because it
is being slid in the opposite direction to normal. Ensure witness marks are
made on the in-situ replacement and pipe spigots and carefully align the short
length in the trench. Push each slip coupling over the lubricated in-situ spigots
as far as the witness marks. An observer inside the pipeline must monitor this
operation.
12) Where a mechanical coupling has to be used for the closure pipe follow the
separate General Assembly Guide specifically for this joint. Typically bolt
torques for PN 16 joints should typically be in the range of 80 to 120 N.m.
Note that mechanical couplings also require lubrication.
13) IMPORTANT: Use the information in the Technical Note to check the
distortion Figure 7.12 of the pipe under the mechanical gasket to ensure the
allowable bending strain in the pipe in the axial direction wall has not been
exceeded. Adjust bolt tensions where necessary.
14) It is desirable to leave mechanical joints exposed until the completion of
hydrostatic testing, as bolts may need to be re-tightened.
110
Figure 7.10 Gibault, Viking

Johnson and Klamflex couplings
Figure 7.11 Teekay, Norma and

Straub couplings
Figure 7.12 Note: The magnitude of any

distortion under the gasket of large
diameter mechanical couplings should
be monitored internally during
installation - see separate technical
note.
111
8
8.1
FIELD TESTING
Leakage testing pressure pipelines
The test procedures of Clause 6.3.4 of AS/NZS 2566.2 Buried flexible pipelines, Part
2: Installation are recommended for Flowtite. The recommended test pressure
should be not less than the maximum design pressure and at the same time not
exceed 1.25 times the pipe rating at any point along the pipeline that is not exceeding
2000 kPa.
Before carrying out, the test pipes should be substantially backfilled to ensure they
cannot move. Where joints are exposed some movement of the witness mark away
from the socket may be apparent due to the Poisson effect that is the shortening of
the pipes under circumferential working stress.
If no make-up water is required to maintain pressure after one hour at test pressure
or after the time needed to inspect the whole pipeline, it can be considered that the
test has been passed. The need for make up water may not indicate a leak if it is
within certain limits. The following equation for calculating the allowable make-up to
maintain the test pressure is given in the Standard. That is: Q
0.14xLxDxH
Equation 8.1
Where
Q = allowable make-up water, litres per hour
D = nominal diameter, in metres
L = test length, in kilometres
H = average test head over length of pipeline under test, in metres
This allowance is intended to compensate for the apparent loss due to entrapped air
being forced into solution.
Prior to carrying out a hydrostatic test it is normal to complete the pipe installation
including the backfilling and allow sufficient time to elapse to allow for curing of
concrete thrust and anchor blocks. It is recommended that mechanical joints and
flanged connections remain exposed so that they can be visually checked for leaks.
Where testing against closed valves, arrangements should be made for checking
these for leaks. Appendix M4 of AS/NZS 2566.2 describes the test procedure and
Figure 10.1 illustrates the usual test equipment arrangement.
112
Air bleed valve
Mains supply
Reference
Sight level
gauge
glass -for
Pressure
volume
relief valve
check
Calibrated test
gauge(s) (150 mm min.
dia . preferred)
Make -up
water
reservoir
Stop cock to protect gauge

during pump - up period
Pump isolation valve
Test Pump
Supply pipe
Return pipe
Pressure
control valve
End closure
(possible swab
insertion point)
End closure
Pipeline under test
(at lowest point)
Temporary thrust supports
Temporary tee
Figure 8.1 Typical arrangement of pipeline testing equipment
WARNING:
High pressure (i.e. >30kPa) air testing is not recommended for safety reasons as the
energy stored by a significant volume compressed air or other gas in a pipeline can
be both extremely destructive and life threatening if released accidentally.
Individual joint testing

For large (man entry) diameter pipelines in situations where it is impractical to charge
the pipeline with water for hydrostatic testing purposes, individual joints can be proof
tested using portable equipment inside the pipe as shown in Figure 8.2. This purpose
built equipment is comprised of segmented circular moulds, which support twin
sealing gaskets. These rubber gaskets are hollow and designed to be inflated with
water under pressure to create a seal against the inside surface of the pipe. When
the equipment placed across a joint it is possible to pressurise the annular joint
space using a hand operated hydrostatic test pump. Water can be obtained from a
small water cart not shown in Figure 8.2.
Typically this equipment is limited to about 60 kPa but for higher-pressure mains this
may still be sufficient for a proof test. Note that pipes must be backfilled before
attempting this test to stop the joint separating. In some situations it may be possible
substitute air for water but the test pressure must be limited to a safe level See the
warning above.
113
Figure 8.2 Typical arrangement of joint testing equipment
8.2
Leakage testing non-pressure pipelines
Field testing is used for revealing damaged pipes, unsatisfactory embedment, joints
incorrectly installed, or other laying deficiencies. Where watertight pipelines are
required as in the case of sewers, a leakage testing is usually required before
acceptance
A leakage check on a buried non-pressure pipeline can be done using any one of the
following methods:
Hydrostatic pressure test ,
Vacuum test
Low pressure air test,
Infiltration test.
The air and vacuum tests are usually more convenient as they do not require water.
An infiltration observation/ test measurement is a further option where a pipeline is
been laid well below the water table.
Hydrostatic (exfiltration) testing
The pipeline should be filled with water to a height of not less than 1m above the
natural ground level at the highest point of the test length but not exceeding 6m at
the lowest point of the test length. A minimum of 2 hours should elapse to allow
temperature changes to stabilise. Then during a minimum time of 30 minutes any fall
in water level in the test vessel must not exceed the hourly allowance amount shown
in Table 8.1
114
Table 8.1 Hydrostatic - leakage limits for non pressure pipes

DN
Make- up allowance*
DN
Make- up allowance*
(Litres / m / hour)
(Litres / m / hour)
0.14
0.60
300
1200
0.19
0.70
375
1400
0.23
0.8
450
1600
0.26
0.9
525
1800
0.30
1.00
600
2000
0.34
1.10
675
2200
0.37
1.20
750
2400
0.45
1.50
900
3000
0.50
1000
* Based on an allowance of 0.5 litres per hour per mm diameter per km (Ref. AS/NZS
2566.2)
If this is not achieved the pipeline should be carefully examined visually for leaks,
and any defects repaired. The pipeline should then be retested.
Low pressure air (exfiltration) testing
The test length of pipeline should be generally restricted to lengths between access
chambers (the most convenient places for fixing temporary bulkheads).
The procedure for low-pressure air testing of large diameter pipelines is potentially
hazardous at higher pressures because of the very large forces to be resisted by
temporary bulkheads and the serious consequences of accidental bulkhead blow-out.
The procedure should be as follows:
Pump in air slowly until a pressure of 28 kPa above any external ground water
pressure is reached (but do not exceed 50 kPa gauge).
Maintain the pressure for at least 3 minutes.
If no leaks are detected, shut off the air supply.
The low pressure air test for a test length of pipeline is satisfactory if the test
pressure does not drop more than 7 kPa, within the time period shown in Table 5.2
after the shut-off of the air supply. Note that if there is no discernible pressure loss
after 1 hour has elapsed, the test can be considered satisfactory and terminated.
If the pipeline fails the test, re-pressurise to 28 kPa and check for leaks. This may be
assisted by the use of leak detecting equipment. Establish the source of any leak.
Leaks in small installations with joints exposed may be detected by pouring a
concentrated solution of soft soap and water over joints and fittings. Repair and then
repeat the test.
115
Table 8.2 Minimum allowable times for test (for 7 kPa pressure drop)
Minimum allowable time* (minutes) for different test
lengths
DN
50 m
100 m
150 m
6
9
14
300
7
14
22
375
10
21
31
450
14
28
42
525
18
37
55
600
23
46
70
675
29
57
86
750
41
83
124
900
51
102
153
1000
73
147
220
1200
* These times may be halved where a pressure drop of 3.5 kPa is used. Refer to
AS/NZS 2566.2 for calculation basis.
Infiltration testing
Where a freestanding water table exists at a level of at least 1.5m above the pipeline
and 150mm above any sideline connections the absence infiltration can remove the
need for either of the previous pressure tests. In all cases where infiltration is
observed the source should be investigated and the leak plugged. Where the size of
the catchment and number of side connections precludes this approach then the
inflow should be measured over a 24-hour period and the principal informed for
determination of the acceptable allowable inflow. Generally this should not exceed 5
litres / mm diameter / km length / day.
116
8.3
Structural assessment on installation
Compaction testing
A method of monitoring the compaction of bedding and side support zones of the
embedment material around all flexible pipelines is desirable for proper quality
control of a buried flexible pipeline at the time of installation. Some soil compaction
tests used for civil earthworks may be inappropriate for pipeline work as they are
more suited to the higher levels of compaction control needed, for example, with
pavement construction. There also may be some delay while samples are being
checked at an offsite laboratory. However, methods employing Clegg Impact
Hammers are readily adaptable for pipeline work and have the added advantage that
the impact figures obtained can be read as an approximation to the soil deformation
modulus.
Deflection testing
Deflection measurements are a useful means of checking that installation
requirements have been met and should be done as soon as possible after the
completion of the installation. These measurements are frequently used as a quality
control device for indirectly assessing the relative embedment compactions achieved
during installation. Typical deflections that might be expected in a normal installation
would be about half of the values given in Table 8.3.
For non-man entry pipes AS/NZS 2566.2 gives a deflection test method using pullthrough go / no go provers.
Prover design
Suitable types of provers are described in AS/NZS 2566.2. A lightweight vaned type
with a minimum of eight vanes between 1.0 and 1.3 pipe diameters in length may be
used. The acceptable prover diameter should be determined after giving
consideration to the effect of different time periods after completion of construction.
Table 8.3 shows the outside diameter of provers required for the maximum allowable
deflections (less a further clearance of 2.5mm) at various times after the completion
of the installation. The prover should be pulled through the pipeline by hand or
means of a hand-operated winch. A tail rope should be attached to ensure it could be
retrieved if pipes are found to be over-deflected.
117
Table 8.3 Max. prover ODs for PN 1 SN 10000 at various times after backfill
completion. (These values would be different for other stiffness pipes)
24 hours
3 days
7 days
14 days
30 days 3 months
1 year
Adjustment Factor
0.7
0.75
0.85
0.95
1.1
1.2
Deflection (%)
3.5
3.8
4.3
4.8
5.5
DN
Pipe ID
Prover OD
100
114
108
107
107
106
106
105
105
150
166
158
157
156
156
155
154
154
200
220
210
209
208
207
207
205
204
250
270
258
257
256
255
254
253
251
300
328
314
313
312
310
309
307
306
375
409
392
391
389
387
386
384
382
450
487
467
466
464
461
460
458
455
525
564
542
540
538
535
533
530
528
600
641
616
614
611
608
606
603
600
675
718
690
689
685
681
680
676
672
750
794
764
762
758
754
752
748
744
Where a prover cannot pass along the test length the cause of the obstruction should
be determined, generally by a CCTV investigation and appropriate remedial
construction undertaken. In extreme situations this may require the exposure of the
affected section of the pipeline and proper compaction of the side support zone
material carried out. Flowtite pipes are rarely damaged by greater than normal
deflections. A visual inspection of any pipe that has been over-deflected is usually
sufficient to determine if further embedment compaction or a pipe relay is required.
In larger size pipes a visual line-of-site inspection will usually indicate any abnormal
deflections. Measured deflections should be based on the following calculations:
Deflection (%) =
(Actual ID installed vertical ID) x 100

Actual ID
The actual ID or internal diameter is determined by measuring accessible loose

pipes of the same class and stiffness, which have not been installed (and with no
pipes stacked above them). That is:
Actual ID =
(Vertical ID + Horizontal ID)

2
118
Correcting over-deflected pipes

For pipes deflected up to 10% of diameter:
1) Excavate to a level about 40% below the crown of the pipe using hand tools
to avoid damaging the pipe.
2) Check the exposed pipes for damage. If pipes are damaged they must be
repaired or replaced.
3) Re-compact the embedment material to the specified degree in the side
support zone.
4) Replace the overlay and backfill to the final level.
5) Check that the deflection complies with the specification or Table 8.3.
For pipes deflected more than 10% there is a possibility that the pipes will need to be
replaced. Check with Fibrelogic for advice.
119
8.4
High pressure water cleaning
There are several methods used to clean pipes, depending on diameter and the
degree and nature of blockage, which may use either mechanical means or water
jets. Whenever mechanical means are employed, use plastic scrapers to avoid
damage to the pipes inner surface.
The use of high-pressure water emitted through jet nozzles is a practice used to
clean pipe internal surfaces. If not properly controlled, water emitted under highpressure through a jet nozzle can cause damage or delamination of most pipeline
materials.
Based on experience gained with water jet cleaning of Flowtite sewer pipes, the
following guidelines must be followed to avoid damage to pipes.
Cleaning of Flowtite pressure pipes
1.
Limit maximum pressure to 8,300 kPa (1,200 psi / 83 bar). Due to the
smooth interior surface of GRP pipe, adequate cleaning and removal of
blockages can be achieved below this pressure.
2.
Nozzles with jet holes around the circumference are preferred. Nozzles
with cleaning chains, wires, or rotating, aggressive damaging nozzles
must not be used.
3.
The water discharge angle must be between 6 and 15 relative to the
pipe axis. See Figure 8.4.
4.
The number of jet holes should be 6 to 8 or more and holes size must be
at least 2.4 mm.
5.
The external surface of the nozzle shall be smooth and the maximum
weight 2.5kg. See Figure 8.5.
6.
The forward and backward moving speed of the nozzle shall be limited to
30m/min. Uncontrolled movement of the nozzle is not allowed. When
inserting the nozzle into Flowtite pipe, care should be taken to prevent it
from hitting the pipe wall.
7.
Jetting/swabbing sleds with several runners give a greater distance
between nozzle and pipe wall are required. See Figure 8.4.
8.
The use of equipment or pressures that do not meet the above criteria
could cause damage to the installed pipe.
Figure 8.4 Water jet discharge angle.
Figure 8.5 Nozzle weight 2.5 kg.
120
FIBRELOGIC PIPE SYSTEMS PTY LTD

ABN 34 353 154 329
For enquiries and orders contact

PH 08 8329 1111
FX 08 8329 1122
See also www.fibrelogic.com
121

Fibrelogic Flowtite Engineering Guidelines DES M-004

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Fibrelogic Flowtite Engineering Guidelines DES M-004

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Engineering Design and

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Fibrelogic Pipe Systems Pty Ltd

INTRODUCTION TO FIBRELOGIC FLOWTITE PIPES .................................................. 4

Fibrelogic Pipe Systems Pty Ltd

FIELD TESTING .............................................................................................................. 112

Fibrelogic Pipe Systems Pty Ltd

INTRODUCTION TO FIBRELOGIC FLOWTITE PIPES

Fibrelogic Pipe Systems Pty Ltd

Light weight(1/4 weight of

Dimensions compatible with

Precision Flowtite coupling

High technology pipe design

High technology pipe

Fibrelogic Pipe Systems Pty Ltd

Fibrelogic Pipe Systems Pty Ltd

Fibrelogic Pipe Systems Pty Ltd

Fibrelogic Pipe Systems Pty Ltd

Water supply transmission and distribution mains

Fibrelogic Pipe Systems Pty Ltd

DN 250 Flowtite pipes for a corrosive bore water

DN1000 PN16 SN 10000 Flowtite pressure

Fibrelogic Pipe Systems Pty Ltd

DN1000 PN16 SN10,000

Fibrelogic Pipe Systems Pty Ltd

0.14 to 0.22 W/m.K

150 700 MPa

2.1.1 Embodied Energy

Fibrelogic Pipe Systems Pty Ltd

stiffness (Newtons / metre per metre length of pipe)

According to the Australian and ISO Standards, stiffness is expressed as follows:

Fibrelogic Pipe Systems Pty Ltd

Where Rm = mean radius (m).

(Pounds per square inch)

Where F = load per unit length (pounds per inch)

Nominal Stiffness / Comparison of Units

Sp (ISO & Aust.)

Fibrelogic Pipe Systems Pty Ltd

Ultraviolet solar radiation resistance

Flowtite pipes have a non-structural external layer of reinforced resin to provide a

Fibrelogic Pipe Systems Pty Ltd

Flowtite pipes and fittings meet the requirements of AS 4020.

Maximum service conditions

Performance in exceptional chemical environments

Fibrelogic Pipe Systems Pty Ltd

SPECIFICATIONS AND TESTING

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United States of America Standards

International Standards ISO 10639 & 10467.

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Standards for Fittings

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Ductile Iron Fittings

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Test requirements for pipes

Elastomers for Flowtite seals

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Every pipe is subjected to the following control checks:

Tolerances on spigot outside diameters

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Hydrostatic Leak Tightness Testing

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Specific ring stiffness