Wavin PE Pressure Product and

Pipe Systems Technical Guide

Intelligent Solutions for Pressure Pipe Projects

1
 PE Pressure Pipes
Content

Content

1. Flying the flag in the world page 3

2. Materials for gas and water distribution page 4

2.1 Classification of plastics for piping systems page 4
2.2 Standard Dimension Ratio SDR page 5

3. General material properties page 6

3.1 Polyethylene PE page 6
3.2 Wavin TS page 7
3.3 Technical data PE page 8
3.4 Characteristics & properties page 9

4. Design & Testing page 12

5. Product range page 22

6. Standards & Regulations page 27

7. Installation page 29
7.1 Installation methods page 29
7.2 Jointing page 33

8. Laying instructions page 40

9. Anchorage page 42

10. Handling & Storage page 45

11. Notes page 47

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PE Pressure Pipes
Introduction
1. Flying the flag in the world
Wavin
The Wavin group of companies is one of
the largest manufacturers of complete
plastic pipe systems for the Building, Civil
and Utility markets in Europe. In addition
to having its own production facilities in
almost every country on the European
continent, Wavin also participates in the
equity of plastic pipe companies in
Australia and New Zealand. In the
remainder of the world the company is
proud of an ever increasing impressive
network of licensees, distributors and
agents. Wavin has manufactured and
supplied plastic pipe systems since 1955.
The strength of the Wavin Group in terms
of manufacturing capability and technical
resources places the company at the
forefront of the industry for product
quality, innovation, technical support and
customer service.
Wavin Overseas
Wavin Overseas B.V., situated in The
Netherlands, is the central export organi-
sation of the Wavin Group dedicated to
providing a global service. Wavin
Overseas sells Wavin products, supplies
technology (under licence) and equipment
to manufacture these products locally.
Wavin Overseas is experienced in setting
up complete factories, delivering a
comprehensive package of
manufacturing equipment, ancillaries and
services such as production know-how
and technical support. In effect Wavin
Overseas can supply all the help you
need to supply your market. Wavin
Overseas operates under a Quality
Management System, which is accredi-
ted to EN ISO 9001:2000 by the Dutch
Council for Accreditation.
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Extensive product range
Wavin’s extensive range of plastic pipe
systems is designed and manufactured
to meet the highest standards set by the
building and construction industry world-
wide.
Wavin’s products are generally available
ex-stock from one of our numerous
distributors around the world or directly www.wavinoverseas.com
through our export department at Wavin More information about all Wavin
Overseas. products can be found in our extensive
on-line product catalogue on our website
The Wavin product range comprises: www.wavinoverseas.com
Hot & Cold Water Systems (PEX,
Metalplastic, PPR and PB) Furthermore this website contains
Soil & Waste (DWV) Systems information about Wavin Overseas,
(PVC, PE and PP) latest news and developments, licensing,
Sanitary Systems machinery and equipment and
(traps and siphons) environmental issues.
Rainwater Management Systems
(collection, re-use and infiltration)
Gutter Systems
Road Drainage Systems / Road
Gullies
Surface Drainage / Channel Drainage
Sewer Systems (PVC, PE and
PP/solid and structured wall)
Inspection Chambers & Manholes
Pressure Systems
(U-PVC, O-PVC and PE)
Cable Duct Systems
Relining/No-Dig Pipe Renovation
Systems (gas/water/sewer)
Land Drainage Systems
Irrigation Systems
Introduction
3

2. Materials for water and gas distribution
2.1 Classification of plastics
for piping systems
The development of plastics used in gas
and water distribution is continuous. In
recent years outstanding progress has
been achieved.
The creation of new material types with
increased strength, higher property con-
sistency and at the same time good or
better processability are paramount.
Moreover, European standardisation
already shows the first conceivable
effects in as far as classification systems
come into use today, with subsequent
lasting influences on pipe construction
with plastics (prEN 1555, prEN 12201,
EN1452).
The starting point for the new classifica-
tion system according to ISO 12162 and
EN 32162 is the long-term behaviour of
the respective material under internal
pressure. For this purpose, values are
obtained with a pipe-type specimen filled
with water at different temperatures and
evaluated by means of the Standard
Extrapolation Method in accordance with
ISO/DIS 9080.
Procedure
At different temperatures, different
internal pressures (= circumferential
stress in the pipe wall) are applied to the
specimens. The (load) duration until break
is determined. The respective breaking
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Materials for gas and water distribution
stress is applied over the appropriate load
time. This results in the load duration
graph.
The circumferential stress values for 20˚C
are extrapolated to 50 years according to
ISO/DIS 9080 and lead to
the LTHS anticipated value, 50 years
(Long Term Hydrostatic Strength),
the 97.5 % LCL (Lower Confidence
Limit).
This LCL value is categorised in accor-
dance with the Renard series of numbers
(R10 or R20 in accordance with ISO 3
and ISO 497). The calculated LCL value is
reduced to the next lower Renard num-
ber. This results in the required MRS
(Minimum Required Strength)
This MRS value in MPa is the basis for
the classification. The MRS value
multiplied by 10 results in the
"classification" of the material. As
example, common PE pipe materials.
They have a MRS of 10 MPa. They are
therefore called PE 100 in accordance
with the new system.
Unlike the existing classification methods
based upon the dimensional stress and
the "safety coefficients" (sometimes
different in each nation), the new system
refers to a uniformly determined material
parameter. This eliminates earlier
misunderstandings due to the different
starting points.
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From classification to
application
The MRS value represents the long-term
circumferential stress in the pipe where
the break may occur after 50 years at the
earliest. The calculation stress ss is
applied for dimensioning of the piping
network. This is calculated from:
MRS
σs = ----------
C
with C= total operating coefficient.
The total operating coefficient replaces
the classical "safety coefficient” and
considers the facts of application, the
installation conditions etc.
Within the course of harmonisation of
standards in Europe, uniform guidelines
were also created by defining the
"minimum applied total operating
coefficient'. For PE materials primarily
used in the distribution industry, the
minimum values for C are as follows:
Material Application C min
PE Water 1.25
PE Gas 2
The responsibility of selecting the C factor
to be applied lies with the planning
engineer, who can/must also apply higher
values after taking into consideration all
relevant operating and ambient
conditions.
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PE Pressure Pipes
Materials for gas and water distribution

2.2 Standard Dimension The relation between the SDR

Ratio SDR
In the relevant regulations for plastic
pipes for distribution, specific pipe
dimensions have been fixed based on the
pipe outer diameter and the pipe wall
thickness in accordance with the respec-
tive pipe series. At the same time, each
pipe series is geometrically defined by the
SDR code = Standard Dimension Ratio,
whereby:
geometrical code and the maximum
permitted internal pressure in the pipes
important for the user is produced from
the equations:
σu= p x (da – e) / (20 x e)
and
σv = σu ≤ σzul.

SDR = d / e The following equation:

or SDR = 20 x (σzul./p) + 1

SDR = 2[s] + 1 If one defines, based on the PE tensile

properties for the life span of 50 years for
to calculate [s]: example,

outside diameter - wall thickness σzul.= MRS/C

[s] =
2 x wall thickness The following relation is produced:

The essential pipe series used for gas SDR = (( 20/p) x (MRS/C)) + 1
and water distribution are described by
the pipe outer diameter d and the pipe As alternate you can use
wall thickness e.
outside diameter
SDR =
wall thickness

or
OD
SDR =
e

Materials for water and

5
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3. General material properties
3.1 Polyethylene PE
Polyethylene is the most widely known
mass-produced plastic material. It is the
classical member of the polyolefine fami-
ly. The chemical formula is: -(CH2-CH2)n,
so it is an environmentally compatible
hydro-carbon product.
Wavin offers a comprehensive range of
PE (polyethylene) pressure pipe systems
designed for potable water and gas
applications (according to EN1555 and
EN12201), as well as for many other
pressure and non-pressure applications.
These provide the professionals the
option to choose the best system even
for the most demanding of projects.
Wavin PE pressure pipes are manufactu-
red from high-density polyethylene, PE 80
and PE 100. PE is especially suitable for
the transport and distribution of gas and
potable water, for industrial applications
and pressure sewers. PE has a high flexi-
bility level and guarantees impact resi-
stance even at low temperatures.
PE has become most widely used in
pipelines systems for the assembly of
buried gas and water piping together with
PVC. It has become one of the dominant
piping material in this sphere of
applications in many countries. However,
this material also offers many advantages
in domestic installations and industrial
piping systems. These include low
weight, excellent flexibility, low pipe fric-
tion losses, ductile fracture properties,
toughness even at very low temperatu-
res, good chemical resistance, fusionable
and low price. PE has predominantly
good resistance against acids and caus-
tic substances. It is insoluble in all organic
and inorganic solvents at 20 ˚C. PE is
destroyed by highly oxidized acids over
the course of time.
The polyethylene we use is stabilised
against the effects of ultraviolet radiation
by the addition of carbon black. The sta-
bilisation also counteracts the heat fati-
gue and thus increases the operating life.
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General material properties
The PE types used by Wavin are suitable
for drinking water applications and for
storing foodstuff. The fittings are odour-
less, tasteless and physiologically safe.
They can therefore be used in all relevant
applications.
PE is a covalent material. The material
can neither swell nor dissolve. Therefore
PE pipes cannot be joined with fittings by
means of solvent cement. The
appropriate jointing method for the
material is fusion jointing. We offer four
jointing methods for pipeline systems in
our range: electrofusion, compression
coupling, heating element butt fusion and
heating element socket fusion. The first
of these jointing methods is favoured for
pipelines carrying gas, water,
compressed air or other less aggressive
media.
In buried pipe construction, a high mole-
cular type with average to high density is
accepted. The shortform is: PE80 (PE
second generation) or PE100 (PE third
generation). There are hardly any repre-
sentatives of the PE types from the first
generation - in accordance with the pre-
sent classification PE63 - in the market.
In the past the above mentioned mate-
rials were named differently. Below you
can see an overview of the former and
current material names.
Old name New name
LDPE PE 40
MDPE PE 80
HDPE PE 63, PE 80, PE 100
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Features & Benefits
High reliability and proven service
performance
PE is the preferred choice, particularly
in buried pipe systems like gas
distribution systems.
Resistance to low temperatures
Due to its high ductility, toughness
and elasticity, Wavin PE gives no
problems during installation and
operation at low temperatures.
High impact resistance
The enormous resistance against
surge and fatigue eliminates the
necessity of a higher pressure rating
and investments in anti surge
devices.
Abrasion resistance
Comparisons have shown that PE
pipes have a higher abrasion resistan-
ce than other materials, therefore PE
pipes are the most preferred for slurry
transporting pipe systems.
Excellent flow characteristics
The smooth bore and resistance
against surge allows higher flow
velocities.
Excellent chemical resistance
To a great number of chemical
agents.
Weldability
Because of the good weldability and
elasticity of PE, long lengths can be
assembled outside the (narrow)
trench. The welded joints are strong
and highly reliable.
Wide variety of installation methods
PE pipes offer the installer all possible
solutions for installation, which can
provide considerable time and costs
savings. PE pipes are for example
preferred in trenchless and “narrow
trenching” installation.
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PE Pressure Pipes
General material properties
3.2 Wavin TS
The increased pressure on Gas- and
Water Boards to reduce installation
costs, results in new installation
techniques, like trenchless applications
and installations without sand
embedding. With these techniques pipe
damage during installation cannot always
be avoided, leading to scoring and point
loads during operation. Therefore a pipe
is required which service life is not being
affected by outside damages. To meet
this challenge Wavin developed Wavin
Total Security.
Wavin TS is a co-extruded three-layer
pipe with inner and outer protection
layers made of the innovative, extremely
robust plastic XSC 50, and a middle layer
made of PE 100. The three layers are
integrated and cannot be separated
mechanically. The small Wavin TS sizes
25 mm – 75 mm are completely made
out of XSC 50. Due to the material
characteristics of XSC 50 (inner and outer
layers amount to 25% of total wall
thickness each), Wavin TS offers
increased security and a longer service
life compared to traditional PE pipes.
Even when it comes to extreme loads as
a result of notches, grooves and point
loads.
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Features & Benefits
Wavin TS can be installed as easy as
traditional PE pipes. Wavin TS has the
same welding characteristics as PE 100
pipes. The pipes and fittings can be
connected by butt-fusion or electrofusion
as well as other standard jointing
techniques applicable for PE pipes.
Wavin TS pipes are compatible with
Wavin PE 100 fittings and those from all
major fitting manufacturers. Wavin TS
does not require special embedding
material, which is the most economic
advantage.
General material
properties
Optimum protection
Against point loads and surface
damages.
Ideal for trenchless applications and
installations
No sand embedding needed.
See picture below.
Suitable for all modern welding tech-
niques
All common fusion methods used for
PE 100, can be applied.
Easy and economical installation
Similar to traditional PE.
No “imported” backfill material is
needed.
Very long service life
Even with outside damages.
More cost effective than
comparable PE multilayer
products
The possibility of using the native soil
for backfill, reduces substantially the
installation costs.
More benefits
All other benefits of standard PE pipe
systems are also applicable for Wavin
TS, such as for example cold bending
and resistance against surge and
fatigue.
7
 PE Pressure Pipes
General material properties

3.3 Technical data PE

PE 80 PE 100
Properties Typical Value TypicalValue Unit Test method
Density > 0.93 > 0.95 g/cm3 ISO 1183
Melt flow index MFI 190°C /50N 0.4-1.3 0.4-0.55 g/10 min ISO 1133 cond. 18
Yield stress 22 25 N/mm3 Test rate 125 mm/ min
Elongation at fracture > 800 > 600 %
Bend creep module (1 min. value) 800 840 N/mm2
Crystallite melting range 127-131 127-131 °C
Coefficient of linear expansion 0.20 0.13 mm/m*K
Heat conductivity at 20°C 0.43 0.38 W/m*K
Surface resistance 1013 >1014 Ω
Modulus of elasticity (1 mm/min.) 1200 MPa ISO 527
Linear coefficient of thermal expansion 1.3x10-4 ° K-1 VDE 0304
Specific heat 1.9 J/g ° K Calorimetric at 23 °C
Thermal conductivity 0.38 W/m ° K DIN 52 612 at 23 °C
Min. radius of curvature 25 x dy * at 20°C
*dy = outside diameter of plastic pipe

Environmental technical properties Wavin’s pressure pipes and fittings are tested and approved according to The
Environmental Agency’s demands and found suitable for conducting potable water in
water supply systems.

Pressure rating SDR PE 80 PE 100 Wall thickness

MDPE (PE80) has a minimum required for d110
strength (MRS) derived from a 50 year (MRS = 8, C = 1.25) (PN) (MRS = 10 C = 1.25) (PN)
extrapolated 97.5% lower confidence SDR 7.5 16 bar (20 bar) 24 bar 15.5 mm
limit of 8 MPa and HDPE (PE100) has a SDR 9 16 bar 20 bar 12.5 mm
MRS of 10 MPa. The Hydrostatic Design SDR 11 10 bar (12.5 bar) 16 bar 10 mm
stress for both materials is determined by SDR 17 6 bar (8bar) 10 bar (9.6 bar with SDR 17.6) 6.5 mm
applying a safety factor of 1.25. The SDR 26 5 bar 6 bar 4.5 mm
design life for the Water Industry requires SDR 33 4 bar 5 bar 3.5 mm
a minimum life of 50 years, therefore the
design stress for PE80 and PE100 is as P = (20*MRS)/(C*(SDR-11)) [bar] = PN
follows:
In other liquids or at medium
PE80 = 5 MPa temperatures above 20°C appropriate
PE100 = 8 MPa reduction factors should be taken into
consideration for the maximum permitted
Polyethylene pipe pressure rating is operating pressure.
generally referred to in bar; 1 bar is
approximately equivalent to 10.2 metre The maximum permitted operating
head. pressure for gas should be in
accordance with the corresponding
The maximum permitted operating pres- national standards.
sure (PN) for water at 20°C and a plan-
ned operating duration of 50 years is:

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PE Pressure Pipes
General material properties
Durability graph PE 100
To calculate the safety factor and permis-
sible operating pressure it is necessary to
know the durability strength of the mate-
rial.
Depending on the desired service life and
the maximum operating pressure, the
appropriate durability strength can be
taken from this diagram.
3.4 Characteristics &
Properties
Chemical Resistance
Plastic pipe systems are ideal for trans-
porting a wide variety of chemicals and
are widely used in industries where con-
veyance of highly corrosive liquids and
gases require products with excellent
corrosion resistance.
The exceptional resistance of PE to che-
mical attack is well known and generally
there are no naturally occurring ground
conditions which affect the material.
Polyethylene does not corrode, rot, pit or
lose its mechanical strength properties
through electrical or chemical reactions
with backfill soils. PE does not under nor-
mal operating conditions, support the
microbiological growth of algae, bacteria
or fungi, nor is it affected by these condi-
tions.
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The addition of carbon-black and stabili-
zers (mostly aromatic amines and phe-
nolic compounds) protects polyethylene
against ageing and alterations caused by
UV rays.
Thanks to its paraffinic structure, it has a
high resistance to chemical agents:
It is insoluble at 20˚C in every organic
and inorganic solvent
Only at temperatures higher than
90˚C it dissolves in aliphatic and aro-
matic hydrocarbons and in their
halogenated compounds
At room temperature, polyethylene is
only destroyed, as time goes by,
from strongly oxidizer substances
(conc. HNO3 , conc. H2SO4 and so
on).
Polyethylene may be affected by certain
chemicals and care must be exercised
when considering re-development of old
industrial brownfield sites.
Where soil conditions are unknown or
known to be harmful, a soils analysis
should be carried out to determine any
likely contaminents or talk directly to
Wavin.
Polyethylene is in chemical terms a non-
polar high molecular weight paraffin of
the hydrocarbon family. Hence it is very
resistant to (non oxidising) strong acids,
strong bases and salts. It is mildly affec-
ted by aliphatic solvents although aro-
matic and chlorinated solvents will cause
some swelling.
Polyethylene is attacked by strongly oxi-
dising substances such as halogens and
concentrated inorganic acids such as
nitric, sulphuric (including oleum), perch-
loric, etc.
General material
properties
The harmful chemicals can be grouped
into 3 main types:
Oxidisers, eg very strong acids
Cracking agents, eg detergents
Solvents, eg hydrocarbons (petrol, oil)
The degree of resistance to any chemical
is dependent on concentration, tempera-
ture and the working pressure, all of
which may have an effect on the lifetime
of the pipeline. The effects may be detri-
mental to the pipes strength or permeate
the pipe wall causing tainting of the pota-
ble water supplies.
Wavin provides extensive technical sup-
port and will be pleased to assist when
doubt exists over a product's suitability.
Abrasion Resistance
Polyethylene has an extremely low co-
efficient of friction and therefore has sig-
nificant advantages over other pipe mate-
rials for the transportation of abrasive
slurries and in its resistance to abrasion.
Wavin polyethylene pipe has been used
extensively for pumped slurry applications
over many years and has been used for
power station fly ash, china clay slurry,
quarries and sand slurries. Field use and
laboratory testing has shown that the
performance of PE exceeds metallic pipe
systems. This coupled with its flexibility,
lightweight and ease of installation makes
it the ideal choice for abrasive slurry
applications.
The external effects of abrasive backfill
materials have only a negligible effect on
PE. Where pipe has been damaged by a
sharp object and the cut or gouge
exceeds 10% of the pipe wall thickness,
the damaged section should be cut out
and replaced.
9
 PE Pressure Pipes
General material properties

Low Temperature Usage
Site practices do not generally allow pipe
laying to continue below 0˚C, however
there may be instances during installation
or pipeline operation where temperatures
below 0˚C are encountered.
The mechanical properties of PE, opera-
ting pressure and impact resistance are
maintained at temperatures as low as
-60˚C and therefore moderate winter
temperatures do not pose any particular
problems to the performance of PE pipe.
Polyethylene is a particularly low thermal
conductor and will delay the freezing of
water within the pipe. Where the water
does become frozen, the flexibility of PE
and its ability to expand without rupture
ensures the security of the pipeline.
Expansion & Contraction
Polyethylene has a co-efficient of linear
expansion of approximately 1.5 x 10-4˚C-1
which is approximately 10 times greater
than metallic pipes. Expansion is an
important factor which should therefore
be considered in the design of pipelines
where a significant variation in temperatu-
re is expected, particularly above ground
pipework.
For design purposes pipe expansion can
be more practically understood if we
consider the expansion as 1.5mm/10˚C/
m. In above ground installations careful
consideration should be given to the
positioning of support brackets and
anchor points and the use of fully end
load bearing joints. Where possible
expansion and contraction may be
accommodated at changes of direction.
Where non-end load bearing fittings are
used it is important that such fittings are
securely anchored to prevent pipe
pullout.
With below ground installations new pipe-
lines should be allowed to stabilise to
ambient temperatures before making the
final tie-in connections, partial backfilling
of the pipe will assist in minimising the
effects of direct sunlight.
Electrolytic reaction/
Electrical conduction
Polyethylene is a poor conductor of
electricity and does not suffer from
electrolytic corrosion when in contact
with metal components (valves etc) or
when connected into existing metal
pipelines.
As a non-conducting material PE should
not be used for the earthing of electrical
equipment nor can it be used as a
conductor for frost protection systems.
Similarly PE should not be used where
there are high levels of static electricity,
eg. in mines.
Permeability
PE pipework for potable water can be
laid in close proximity to PE gas mains.
The presence of naturally occurring gas,
such as is found in landfill sites, similarly
has no effect on PE pipework.
Notch sensitivity
Polyethylene is known to be extremely
durable in normal use and it is not
uncommon for pipes to be scratched and
scuffed during handling and installation,
particularly with re-habilitation methods
such as slip lining and mains bursting.
This sort of typical site damage will have
no adverse long-term effect on the pipe
provided the damage does not exceed
10% pipe wall thickness. If the damage is
greater than 10% the pipe should not be
used.

PIPE EXPANSION/CONTRACTION (mm)

PIPE 5˚c 10˚c 15˚c 20˚c 30˚c 40˚c
LENGTH (M)
1 0.75 1.5 2.25 3.0 4.5 6.0
2 1.50 3.0 4.50 6.0 9.0 12.0
5 3.75 7.5 11.25 15.0 22.5 30.0
8 6.0 12.0 18.0 24.0 36.0 48.0
10 7.50 15.0 22.5 30.0 45.0 60.0
15 11.25 22.50 33.75 45.0 67.5 90.0
20 15.0 30.0 45.0 60.0 90.0 120.0
50 37.5 75.0 112.5 150.0 225.0 300.0
75 56.25 112.5 168.75 225.0 337.5 450.0
100 75.0 150.0 225.0 300.0 450.0 600.0
150 112.50 125.0 337.5 450.0 675.0 900.0
200 150.0 300.0 450.0 600.0 900.0 1200.0

Figure 1. The expansion and contraction of PE pipe in mm for a temperature

variation range over pipe lengths up to 200 metres.

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 PE Pressure Pipes
General material properties

Operational pressures for Hydraulic Properties Fittings formula

elevated temperature use Polyethylene pipe has an extremely Determining the pressure drop in fittings
Polyethylene is a thermoplastic material smooth bore giving exceptionally good is more complex. However, using a
and a loss in strength occurs with flow characteristics. As polyethylene is simple formula to give an equivalent
increasing temperature. The maximum non-corrosive and maintains its smooth increase in pipe length, pressure drop
operating pressure for any specific pipe is bore throughout its lifetime there is no can be carried out using the following
based upon a 50 year design life at 20˚C. deterioration in its hydraulic performance. formula;
Any increase above 20˚C will result in a Polyethylene pipe is classed as hydrauli-
reduction in the maximum allowable cally smooth and the hydraulic frictional L = F x ID
operating pressure or lifetime or possibly co-efficients used for design purposes where L = equivalent pipe length in
both. Polyethylene pipe systems should are as follows: metres
not be operated above 60˚C. The F = Fittings constant
following chart gives the reduction factors Colebrooke - White Ks 0.003 mm ID = Internal diameter of the fitting
to be applied to the maximum operating Hazen Williams C = 150
pressures at 20˚C. BEND FITTING F
All pipelines carrying water or slurries will 90˚ Elbow 0.030
100 see pressure losses due to the friction 45˚ Elbow 0.015
91 between the liquid and pipe wall. These 90˚ Tee (straight through) 0.020
82
are general losses due to fluid flow. In 90˚ Tee (side branch) 0.075
% Rating

73
63
50
55 addition there are point losses caused by 90˚ Long Radius bend 0.020
46
36 fittings in the system. 45˚ Long Radius bend 0.010

20 25 30 35 40 45 50 55 Flow calculations Figure 3. Fittings Constant

Operating T emperature ˚C

Pipe sizing and pressure drop can be

If the temperature falls within this range
the life expectancy of the pipe can be
affected. Please contact Wavin for furt-
her details.
determined using the Flow Charts
overleaf. These are based on the
Colebrook - White Formula. Using the
required design flow rate (l/sec) the
following data can be determined:

Figure 2. Pressure Reduction Factors for Pipe Diameter (mm)

PE Pipe at Elevated Frictional Head Loss (m/1000 metres)
Temperatures Flow Velocity (m/sec)

General material
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 PE Pressure Pipes
Design & Testing

4. Design & Testing

Although a polyethylene pipeline, like any
other pressure system, is primarily
designed to take the wall stresses produ-
ced by the internal pressure of the sys-
tem, it is important to consider other
potential loading conditions. This is parti-
cularly true if full benefit is to be made of
the flexibility of the system in the use of
modern installation techniques.
For example, in close-fit insertion or
moleplough operations there is a
tendency to score the outside diameter
of the pipe. Therefore it is essential to
ensure that the pipe has sufficient
resistance to the growth of cracks that
could arise from these external notches.
This and many other potential hazards
are taken into account in the design and
performance testing of the Wavin range
of polyethylene water systems to ensure
that they have a long and maintenance
free service life under design operating
conditions. In addition to a sound design
Design for internal
pressure
The burst pressure of polyethylene pipe is
time dependent and therefore it is neces-
sary to define the strength of the material
at a reference lifetime.
The lifetime chosen for this reference
value is 50 years - it should be noted that
this does not mean that the pipeline will
fail after 50 years, as the various safety
factors that are incorporated into the
design mean that the actual lifetime will
be many times greater. In order to gene-
rate the burst strength of the material at
50 years, a number of pipe samples are
pressure tested to failure at lifetimes
between 10 and 10,000 hours. The
results of these tests are graphically or
numerically analysed to obtain the mini-
mum required strength (MRS) at 50
years. A graphical representation of this
process is shown in Figure 4.
MPa
TYPE MRS
PE80 8.0
PE100 10.0
Within the classification system develo-
ped at ISO/CEN, there has also been
considerable discussion of the application
of design factors that should be used to
determine the allowable operating pres-
sures (PFA) of a particular plastic pipe
system. This design factor is applied to
account for any ‘unknown’ loading or
environmental conditions.
The classification group has recommen-
ded minimum values only, which allow
the pipeline engineer to use additional
factors if difficult conditions exist (eg
surge, elevated temperature or poor
ground conditions). For polyethylene
pipeline systems, the recommended
design factor is 1.25, which enables the
allowable operating pressure to be calcu-
lated for each system using Lame’s for-

philosophy, it is also necessary to work mula for thick walled pipes:

MRS
to a rigorous Quality Assurance testing
scheme if this high level of performance Hoop stress: s = P (D - t)
Log Stress

is to be maintained in day-to-day 2t
production. This is best carried out where:
under a third party certification scheme 10 Log Time Hrs 10,000 50 yrs s = Hoop stress MPa
where an external body regularly checks Figure 4. Hydrostatic Pressure Test Curve P = Max. operating pressure bar
test procedures and product D = Outside Diameter mm
performance. Within the CEN and ISO Standards, it is t = Wall thickness mm
recommended that the MRS value is Therefore:
This provides the end user with complete based upon the 97.5% lower confidence s = P (D - 1)
assurance of quality for the product limit obtained by regression analysis, in 2 t
range. At the present time the Wavin accordance with the method outlined in
range of polyethylene water systems are ISO / DTR 9080.2. Now the Standard Dimensional Ratio
manufactured and tested in accordance (SDR) is related to the diameter and wall
with ISO & CEN Standards. Within the Wavin range of polyethylene thickness of the pipe by the formula:
water systems, one basic polymer is SDR = D
included – High Performance t
Polyethylene (PE100). Therefore:
s= P (SDR - 1)
PE80 has a minimum required strength of 2
8MPa while PE100 has a minimum or
required strength of 10MPa as shown in P= 2s
the following table. (SDR - 1)

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PE Pressure Pipes
Design & Testing

If this equation is applied to polyethylene
pipe systems it is possible to calculate
the allowable operating pressure (PFA) as
shown below:
PFA = 2 x MRS
(SDR - 1) a
where:
a = minimum design factor
This equation gives the stress in MPa.
For conventional use, and to express the
pressure in bar rating, the value in MPa is
multiplyed by 10. For example:
When operating a pipeline above 20˚C, it
is important to allow for the reduction in
the strength of the material at elevated
temperatures. Within the ISO TC 138
SC5 committee some work has been
carried out to establish the relationship
between the maximum operating pres-
sure and the operating temperature of
the pipeline.
Their recommendations are given in
Figure 6.
100
This is particularly true when the pipe is
being inserted into an existing main, or
where trenchless laying methods are
being used. In order to ensure that brittle
failure will not develop in the short or long
term from these surface notches, it is
usual to carry out elevated temperature
pressure tests on notched pipe samples.
It should be noted that this test is only
used within the UK, although discussions
are now taking place within ISO/CEN
committees for a wider adoption of these
tests.

91
For PE80: 82 In practice, during installation it is recom-
% Rating

PFA
= 2 x 8 x 10
(SDR - 1) x 1.25
= 128
(SDR - 1)
For PE100:
PFA = 2 x 10 x 10
(SDR - 1) x 1.25
= 160
(SDR - 1)
In calculating the operating pressure, it is
normal to round up or down the values to
the nearest useful pressure class.
It should be noted that the above repre-
sent the maximum operating pressures
for the pipeline and additional considera-
tion may cause engineers to reduce the
operating pressure to a lower level. For
example, on large diameter PE80 pipeli-
nes where rapid crack propagation may
be of concern (please refer to the section
on Fast Fracture).
73
50
63
55
20 25 30 35 40 45
Operating T emperature ˚C
If the temperature falls within this
range the life expectancy of the pipe
can be affected. Please contact the
Wavin Technical Services Helpdesk
for further details.
Figure 6. Pressure Reduction Factors for
Polyethylene Pipe at Elevated
Temperatures
Notch sensitivity
Many materials may be extremely strong
in laboratory tests but when they are
notched or scored in handling they can
become very brittle. The classic material
in this category is glass, which is brittle
enough to snap along a defined line
when it is lightly scored. When laying
pipelines it is common for the pipe sur-
face to become lightly scored.
mended that pipe with notches up to a
46 maximum of 10% of the wall thickness
36
can be used.
50 55
Fast fracture
For virtually all materials it is possible for a
dynamic crack to grow along the pipe
length provided that sufficient energy is
available to overcome the material’s resi-
stance to crack growth. Fractures of this
type have travelled many kilometres in
welded steel pipelines and are only arres-
ted by a valve or other pipeline fittings.
Over the past 10 years considerable test
work has been carried out to investigate
the relevance of this mode of fracture to
polyethylene pressure pipelines.
The conclusions of this work may be
summarised as follows:
Crack propagation cannot occur if the
pipeline is full of water. However, if
the pipeline contains 10% or more air
then propagation can occur.

PRESSURE CLASS (BAR)

TYPE SDR 11 SDR 17 SDR 26
PE80 12.5 8.0 5.0 TEST CONDITIONS
PE100 16 10 6 Type Notch Depth Temp˚C Stress (MPa) Life (hrs)
PE80 20% 80 4.0 170
Figure 5. Pressure Class for Polyethylene PE100 20% 80 4.6 170
Systems
Figure 7. Test Conditions for Polyethylene Systems

Design & Testing

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Cracks will not propagate through fit-
tings including flanges or electrofu-
sion couplers. Therefore the crack
will be limited to one pipe length in
these cases.
Crack propagation canno occur in
small diameter pipelines and therefo-
re only large pipelines need be consi-
dered:
PE80 - pipe diameter
250mm or above.
PE100 - pipe diameters
above 500mm.
The critical pressure at which rapid
crack propagation will occur is
dependent upon the pipe material
and the pipe diameter.
(see Figure 8).
PE100
Pressure
PE80 Crack Propagation
24 BA R
Crack Arrest
250m m Pipe Dia 500m m
Figure 8. Critical Pressure Curve for
Polyethylene Pipe
If, in a particular scheme, it is important
to design against rapid crack propaga-
tion, the maximum working pressures
given in figure 14 should be used. For
information on the suitability and maxi-
mum operating pressure of Wavin
Polyethylene systems outside
of the information given, please contact
the Wavin Technical Services Helpdesk.
Other design
considerations
In designing any pipeline system, it is
necessary to consider other factors that
may influence the performance of the
pipe. In most cases, sufficient data will
have been gathered to provide formal
design recommendations,
but in other situations advice should be
sought from Wavin
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PE Pressure Pipes
Design & Testing
Additional design details Elevated temperature test
Yield Strength Samples from all production of pipe from
PE100 23 N/mm2 PE80 material are notched to 20% of wall
PE80 18 N/mm2 thickness at four points around the cir-
Linear Thermal Co-efficient of cumference and subjected to a wall
expansion stress of 4.0MPa (8 bar for SDR 11) at
PE80 1.5 x 10 -4˚C-1 80˚C for a minimum period of 170 hours,
PE100 1.3 x 10 -4˚C-1 to establish comparative performance
trends in relation to the resistance of the
This equates to the following more useful system to failure by stress cracking.
terms: For PE100 material, the notched pipe is
PE80 0.15mm/m/˚C subjected to a wall stress of 4.6MPa (9.2
PE100 0.13mm/m/˚C bar for SDR 11). The purpose of this test
is to monitor the stress crack resistance
(eg for 1 metre of PE80 pipe its length of the system and to ensure that crack
increases 0.15mm for every 1˚C rise in growth does not occur in less than the
temperature). required test life represented by the test.
Quality assurance
testing
Continuous performance tests are carried
out on Wavin polyethylene pipe systems
during manufacture. These are:
Tensile tests
Test specimens from pipe production are
tensile tested to determine the yield
strength and elongation at break. Typical
minimum results give elongation at more
than 600%.
Delayed burst test
For PE80 pipe, samples taken at regular
intervals are subjected to a circumferen-
tial wall stress of 12 MPa for a period of
one hour at 20˚C. The pressure is steadily
increased until the pipe bursts, and it
must be at a stress greater than
16MN/m2. For PE100 the same test is
carried out at a wall stress of 12.5 MPa
for 100 hours.
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PE Pressure Pipes
Design & Testing

For fewer than 200 housing For a normal single-family house with tour Calculations
units occupants this gives a design water flow
Here the design water flow (qd) is deter- qmax of: Water consumption/house:
mined using DS 439, the DIF (Danish qmax = 167l / hour = 0,046 l/s
Association of Engineers) code of practi- 400 l/24 hours/pe x 4 (pe) x 2.5
ce for water installations. DS 439 states q max
= 24 Water quantity is calculated for each pipe
that the sum of the predicted water flows = 167 l/hour = 0.046 l/s section for instance:
can be set at 1.6 I/s per housing unit,
which gives a (qd) of 0.36 I/s per unit. Example of design of water A - B: (10 + 15 + 8) houses x 0,046 l/s =
supply pipeline 1,52 l/s
For more than 200 housing
units The example is based upon the following Pressure loss is found by means of the
Here the design water flow (qmax) is deter- data: water flow diagram for PE 80 pressure
mined using DS 442, the DIF code of pipes PN 10, diagram on the next page.
practice for public water supply systems. Pressure at station A is measured at
DS 442 states that qmax can be determi- 3.5 bars (35 m Wat.Col.) Using the pipe dimensions below the fol-
ned from the following formula: PE 80 pipes PN 10 are used as lowing pressure will be available at the
pipeline material consumer in station D:
Formula 1 Maximum daily water consumption
(Qmax )= 400 l/24 hours/pe 35 m Wat.Col. – 13 m Wat.Col. = 22 m
Q max
x ft max
Maximum consumption per hour = Wat.Col. > 20 m Wat.Col. OK
qmax
= 2,5 x Q max

24 Necessary pressure at consumer: 2

bars (20 m Wat.Col.)
where Q max
= avarage daily consumption 4 persons per household
[Qm] x 24-hour
factor [fd]
ft max
= hour factor
8
Where normal types of housing are invol- 10 houses
C
ved, Qmax can be set at 200 I/24 hours/pe A houses
Main line

and fd at 2. This gives a Qmax of 200 x 2

50 m
D
= 400 l / 24 hours/pe. For normal types
of housing ft max
is set at 2.5.
15
B houses

500 m 650 m 200 m

Figure 9. Diagram of pipeline in example

Section Quantity of water (l/s) Length (m) Pipe-dimension (mm) Pressure loss Pressure loss of
M Wat.Col./km) section (m Wat.Col.)
A-B 1,52 500 Ø 63 15 7,5
B-C 1,06 650 Ø 63 7 4,6
C-D 0,37 250 Ø 63 3,7 0,9

Sum 13

Table: Example of dimensioning diagram for calculation of pressure loss

Design & Testing

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Design & Testing

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PE Pressure Pipes
Design & Testing

Longitudinal expansion and Hydraulic flow: k = frictional resistance [m]

contraction of
plastic pipes
Plastics have a comparatively high coeffi-
cient of linear heat expansion, which
should be taken into account when laying
plastic pipes.
Pipe with socket joints do not normally
require special measures to be taken
regarding expansion caused by tempera-
ture changes, as each socket acts as an
expansion piece.
However, in the case of a long section of
adhesive-jointed PVC pipes, the whole
section will behave as a single long pipe.
Expansion or contraction will thus be
concentrated and the whole section will
expand or contract.
Formula 2
∆L = ∆t x L x α
frictional losses for diameter ≤ 200 mm
k = 0.00001 m
Formula for diameter > 200 mm
Water flow diagrams are calculated k = 0.00005 m
according to the Colebrook-White
formula: The curves are designated by trade
name (external diameter) but calculated
Formula 4 according to the internal pipe diameter
making it possible to read the capacity of
0.74 k the pipes direct without having to inter-
Q = -6.95 x log ( + ) x Di 2 x √ Di x I polate between the curves.
Di x √ Di x I x 106 From the diagrams the frictional loss of
3.71 x Di the plastic pipe itself appears. Individual
resistances such as bends, valves, redu-
cers, tees, inlet and outlet taps etc. are
Q = water discharge [m3/s ] not taken into account.
Di = internal pipe diameter [m]
I = frictional loss [m/m] [number]

where ∆L = longitudinal expansion/con-

traction [m]

∆t = T1 - T1 [°C]

T1 = stable soil temperature

T1 = temperature of pipe when laid
L = length of section [m]
α = coefficient of linear heat expan-
sion

Use of plastic pipes at

temperatures exceeding
20°C

Where circumstances require that the

normal maximum operating temperature
of a pipe be exceeded, the reduction in
pressure necessary to obtain the same
service life as at a 20°C operating tempe-
rature can be calculated from the dia-
gram below.

Formula 3

PNt = PN x Ct

Diagram: Permissible operating pressure at temperatures exceeding 20°C

Design & Testing

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For most water supply projects the diffe-
rent individual resistances will normally
not be calculated. In such a case 2 - 5%
is added to the frictional loss of the pipe-
line.
High water velocity
For projects with much higher water velo-
city or projects for which a detailed cal-
culation of different individual resistances
is desirable the following formula can be
used:
Formula 5
v2
∆H = ζ x –––
2g
where ∆H = pressure head loss(m)
ζ = resistance (number)
v = velocity (m/s)
g = gravity = (9.81 m/s2)
If the ζ -values of our products are
required please contact Wavin.
Pressure variations
Water Hammer
Each time the rate of flow in a pipe
system changes, a pressure wave is
created. This can result in such large
variations in pressure as to cause a
water hammer, which may exceed the
permissible load on the pipes (force
acting upon it).
In pump systems changes in the rate of
flow can occur in the case of e.g. power
cut, sudden blockages, rapid closing of
valves etc. If this takes place at one end
of a long pipe line, the pressure waves
will rebound from the other end and may
cause damage when they return to their
point of origin - particularly if this end is
completely shut off and the increased
18 TEL.
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pressure cannot escape. The risk of
water hammer may necessitate the
installation of devices to minimize the
effect of the pressure waves and will
often require special operating
instructions.
There is ample technical literature
available on the subject. Comprehensive
guidance is given on calculation methods
but these are both complicated and
time-consuming. However, data
programs have been produced which are
able to solve even the most complicated
problems. In compiling these programs,
information concerning the special
characteristics of the pump, pressure
head and torque, the valve closure, the
air valves and various designs of the
longitudinal profile etc. has been inclu-
ded. As a result there is a risk of pressure
variations, rates of flow, vibration
frequencies, volumes of air valve and
pressure changes along the pipe line
as a function of time.
Rapid filling of a pressure pipe line and
variations between trapped air masses
may also cause sharp rises in pressure.
Pipe lines should therefore be designed
to allow bleeding wherever required and
filling speeds should be kept low.
The speed of the pressure wave depends
on the pipe material, wall thickness and
the substance carried by the pipe.
The following pressure wave speed
values a [m/s] apply for water carrying
(incl. waste water) Wavin pipes:
Pressure class PE
PN a [m/s]
16 444
10 362
8 327
6.3 - Figure 10. Example of variation in
6 288
5 263
4 237
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Design & Testing
All known materials show to a varying
degree a tendency to suffer fatigue when
subjected to dynamic forces. Incidences
of water hammer will therefore reduce the
service life of the pipes - the extent of
such reduction depending upon the com-
position of the dynamic forces i.e.:
The duration of the pressure rise
The maximum value of the above
compared with the level of the static
mean stress
The time interval between rises in
pressure (frequency) etc.
The following permissible pressure rises
apply for pressure pipes used in water
supply systems:
Where pressure rises occur infrequently,
e.g. pressure testing, power failure etc.,
the permissible maximum pressure may
exceed the nominal pressure by 50%.
For plastic pipes it furthermore applies
that where pressure rises occur frequent-
ly (maximum 106 instances in a 50-year
period) the permissible maximum pres-
sure may exceed the nominal pressure
by 25%, but such pressure rises must
not result in a pressure amplitude higher
than 30%.
In case of doubt please contact Wavin.
pressure
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PE Pressure Pipes
Design & Testing

Flow diagram for Wavin Polyethylene pipe sizes 20 mm to 315 mm

Please note: this diagram is for water at 15˚c. and utilises a roghness factor (ks) of 0.003 mm

Design & Testing

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 PE Pressure Pipes
Design & Testing

Flow diagram for Wavin Polyethylene pipe sizes 90 mm to 1000 mm

Please note: this diagram is for water at 15˚c. and utilises a roghness factor (ks) of 0.003 mm

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 PE Pressure Pipes
Design & Testing
Testing &
commissioning
Site pressure testing
The traditional testing procedures used
for most pipeline materials are generally
intended for linearly elastic materials, eg
ductile iron and steel, and are not
suitable without modification for visco
elastic materials such as polyethylene.
Pipe manufactured from such materials
exhibit creep and stress relaxation. With
a PE pipe sealed under a test pressure,
there will be a reduction in pressure
(pressure decay) due to the visco elastic
(creep) response of the material.
This will occur even in a leak free system.
This pressure decay is non-linear in an
unrestrained pipe. In view of this charac-
teristic a pressure test has been develo-
ped which accounts for the effects of
creep and stress relaxation.
Pressure
Pipe
Figure 11. Test Pressure Curve
Test pressures
PE pipe systems could be pressure
tested up to a maximum of 1.5 times the
rated pressure of the pipe. However, for
practical purposes it is usual and may
only be necessary to pressure test up to
1.5 times the pipeline working pressure
(operating pressure).
Test section preparation
Test in sections of 1000 metres or
less.
Pipework should be backfilled, with
joints left exposed at the engineers
discretion.
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Pipework must not be tested at
temperatures in excess of 30˚C.
Air valves should be placed at all high
points in the system.
Data loggers with pressure transdu-
cers should be used to provide a
precise analysis of the pressure test
data and can provide the engineer
with an early indication of any
leakage.
For on site calculations a pocket
calculator is sufficient.
Test procedure
Upon reaching the test pressure, the
test section is isolated.
Pressure loading time is used as the
base reference point,(t1).
A correction factor, 0.4tL, is used to
calculate ratios (N), this accounts for
the pipeline beginning to relax during
the pressurisation period.
Take a first reading of pressure P1 at
t1 where t1 is equal to the pressure
loading tL. Corrected value = t1c
t1c = t1 + 0.4tL
Take a second reading of pressure
P2 at a decay time of 7tL this is time
t2.
Corrected value = t2c
t2c = t2 + 0.4tL.
Calculate N1 = log P1-log P2
log t2c-log t1c
For a pipeline without leaks, N1 should
be:
a) 0.08 to 0.10 for pipes without
constraint (eg sliplined, or not
backfilled)
b) 0.04 to 0.05 for pipes with compacted
backfill. If the resultant values are
significantly less than those specified,
this indicates that there is too great a
volume of air in the pipeline. This air
must be removed before a re-test can
be satisfactorily carried out.
Design & Testing
Take a further reading of pressure P3
at a decay time of not less than 15tL,
this is time t3.
t3c = t3 + 0.4tL
Calculate Nz = log Pz - log P3
log t3c - log t2c
The ratio N2 should again be as those
identified above. The test sensitivity can
be increased by extending the value of
t3.
If an unacceptable leak is indicated,
all mechanical joints should first be
checked, followed by checks on any
Butt or Electrofusion joints.
If a further test is necessary, a period
of at least five times the first test
period should elapse before re-
testing. This allows the pipeline to
recover from the previous pressurisa-
tion.
Commissioning procedure
Upon the successful completion of a
test, the remaining pressure in the
pipeline should be released slowly.
Following successful pressure testing all
new mains, lined or re-furbished, should
be commissioned in the following manner
and in accordance with any local require-
ments:
Cleaning and/or swabbing of the
main
Filling and sterilisation
Flushing and/or neutralisation
Refilling the main
Bacteriological sampling
Acceptance certification
Introduction of the main into service
21
 PE Pressure Pipes
Product range

5. Wavin PE pipes product range

Product range Wavin PE pressure pipes

The Wavin PE pressure pipe range consists of a wide assortment of pipes available in many diameters, different pressure classes
and a variety of colours.
Wavin PE pipe systems are available in sizes 20 mm - 630 mm.
The small sizes are available on coils. Larger sizes are available in pipe lengths.

PE pressure pipes for Gas

SDR 11, SDR 17, SDR 17,6

PE 80 PE 80 PE 100 PE 100
Yellow Yellow Orange Orange
SDR 17.6 SDR 11 SDR 17 SDR 11
OD wall/weight wall/weight wall/weight wall/weight
32 2,0 / 0,194 3,0 / 0,277 -/- 3,0 / 0,277
40 2,3 / 0,283 3,7 / 0,427 -/- 3,7 / 0,427
50 2,9 / 0,437 4,6 / 0,661 -/- 4,6 / 0,661
63 3,6 / 0,683 5,8 / 1,043 -/- 5,8 / 1,043
75 -/- 6,8 / 1,455 -/- 6,8 / 1,455
90 5,2 / 1,433 8,2 / 2,106 5,4 / 1,447 8,2 / 2,106
110 6,3 / 2,00 10,0 / 3,121 6,6 / 2,150 10,0 / 3,121
125 7,1 / 2,643 11,4 / 4,074 7,4 / 2, 741 11,4 / 4,047
140 -/- -/- 8,3* / 3,439 -/-
160 9,1 / 4,319 14,6 / 6,616 9,5 / 4,485 14,6 / 6,616
180 10,3 / 5,484 16,4 / 8,360 10,7 / 5,671 16,4 / 8,360
200 -/- -/- 11,9* / 6,995 18,2* / 10,308
225 12,8 / 8,488 20,5 / 13,043 13,4 / 8,868 20,5 / 13,043
250 14,2 / 10,475 -/- 14,8 / 10,865 22,7 / 16,039
280 -/- -/- 16,6 / 13,645 -/-
315 17,9 / 16,579 28,6 / 25,443 18,7 / 17,275 28,6 / 25,443

*Colour Black with yellow stripes

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PE Pressure Pipes
Product range

PE pressure pipes for water

SDR 9, SDR 11, SDR 13,6, SDR 17
Pipe series S
SDR 9 SDR 11 SDR 13,6 SDR 17
S4 S5 S 6,3 S8
Nominal pressure, PN a in bar
PE 80 PN 16 PN 12,5 PN 10 PN 8
PE 100 PN 20 PN 16 PN 12,5 PN 10
Nom. Wall thicknessess b Dimensions in millimetres
size e min e max e min e max e min e max e min e max
16 2,0 c 2,3 x x x x x x
20 2,3 2,7 2,0 c 2,3 x x x x
25 3,0 c 3,4 2,3 2,7 2,0 c 2,3 x x
32 3,6 4,1 3,0 c 3,4 2,4 2,8 2,0 c 2,3
40 4,5 5,1 3,7 4,2 3 3,5 2,4 2,8
50 5,6 6,3 4,6 5,2 3,7 4,2 3 3,4
63 7,1 8 5,8 6,5 4,7 5,3 3,8 4,3
75 8,4 9,4 6,8 7,6 5,6 6,3 4,5 5,1
90 10,1 11,3 8,2 9,2 6,7 7,5 5,4 6,1
110 12,3 13,7 10 11,1 8,1 9,1 6,6 7,4
125 14 15,6 11,4 12,7 9,2 10,3 7,4 8,3
140 15,7 17,4 12,7 14,1 10,3 11,5 8,3 9,3
160 17,9 19,8 14,6 16,2 11,8 13,1 9,5 10,6
180 20,1 22,3 16,4 18,2 13,3 14,8 10,7 11,9
200 22,4 24,8 18,2 20,2 14,7 16,3 11,9 13,2
225 25,2 27,9 20,5 22,7 16,6 18,4 13,4 14,9
250 27,9 30,8 22,7 25,1 18,4 20,4 14,8 16,4
280 31,3 34,6 25,4 28,1 20,6 22,8 16,6 18,4
315 35,2 38,9 28,6 31,6 23,2 25,7 18,7 20,7
355 39,7 43,8 32,2 35,6 26,1 28,9 21,1 23,4
400 44,7 49,3 36,3 40,1 29,4 32,5 23,7 26,2
450 50,3 55,5 40,9 45,1 33,1 36,6 26,7 29,5
500 55,8 61,5 45,4 50,1 36,8 40,6 29,7 32,8
560 x x 50,8 56 41,2 45,5 33,2 36,7
630 x x 57,2 63,1 46,3 51,1 37,4 41,3

a PN values are based on C = 1,25

b Tolerances in accordance with grade V of ISO 11922-1:1997[1]
c The calculated value of emin. (ISO 4065 [2]) is rounded up
to the nearest value of either 2,0, 2,3 or 3,0.
This is to satisfy certain national requirements.

Product range
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 PE Pressure Pipes
Product range

PE pressure pipes for water

SDR 17,6, SDR 21, SDR 26, SDR 33
Pipe series S
SDR 17,6 SDR 21 SDR 26 SDR 33
S 8,3 S 10 S 12,5 S 16
Nominal pressure, PN a in bar
PE 80 x PN 6 c PN 5 PN 4
PE 100 x PN 8 PN 6 c PN 5
Nom. Wall thicknessess b Dimensions in millimetres
size e min e max e min e max e min e max e min e max
32 2d 2,3 x x x x x x
40 2,3 2,7 2d 2,3 x x x x
50 2,9 3,3 2,4 2,8 2 2,3 x x
63 3,6 4,1 3 3,4 2,5 2,9 x x
75 4,3 4,9 3,6 4,1 2,9 3,3 x x
90 5,1 5,8 4,3 4,9 3,5 4 x x
110 6,3 7,1 5,3 6 4,2 4,8 x x
125 7,1 8 6 6,7 4,8 5,4 x x
140 8 9 6,7 7,5 5,4 6,1 x x
160 9,1 10,2 7,7 8,6 6,2 7 x x
180 10,2 11,4 8,6 9,6 6,9 7,7 x x
200 11,4 12,7 9,6 10,7 7,7 8,6 x x
225 12,8 14,2 10,8 12 8,6 9,6 x x
250 14,2 15,8 11,9 13,2 9,6 10,7 x x
280 15,9 17,6 13,4 14,9 10,7 11,9 x x
315 17,9 19,8 15 16,6 12,1 13,5 9,7 10,8
355 20,1 22,3 16,9 18,7 13,6 15,1 10,9 12,1
400 22,7 25,1 19,1 21,2 15,3 17 12,3 13,7
450 25,5 28,2 21,5 23,8 17,2 19,1 13,8 15,3
500 28,3 31,3 23,9 26,4 19,1 21,2 15,3 17
560 31,7 35 26,7 29,5 21,4 23,7 17,2 19,1
630 35,7 39,4 30 33,1 24,1 26,7 19,3 21,4

a PN values are based on C = 1,25

b Tolerances in accordance with grade V of ISO 11922-1:1997[1]
c Actual calculated values are 6,4 bar for PE 100 and 6,3 bar for PE 80.
d The calculated value of emin. (ISO 4065 [2]) is rounded up to the nearest value of either 2,0,
2,3 or 3,0. This is to satisfy certain national requirements.

Note: Grade V tolerances are in accordance with ISO 11922-1:1997[1] and calculated
from the following formula: (0,1 emin + 0,1) mm, rounded to the next 0,1 mm higher.

For certain applications for e>30 mm tolerance grade T in accordance with

ISO 11922-1:1997[1] can be used and the tolerance calculated from the following formula:
0,15 emin, rounded to next higher 0,1 mm.

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PE Pressure Pipes
Product range

Coil dimensions
The smaller PE pipe sizes are available on coil.
Please find below a coil dimensions overview.

Coil Dimensions
OD id od width length weight
20 660 840 190 100 16,7
670 950 250 200 33,4
25 660 880 240 100 21,6
660 1060 240 200 43,2
32 880 1060 210 50 14,3
880 1170 240 100 28,5
880 1330 270 200 57,0
880 1440 300 300 85,5
40 880 1100 260 50 17,8
880 1240 300 100 35,6
880 1380 380 200 71,2
880 1510 420 300 106,8
880 1900 420 500 178,0
50 1000 1280 330 50 22,7
1000 1450 330 100 45,3
1000 1790 330 200 90,6
1000 1710 530 300 135,9
1000 1880 530 400 181,2
1000 2050 530 500 226,5
63 1750 1990 350 50 36,1
1750 2090 410 100 72,1
75 1750 2290 410 100 101,5

Product range
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 PE Pressure Pipes
Product range

Wavin TS - SDR 17 - in pipe lengths

d / mm s / mm L* / m kg/m Quantity per pallet
225 13,4 12 8,93 14
250 14,8 12 11 11
280 16,6 12 13,7 11
315 18,7 12 17,4 8
355 21,1 12 22,1 8
400 23,7 12 28 5
450 26,7 12 35,4 4
* Special lengths on request

Wavin TS - SDR 11 - in pipe lengths

d / mm s / mm L* / m kg/m Quantity per pallet
32** 3 12 0,28 473
40** 3,7 12 0,43 250
50** 4,6 12 0,67 160
63** 5,8 12 1,05 132
75** 6,8 12 1,47 102
90 8,2 12 2,12 58
110 10 12 3,14 48
125 11,4 12 4,08 34
140 12,7 12 5,08 38
160 14,6 12 6,67 20
180 16,4 12 8,42 17
200 18,2 12 10,4 14
225 20,5 12 13,1 14
250 22,7 12 16,2 11
280 25,4 12 20,3 11
315 28,6 12 25,6 8
355 32,2 12 32,5 8
400 36,3 12 41,3 5
450 40,9 12 52,3 4
* Special lengths on request
** Completely made out of XSC 50

Wavin TS - SDR 11 - in coils

d / mm s / mm L* / m/coil kg/coil A/mm B H / mm
25** 2,3 100 17,1 800 660
32** 3 100 27,9 1170 880 240
40** 3,7 100 43 1240 880 300
50** 4,6 100 66,6 1450 1000 325
63** 5,8 100 105 2090 1750 410
75** 6,8 100 147 2290 1750 413
90 8,2 100 212 2890 2400 495
110 10 100 314 3000 2400 605
125 11,4 100 408 3080 2400 688
140 12,7 100 508 3165 2400 770
160 14,6 100 667 3270 2400 1200
180 16,4 100 842 3384 2400 990
* Special lengths on request
** Completely made out of XSC 50

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PE Pressure Pipes
Standards & Regulations

6. Standards & Regulations

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

SN,DS, National Committees for Norms

UNI,
DIN,
BS, NF,
O Norm,
DVGW etc.

European product
standards
The harmonisation of European stan-
dards is one of the key achievements of
the common European market. Technical
regulations and national standards are no
longer allowed to restrict the free exchan-
ge of goods and services.

In the CEN (Comité Européen de

Normalisation) committees, users national
associations/ organisations and manufac-
turers have come together to create uni-
form European standards. These CEN
Standards will become imperative for all
members of the European Community as
well as for the EFTA States who voted in
its favour. They may then not be overru-
led by a national standard.

standards & Regulations

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 PE Pressure Pipes
Standards & Regulations

List of relevant standards PE pipe systems

ISO 161-1 Thermoplastic pipes for the transport of fluids

ISO 1183 Polyethylene - measurement of density
ISO 3607 PE pipes - tolerances on o. d. and wall thicknesses
ISO 3663 PE pressure pipes and fittings - dimensions of flange
ISO 4427 Buried PE pipes for the supply of potable water
ISO 4437 Buried PE pipes for the supply of gaseous fuels
ISO 4440 PE pipes and fittings - determination of melt flow rate
ISO 6447 Rubber seals-joint rings used for gas supply pipes and fittings
ISO 8085 PE fittings for the supply of gaseous fuels
PrEN 1555 Plastic piping systems for gas supply - Polyethylene (PE)
PrEN 12201 Plastic piping systems for water supply - Polyethylene
PrEN 13244 Plastic pipe systems for buried and above-ground pressure systems for water for general purpose, drainage end sewerage
DIN 3535 Gaskets for gas supply
DIN 3543 Valves in PE HD for PE-HD-Mass pipes
DIN 3544 Valves in polyethylene of high density (PE-HD) Requirements and test of tapping valves
DIN 8074 Pipes in polyethylene of high density (PE-HD)-Mass
DIN 8075 Pipes in polyethylene of high density (PE-HD) General quality requirements - Test
DIN 16963 Pipe joints and piping components for pressure pipelines in high density polyethylene (PE-HD)
DIN 19533 Pipes in PE-HD and PE-MD for drinking water supply; pipes, pipe joints, piping components
DS 2131.2 Pipes, fittings and joints of PE type PEM and PEH for buried gas pipelines
UNI 8849 Raccorcdi di polietilene (PE5O), saldabili per fusione mediante elementi riscaldanti, per condotte per convogliamento
di gas combustibili. Tipi, dimensioni e requisiti
UNI 8850 Raccordi di polietilene (PE50), saldabili per elettrofusione per condotte interrate per convogliamento di gas combus-
tibili. Tipi, dimensioni e requisiti
O Norm B 5192 Pipes, pipe joints and piping components in PE for buried gas pipelines
DSV 2207 Fusion of thermoplastic plastics, (PE) pipes and Part I piping components for gas and water pipelines
DVGW G 477 Manufacture, quality assurance and testing of pipes in rigid PVC and PE-HD for gas pipelines
DVGW VP 302 Butterfly valves in PE-HD
DVGW VP 304 Gas and tapping valves for PE-HD piping systems
DVGW VP 607 PE-HD fittings for gas and water pipelines
DVGW VP 608 Polyethylene pipes (PE80 and PE100) for gas and drinking water lines; requirements and tests
DVGW VP 609 Plastic clamp joints for connecting PE pipes in the water supply
DVGW VP 610 Temporary test basis for water tapping valve, requirements and tests
DVGW VP 302 PE-HD butterfly valves
DVGW VP 304 Gas butterfly valves for PE-HD piping systems
DVGW VP 610 Temporary test basis for water tapping valve, requirements and tests
DVGW G 472 Laying gas lines
DVGW G 459 Laying gas domestic connections
DVGW G 477 Pipes and piping components for rigid PVC and HDPE gas lines
DVGW W 320 Rigid PVC, HDPE and LDPE water supply pipelines
O Norm B 5192 Pipes, pipe joints and piping components in PE for buried gas lines
prEN 681 Seals (water)
prEN 1555 Plastic piping systems for gas supply - Polyethylene (PE)
prEN 12201 Plastic piping systems for water supply - Polyethylene
UNI 8849 Raccorcdi di polietilene (PE50), saldabili per fusione mediante elementi riscaldanti, per condotte per convogliamento
di gas combustibili. Tipi, dimensioni e requisiti
UNI 8850 Raccordi di polietilene (PE50), saldabili per elettrofusione per condotte interrate per convogliamento di gas combus-
tibili. Tipi, dimensioni e requisiti.

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PE Pressure Pipes
Installation
7. Installation
7.1 Installation methods
Wavin PE80 and PE100 polyethylene
pipe systems provide a cost effective and
simple to install pipe system.
Polyethylene is a thermoplastic material
resulting in a lightweight, flexible pipe,
which is totally corrosion resistant and
leak free with proven fusion welded and
mechanical jointing methods.
The following notes give a general
guidance into the use of PE.
Buried pipework
One of the key strengths of polyethylene
is its ability to be fusion welded, either by
Butt or Electrofusion. This results in a
continuous, flexible pipe string which can
be easily snaked into pre-dug trenches.
Where site conditions permit welding can
be very easily carried out above ground.
Polyethylene lends itself to a number of
minimum dig and no-dig techniques,
many of which were developed specifi-
cally around PE pipe systems, eg:
Narrow Trenching
Ploughing
Moling
Pipe Bursting
Slip Lining
Folded PE, lining systems
Directional Drilling
Conventional open cut
trenching
Excavation and disposal of waste spoil
are major factors in pipe installation.
Landfill taxes are becoming a significant
cost and environmental factors are
forcing Engineers to look at new
installation methods to minimise the
disruption and amount of waste spoil
generated.
The current practice is to lay service
pipes at 750 mm cover and mains at 900
mm cover, measured from the
pipe crown.
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Marker T ape
Min As dug
900mm material
300mm
100mm
Pipe OD +250mm
Imported or selected
bedding & backfill
material
Figure 12. Typical Open-Cut
Trench Detail
The width of the trench should be the
minimum of pipe O.D. plus 250 mm to
allow for the correct compaction of side-
fill. The location of cables and pipes from
other utilities should be identified prior to
excavation and generally at least 3 pipe
lengths should be excavated prior to pipe
installation to allow for obstructions to
be avoided.
Polyethylene may in some instances be
laid directly onto the trimmed trench
bottom where the soil is uniform, fine
grained and free from large stones and
flints.
In other cases the trench should be
excavated to a depth to allow for a
minimum 100 mm bed of gravel, crushed
stone or coarse sand. A sand/gravel mix
is also acceptable, provided the gravel is
less than 20 mm insize.
Installation
Trench Width +300mm
150mm
Min
Less
than
900mm
Figure 13. Recommended Protection for
Shallow Pipes
Backfilling
Polyethylene is a flexible material and can
deform under load without damage. It is
however, important that any deformation
is minimised and that the placement of
the correct sidefill and initial backfill mate-
rials is carried out correctly with adequate
compaction. A minimum 100 mm cover
should be placed above the crown of the
pipe, with heavy compaction equipment
not being used with less than 300mm
cover. Backfilling can then proceed in
300 mm layers.
Trench backfilling should commence as
soon as possible after pipe laying to give
the pipe protection from damage from
objects possibly falling into the trench.
To protect the pipe from potential future
interference damage it is good practice to
install a marker tape 300 mm above pipe
crown. Marker tapes can also include
a tracer wire to allow future identification
of the pipeline.
29

Shallow cover
There may be situations where pipes
cannot be laid at the recommended
depths of cover. In these situations for
highways or traffic areas the pipe should
be protected by placing a 150mm thick
reinforced concrete bridging slab above
the pipe. A 150 mm thick granular cus-
hion should be placed between the pipe
crown and concrete, fig. 13 on the pre-
vious page details the typical application.
Installation techniques
As discussed earlier a number of techni-
ques have been developed to maximise
the benefits of using polyethylene, these
techniques are briefly discussed below.
Figure 14. Typical Bursting Operation
Narrow trenching
A modification of traditional open-cut
trenching. Using either narrow backhoe
Figure 15. Typical Directional Drilling Operation
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buckets or chain trenchers, trenches
100mm wider than the pipe being instal-
led are excavated. Coiled, drummed or
pre-welded pipe strings can be quickly
installed. Significant savings can be
achieved through reductions in less exca-
vated spoil, less imported fill materials
and reduced labour.
Ploughing techniques
Developed from agricultural machines
laying land drainage, these machines are
used for laying cross-country water and
gas pipelines.
Pipes are laid with little disruption to the
land which is quickly reinstated to agricul-
ture. Pipe is installed continuously
through a hollow plough with bed & sur-
round material plus marker tape installed
simultaneously as required.
Pipe bursting
This is an ever-increasing method of re-
habilitating an existing pipeline where a
non-structural lining method would be
unacceptable. With pipe bursting the
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Installation
existing pipe is cracked open and the
new PE pipe is drawn into the hole cre-
ated, and provides either a size for size
replacement pipe or by use of reamers
the original main can be upsized.
The present day hydraulic bursting tools
are capable of cracking out both pipes
and fittings in very demanding situations,
and further adaptations are now capable
of splitting ductile iron and steel mains.
With this technique, damage to adjacent
utilities plant is possible and therefore
care is required in the planning and ope-
ration of bursting.
Moling
Moling has become an established no-
dig method for the installation of small
diameter service pipes and mains, and
can give significant cost savings over
open-cut trenching. Excavation is limited
to launch and reception pits and moling
is ideally suited for road crossings and
installations under expensive paved areas
and gardens where open-cut trenches
would be very disruptive.
Note: The presence of other services
should be established prior to moling.
The impact mole is an air driven percus-
sion tool, which drives a borehole and
usually pulls a new polyethylene pipe
directly in behind it.
The technique can also be used on car-
riageways in a technique known as "pipe
stitching" where pipe is installed from pit
to pit.
Directional drilling
This technique has also become an esta-
blished installation method for PE pipe
and is used for road, rail and river
crossings where open-cut work would be
usually impracticable and prohibitively
costly.
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PE Pressure Pipes
Installation
The hole is bored by either high-pressure
liquid jets or with drill bits, and fully
steerable systems are available by
monitoring transmitters in the cutting
head.The operation involves drilling a
small diameter ‘pilot’ hole beneath the
obstacle and the final hole size is achie-
ved by progressively back reaming up to
the diameter required.
The PE pipe (coil or pre-welded string) is
finally pulled through on the last pass.
Experienced contractors are necessary
with this technique to ensure the PE
string is not over stressed on the final pull
through.
Slip lining
The insertion of a smaller diameter PE
pipe, slip-lining, into an existing pipeline is
one of many no-dig techniques for
re-habilitation of ageing pipelines.
With slip-lining there is inevitably a reduc-
tion in pipe bore, although this can be
minimised by thorough cleaning of the
old main and choosing the largest possi-
ble pipe size for insertion.
The smaller bore is also compensated for
by the greatly improved flow characteris-
tics of polyethylene and in many cases
the higher operating pressure capability
of the new pipe.
Pressure grouting of the annular gap
provides structural rehabilitation of the
existing pipe and reinforces the overall
strength of the new pipe. Grouting may
also offer a more economical total instal-
lation by allowing the use of a thinner
walled PE pipe. Consideration should be
given to the resistance of the pipeline to
grouting pressures and this will be
dependent on pipe SDR and ovality
(especially coiled or drummed pipe).
Close Fit insertion methods
A number of methods are available for
the structural lining ofexisting pipes,
maximising the overall cost savings of
using the existing ‘hole in the ground’.
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PERMISSIBLE GROUTING PRESSURES FOR PE PIPES
Deformation 0% 1%
SDR Permissible Grouting
33 13 12
26 27 25
17 96 88
11 417 383
Figure 16. Permissible Grouting Pressures
Figure 17. Typical Slip Lining Operation
Two methods rely on physically reducing
the outside diameter of the liner pipe to
provide a clearance gap for insertion.
Both work by either passing the pre-
welded pipe through rollers or a reducing
die. The pipe is either re-expanded using
water pressure or allowed to recover
naturally when the winch load has been
removed.
Wavin have developed and patented their
own re-habilitation method based on
reducing the liner pipe O.D. by physically
deforming the pipe into a ‘C’ shape. This
product which is factory formed is known
as ‘Compact Pipe’ and is available in a
range of diameters and SDR’s .
For further details on Compact Pipe
please contact Wavin.
Thin wall polyethylene liners
For pipelines, which are still structurally
sound and require rehabilitation for
leakage or water quality problems, thin
wall PE liners can provide the solution.
With SDR’s of 33 - 61 the pipe is either
factory or site formed into a folded profile
Installation
3% 6%
Pressure (KN/M2)
10 7
20 15
73 59
317 242
to reduce its diameter for ease of installa-
tion into the existing main.
Lengths of up to 700m can be pulled in,
in one operation, and when in place the
folded pipe is reverted with mains water,
to form a close-fitting liner.
The technique is particularly effective on
small diameter mains, 3 - 12" diameter,
with the full system comprising termina-
tion fittings and ferrule connections.
Pipe bending
One of the major benefits of PE is its
flexibility and this can be utilised to full
advantage for buried pipework. Gradual
changes of direction up to 11.5˚ can
normally be accommodated by the pipe
itself, without the need for additional
fittings and the costs of jointing.
The accepted rule of thumb for Wavin PE
pipe systems (warm conditions for SDR
11 pipe) is, Bend radius = 15 x pipe O.D.
For colder weather and SDR 17 pipe a
safe bending radius is 25 x pipe O.D.
In very cold winter temperatures this
increases to 35 x pipe O.D. Where
thinner walled SDR 26 and SDR 33 pipes
31

are being used these values should be
increased by 50%. Fittings and pipe
joints should not be included in bent pipe
sections; formed bends and elbows
should be used instead to prevent undue
stresses in the pipeline.
Pipe detection
For future location of PE pipelines and in
line with good pipe laying practice, the
simplest and most economical method is
to lay a marker tape/ mesh which incor-
porates a tracer wire. This should be
installed 300mm above the pipe crown
and also provides protection from any
future third party damage.
Pipe anchorage & thrust
blocks
A key feature of a welded PE pipeline is
that it is a fully end load resistant system
and thrust blocks are not required at
changes of direction/diameter or
branches, providing significant time and
cost benefits to the total installed cost of
the system. It should be remembered
that any connection to a non-end load-
bearing fitting will require anchorage to
prevent pipe pull-out.
Where heavy ancillary plant is installed on
a PE pipeline, provision should be consi-
dered for concrete support. This should
provide support both for the dead weight
and resist any turning movements under
operating conditions, eg. valves and hyd-
rants.
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Pipe entry into structures
Pipe entry into rigid concrete or brick-
work structures needs to take account of
a number of design factors and should
include:
Differential settlement
This can usually be accommodated
by the flexibility of the pipe itself and
by incorporating a flexible annular
seal to the pipe sleeve through the
structure.
Watertight seal
The protective sleeve should provide
both a watertight seal to the structure
and to the PE pipe passing through
the sleeve.
In some situations PE pipe may be
connected to the structure by a rigid
flanged joint. To prevent undue
stresses through movement and
settlement, support can be provided
by a reinforced concrete plinth. The
plinth should extend one pipe diame-
ter or 300mm (min) from the flange
face, with pipe straps bolted to the
plinth.
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Contaminated Ground
Polyethylene is resistant to most naturally
occurring ground contaminants.
However, the greater use of previously
developed land (brownfield sites) is resul-
ting in a greater potential exposure to
harmful contaminants.
The main concern for potable water
pipework is the risk of long term mecha-
nical damage to the material and of more
importance, the contamination may
cause water quality problems, taste and
odour, due to permeation through the
pipe wall. Former industrial sites pose
the greatest problem. Development of the
following sites should be carefully
assessed:
Coal workings, including coking and
town gas production.
Chemical works
Gas works
Paint and varnish works
Wood plants (preservatives)
Landfill sites
Garages/petrol stations
Where there is a known risk of contami-
nation, professional guidance should be
sought on soils analysis to identify the
range and degree of contaminants. The
analysis can then be used to determine
the suitability for polyethylene potable
mains and services and whether suitable
protection can be provided.
In some instances where contamination
is negligible protection can be given with
a clean sand/granular surround and a
heavy gauge polyethylene membrane
lining to the trench. If conditions are such
that the use of polyethylene would not be
suitable, the ‘Trigon’ barrier pipe has
been developed specifically for carrying
potable water through contaminated
land. Further guidance is available from
Wavin.
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PE Pressure Pipes
Installation
7.2 Jointing
Polyethylene pipe systems are relatively
simple to joint and install. Two jointing
methods are available to cater for the
components that are used to build an
operational system.
Fusion Welded Joints
a) Butt Fusion
b) Electrofusion
Mechanical fittings
a) Compression fittings
b) Flanged Joints
Fusion welding
Both Butt Fusion and Electrofusion use
specialist equipment to carry out field
jointing. Modern machine developments
now provide totally automatic jointing,
eliminating the risk of operator error and
providing a full record of joint history for
Quality Assurance of site welding.
Machinery can be either purchased or
hired from manufacturers and detailed
product literature is available together
with familiarisation courses to ensure
correct use of the machinery.
Operatives should however receive full
training. Training is available from Wavin
either at its Customer Training facility or
at the customers premises. For more
information, please contact Wavin.
Butt fusion
Butt Fusion jointing involves the fusing
together of two pipe ends in a specialist
machine which prepares the pipe ends,
heats them and brings them together
under pressure to form a homogeneous
weld. The joint is fully end load resistant
and is at least as strong as the parent
pipe.
With Butt Fusion it is essential only similar
grades of PE are welded, eg:
PE 100 – PE 100 a
PE 100 – PE 80 r support rollers.
and similar SDR’s are used, eg:
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SDR 11 – SDR 11 a
SDR 11 – SDR 17 r
Site fusion welding methods cover the
single and dual pressure methods. Dual
pressure welding was introduced as a
result of investigations into joint quality
and this procedure should be used for all
pipes with a wall thickness greater than
20mm. Due to the low pressures invol-
ved in the dual pressure procedure, only
fully automatic machines should be used;
manual machines may still be used for
single pressure Butt Fusion jointing. The
butt fusion process can be used for join-
ting PE pipes and fittings in sizes of 90
mm and above. In general this jointing
operation will be carried out to the side of
the trench and the complete pipeline then
lowered in. All “in trench” jointing will usu-
ally be carried out using electrofusion fit-
tings.
Equipment required
Butt Fusion machine, inclusive of
trimmer, heater plate and hydraulic
pump.
110v Generator, fuel
Welding Tent/Base board
Pipe support rollers
Clean water, lint free cloths
External de-beading tool
Bead gauge
Pipe end covers
Indelible marker pen
Pipe cutting tools
Note: Wavin Overseas can supply the
necessary equipment.
Procedures of manual
butt fusion
Ensure the pipe ends are clean and if
necessary, wash with clean water
and dry.
Cut the pipe ends square and clamp
securely in the B/F machine.
Align and level the pipes with pipe
To prevent cooling of the heater plate
blank off the free pipe ends.
Installation
Trim the pipe ends until a continuous
shaving is seen from each pipe end.
Remove loose shavings and impor-
tantly, do not touch the prepared pipe
ends.
Close the clamps and check for good
alignment of the pipe ends, the
allowable mismatch is; 90mm-
315mm pipe, 1 mm 355mm-630mm
pipe, 2 mm Re-trim if mismatch is
greater than these values.
Open and close the clamps, noting
the gauge pressure to close the
clamps - This is the drag pressure.
The fusion (jointing) pressure is obtai-
ned by adding the drag pressure to
the hydraulic ram pressure given on
the machine data plate.
Place the heater plate in the machine,
checking it is clean and undamaged
and up to temperature, 225˚C -
240˚C.
Close the clamps and apply the pre-
viously determined pressure until a
bead of 2-3mm is formed.
Reduce the pressure in the system to
between 0 and drag, the heat soak
time commences. Ensure the pipes
maintain contact with the heater
plate.
Upon completion of the heat soak
time, remove the heater plate and
close the clamps immediately, (within
10 seconds).
Maintain the required fusion (jointing)
pressure for the specified cooling
period.
Remove the joint & allow to cool for a
similar period.
Clearly mark the joint and bead for
identification with an indelible pen.
Check the joint is free from any con-
tamination, and check the bead
widths meet the specified limits and
are uniform.
Remove the external bead and twist
in several positions. If the bead splits
at any position the joint should be cut
out and re-made.
33

Additional notes for butt
fusion
If the heater plate requires cleaning
this should be done when the plate is
cold. The plate can be washed with
clean water and lint free cloth and
dried thoroughly. Isopropanol may be
used to remove any oil or grease.
Washing the heater plate may not
remove very fine dusty particles,
therefore at the start of each welding
session a dummy weld should be
carried out for pipes up to 180mm in
diameter. For pipe sizes greater than
180mm, two dummy welds should be
made. An actual joint need not be
made, the dummy weld can be abor-
ted at the end of the heat soak
period. Pipe offcuts may be used.
In very cold conditions, below 5˚C,
additional space heating must be
provided in the fusion welding tent to
maintain the required minimum
ambient temperature for welding.
Electrofusion "wet wipes" should not
be used after the pipe ends have
been trimmed, if any contamination
does occur the pipe ends should be
re-trimmed.
Electrofusion
Electrofusion fittings incorporate an elec-
trical heating element which is energised
via an E/F control box to heat the
elements.
When the fitting is energised the material
next to it becomes molten and in turn
causes the pipe surface to melt, resulting
in a molten pool of material fusing the
materials of fitting and pipe.
Once cooled this produces a fully fused
and leak free joint.
Electrofusion fitting design
The design of an E/F fitting is crucial to
its performance and is dependent on the
position and pitch of the heating coil.
The heat distribution should
be consistent throughout the fusion cycle
34 TEL.
+31(0)523-624911
and over the full fusion area. The melt
must be adequately controlled within the
hot and cold zones to ensure a fully wel-
ded, homogeneous joint. The different
zones of an E/F fitting are shown in
Figure 18.
Fusion
Indicator
Fusion
Zone
Cold
Zones
Figure 18. Cross section through an
Electrofusion Coupler
Automatic & manual fittings
Many manufacturers now offer Automatic
and Manual fittings and it is important to
ensure the E/F control unit is compatible
with the fittings being used. Most control
units can be operated in both Automatic
and Manual mode.
Saddle Fittings (Tapping
Tees)
The style of saddle fittings available;
clamp saddles
These provide a service connection to
polyethylene mains.
With clamp saddles the jointing force is
provided by a clamp device, located
beneath the fitting and pulls the fitting
down onto the pipe.
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PE Pressure Pipes
Installation
Equipment required
A number of manufacturers produce E/F
control boxes and the ancillary tooling
required. The correct tooling must be
used to ensure consistently reliable joints
and this may be either purchased or
hired from the tooling manufacturer or
their agents. The site equipment should
include:
E/F control unit
110 volt generator
3 - 3.5 KVA for 39.5 volt fittings
6 - 7 KVA for 80 volt fittings
Jointing shelter
Pipe scraping tool, including mecha-
nical scrapers for pipe end prepara-
tion and hand scrapers for saddle
joints
Pipe cutting tool
Marker pen, solvent wipes, lint free
cloths/paper towels
Note: Wavin Overseas can supply the
necessary equipment.
Principles of EF Jointing
Pipe ends must be cut
square and de-burred.
If necessary clean the pipe ends with
clean water and dry.
Clearly mark the depth of entry, plus
25 mm, around the pipe circumferen-
ce. Use the fitting as a guide, without
removing from its sealed bag at this
stage.
Using the mechanical pipe-scraping
tool, remove the entire pipe surface
over the marked area in a continuous
ribbon of material if possible.
NOTE: Do not touch the cleaned scraped
surface.
Mechanical scrapers are preferred over
hand scrapers as skill and practice is
required with hand scraping and can be
quite time consuming for larger diameter
pipes.
Remove the fitting from its bag,
check it is clean and undamaged,
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PE Pressure Pipes
Installation

and assemble onto the pipe ends Mechanical joints

clearly marking the depth of entry Compression fittings “o” Ring Replacement Pipe

with a marker pen. Compression joints may be dismantled. It

Securely clamp the joint assembly is used as a connection element in plastic
with the appropriate clamps. piping systems and is distinguished by its Pipe Stiffeners

Attach the control unit leads, check low installation costs owing to simple and
the generator has sufficient fuel and quick assembly. Compression jointing
commence the fusion cycle following can be loaded immediately after assem- Figure 19. Cross Section through an
the control unit instructions for the bly. It is sealed with elastomeric ele- Elastomeric Ring Seal
type of fitting being used. ments. Typical applications are domestic
Check the melt indicators have risen, lines in drinking water supply, irrigation a polyethylene stub flange.
these indicate the fitting has been systems, telecommunication applications, Stub flanges are supplied pre-fabricated
energised and has completed a water supply at construction sites and with either spigot or pupped pipe lengths
fusion cycle. sprinkler systems. There are numerous and steel backing ring, drilled to suit
Allow the joint to cool for the required manufacturers of compression fittings metric PN16 flanges. Other flange dril-
time, full fusion details are given on suitable for use with polyethylene pipe, lings are available upon request.
each fitting. they are all based on the same design As polyethylene pipe is sized on the O.D.
principle where an elastomeric ring seal is and Ductile Iron, for example, is sized by
Additional notes for compressed between pipe and fitting. its internal bore, allowances must be
electrofusion Some fittings require the use of pipe bore made for differences in pipe bore and
Jointing must always be carried out in inserts to provide sufficient rigidity for the discrepancies in corresponding mating
dry and dust free conditions. compression seal to be effective. flanges. This occurs more with larger dia-
Do not use rasps/files or abrasive Wavin offers polypropylene compression meter pipes and a flange converter will
sheets to prepare pipe ends. fittings, which offer exceptional joint secu- be required in these instances to ensure
Always use the correct clamps for rity for metric OD PE pipes and form a compatibility of pipe bores.
jointing. seal without distorting the pipe or restric-
When jointing coiled pipe, additional ting the pipe bore. Flange convertor
re-rounding and pipe straightening Where a change in pipe bore is not
tooling should be used to assist in the Flanged joints acceptable, a steel flange converter can
process. One of the simplest and earliest methods be used to maintain a clear bore, the dia-
Do not extend control unit leads to for connecting PE pipe to valves, hyd- gram below shows a typical flange confi-
the fittings and ensure the lead rants and existing pipe materials is to use guration for a 450mm PE stub flange to a
between generator and control unit is 400mm D.I. flange.
not excessive as an unacceptable
power drop can be created. TYPICAL BOLTING TORQUES (PE TO PE)
If the fusion cycle stops in mid-cycle Pipe Nominal Bolts Torque (nm)
first check for any control unit faults. Diameter Flange ± 10%
Check for fuel. If the fault can be 63 (mm) 50 (mm) M16 x 4 35
rectified, welding can recommence 90 (mm) 80 (mm) M16 x 8 35
providing the joint has cooled to 125 (mm) 100 (mm) M16 x 8 35
ambient temperature and the fusion 180 (mm) 150 (mm) M20 x 8 60
time is re-set for a further full cycle. 225 (mm) 200 (mm) M20 x 12 80
For live connections, tapping into the 250 (mm) 250 (mm) M24 x 12 100
water main should be carried out 315 (mm) 300 (mm) M24 x 12 120
after all joints have cooled for a 355 (mm) 350 (mm) M24 x 16 150
minimum of 30 minutes. 400 (mm) 400 (mm) M27 x 16 200
Where E/F couplers are to be used 450 (mm) 450 (mm) M27 x 20 250
for repair situations the existing main 500 (mm) 500 (mm) M35 x 20 300
should be completely dry with no
running water. Figure 20. Typical Bolting Torques

Installation
TEL. 35
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Stub flange jointing
procedure
Jointing is straight forward and the
following guidelines can be used.
Ensure the mating flange faces are
clean and free from damage.
Select the appropriate size and grade
of gasket for the application.
Align both flange faces before bolting
up. Ensure the pipes/components are
aligned and do not impose any
bending stresses on the joint.
Jointing compounds are not
necessary.
Use only clean undamaged nuts,
bolts and washers of the correct size.
Ensure the gasket is aligned and
centred before bolting .
Assemble the joint and finger tighten
all nuts / bolts and progressively
tighten all bolts in a diagonally
opposing sequence as follows,
using a torque wrench:
• 5% of final torque
• 20% of final torque
• 50% of final torque
• 75% of final torque
• 100% of final torque
For evenness of tightening it is
advisable to use two operators for
flanged joints larger than 180mm
diameter.
If practical, final torquing up should be
repeated after the joint has relaxed for
1 hour.
It is important the joint is tightened
evenly and in sequence to ensure a
leak free joint, this is as important as
the use of recommended final torque
values.
36 TEL.
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PE Pressure Pipes
Installation
Connection of flange ring
to PE stub flanges
Flanged joints should always be tightened
with a torque wrench, using the tighte-
ning forces shown in table 9. “Making the
joint as tight as possible” is inadvisable as
this is likely to overload the joint.
Deviations may occur in practice if, for
instance, the pipes resist tightening or
there is great friction in the bolt threads.
Where such situations occur, the problem
should not be solved by increasing the
tightening force. If Wavin standard gas-
kets are not employed, a different shore
of the gasket may alter the tightening
force.
Connection procedure
It is recommended that flat gaskets are
used for flanged joints. Flat butyl rubber
gaskets for pipe dimensions over 90 mm
should be reinforced on account of the
internal pressure in the pipeline. The
shore of the gasket should be approxi-
mately 65ºC.
Figure 21. Diagram showing connection
of blue glass-fibre flange ring
to polyethylene fitting
1) Place the flange ring on the PE pipe.
2) Butt-fuse the stub flange to the pipe
end outlined in the fusion instructions.
The electro-socket fusion method can
also be employed - in such case
remember to locate the flange ring by
the fitting before fusing.
3) Locate the flange gasket.
4) Bolt the flange, using a torque wrench
as outlined in the instructions.
Employ the approximate tightening forces
shown in table 9:
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PE Pressure Pipes
Installation

Outside pipe-diameter dy mm 25 32 40 50 63 75 90 110 125 140 160 200 225

NW mm 20 25 32 40 50 65 80 100 110 125 150 175 200
Tightening force Nm 9 10 20 25 30 35 40 45 50 50 60 75 75

Table 9

A torque wrench should also be used to tighten a flanged joint with flat gaskets. Bolts should always be cross-tightened.

Dim Number Thread A B C D E

of bolts M S L Lfix Bmin L Lfix Bmin L Bmin L Bmin L Bmin
63 4 16 24 80 110 38 70 110 46 70 38 90 38 80 38
75 4 16 24 80 110 38 70 110 46 70 38 100 38 80 38
90 8 16 24 90 120 38 70 110 46 80 38 100 38 80 38
110 8 16 24 90 120 38 80 110 46 80 38 100 38 80 38
125 8 16 24 90 120 38 80 110 46 80 38 120 38 90 38
160 8 20 30 110 150 46 90 120 46 80 46 120 46 100 46
180 8 20 30 110 150 46 90 120 46 80 46 130 52 100 46
200 8 20 30 120 160 46 100 150 60 90 46 140 52 110 46
225 8 20 30 120 160 46 100 150 60 90 46 140 52 110 46
250 12 20 30 150 190 60 110 150 60 90 46 150 52 120 46
280 12 20 30 150 190 60 110 150 60 90 60 150 52 130 46
315 12 20 30 170 220 73 130 190 80 100 60 160 52 130 46
355 16 20 30 190 260 100 130 190 80 100 60 190 52 150 52
400 16 24 36 220 280 100 160 220 80 120 60 220 60 160 60
500 20 24 36 250 330 100 170 220 80 130 73

A = Combi flange, tensile resistant combi flange connected to the same

B = Combi flange, tensile resistant combi flange connected to flange valve, flange fittings
C = Flange valve, flange fittings connected to the same
D = MDPE flange adapter connected to the same
E = MDPE flange adapter connected to flange valve, flange fittings

Lfix = 4 auxiliary bolts used for connection

A = 500 mm cast iron L= 330

B = 500 mm cast iron L = 220

Table 9a. Overview of bolt lengths and dimensions

Installation
TEL. 37
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Connection of Combiflange
- Tensile resistant for PE
(with use of bush)
Tensile resistant Combiflanges are used
to connect PE pipes to valves and fittings
with flanges drilled to take PN 10 (or PN
16).
The Combiflange consists of three parts:
a cast-iron flange, a red brass grip ring
and a rubber gasket. The stainless circu-
lar bush is used together with a wedge.
Its area of application is water and neutral
liquids at temperatures
not exceeding 70ºC. The Combiflange
tolerance is ±1 mm.
38 TEL.
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PE Pressure Pipes
Installation
Figure 22 - Diagram showing connection
of tensile resistant flange for PE
1) Cut the PE pipe at right angles using
a fine-toothed saw.
2) Remove swarf, soil and other impurities
from both the outer and the inner sur-
face of the pipe end. Do not chamfer.
3) Slightly compress the bush and insert
in the pipe as far as its collar.
4) Insert the wedge in the bush groove
by hand and gently knock into place
with a hammer.
5) If the end of the wedge is not com-
pletely flush with the pipe end, remo-
ve the protruding piece with a hack-
saw.
6) Place the cast-iron flange on the pipe
with the smaller end facing away from
the pipe end.
7) Place the red brass grip ring on the
pipe with the small end facing away
from the pipe end.
8) Locate the rubber gasket on the pipe
so that the large end projects 20 mm
from the PE pipe end, i.e. with small
end of rubber gasket facing inwards.
9) Slide the red brass grip ring back until
it connects with the rubber gasket.
10) Apply a thin layer of lubricant to the
outer surface of the rubber gasket.
Place the pipe end with the flange,
grip ring and rubber gasket and bush
in position against the valve or fitting
flange.
11) Push the cast-iron flange by hand
over the grip ring and rubber gasket
as tar as it will go.
12) Locate the bolts and tighten by hand
until the parts connect.
13) Ensure that the assembly is correctly
aligned.
14) Tighten the bolts using a spanner.
Cross-tighten to ensure that the bolts
are evenly tightened.
NB: The same procedure should be follo-
wed when connecting two tensile-resi-
stant Combiflanges. When tightening, two
extra-Iong "auxiliary bolts" will be needed.
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PE Pressure Pipes
Installation

Flange dimensions

DN D k d1 Bolts Number of Holes

n n
PN 10 PN 16 PN 10 PN 16 PN 10 PN 16 PN 10 PN 16 PN 10 PN 16
25 115 - 85 - 14 - M 12 - 4 -
32 140 - 100 - 18 - M 16 - 4 -
40 150 - 110 - 18 - M 16 - 4 -
50 165 - 125 - 18 - M 16 - 4 -
65 185 - 145 - 18 - M 16 - 4 -
80 200 200 160 160 18 18 M 16 M 16 8 8
100 220 220 180 180 18 18 M 16 M 16 8 8
125 250 250 210 210 18 18 M 16 M 16 8 8
150 285 285 240 285 22 22 M 20 M 20 8 8
200 340 340 295 295 22 22 M 20 M 20 8 12
250 395 400 350 355 22 26 M 20 M 24 12 12
300 445 455 400 410 22 26 M 20 M 24 12 12
400 565 580 515 525 26 30 M 24 M 27 16 16
500 670 715 620 650 26 33 M 24 M 30 20 20
600 780 840 725 770 30 36 M 27 M 33 20 20

Table of standard flange dimensions

Figure 23. Flange design

Installation
TEL. 39
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8. Laying instructions
European standard EN 1452-6 “Plastic
piping systems for water supply” guidan-
ce for installation applies for the laying of
pressure pipes.
The standard lays down that a pipeline
should be located at such a distance
from other pipelines and installations that
it causes no damage to these and allows
the repair of other installations. Reference
should be made to the standard for the
distances in question.
Requirements are also attached to the
design of the pipe trench.
The levelling layer must be laid or
loosened and subsequently levelled so
that the pipes are evenly supported.
The side fill layer must provide adequate
side support for the pipes and it is
therefore important that this layer is
compacted, e.g. by stamping with the
foot.
The materials employed for the levelling
layer and the side tilt must meet the
following criteria:
The particle size must not exceed
16 mm
The content of particles of between
8 and 16 mm must not exceed 10%
The material must not be frozen
Figure 24. Diagram of trench design
40 TEL.
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Sharp flints or other crushed material
must not be employed
The back fill must conform with the requi-
rements placed upon it by the type of
construction (road, pavement or the like)
above the pipeline.
The standard states that the soil covering
(hd) must not be less than 0.6 m where
the pipeline will be exposed to traffic
load, unless special measures are taken.
In view of the requirement that pipelines
are laid in frost-free soil, pipelines
carrying, e.g. potable water, are normally
laid with a 1.1 m soil cover.
Pressure testing
Pressure testing of PE
pressure lines
It is possible to pressure test a PE
pressure line, before it is put into service
(taken over by the client).
Pressure testing is carried out according
to DS 455. If pressure testing is reques-
ted, it should form part of the project,
and here the following conditions should
be observed:
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PE Pressure Pipes
Laying Instructions
1) The longitudinal profile should be
projected with a slight upward incline
for ventilation purposes.
2) A form of ventilation (manual -
automatic) should be installed in all
summits - correct installation of
ventilation: In the direction of flow a
little below exact summit.
3) Barring procedures should be
established enabling pressure testing
of the line by stages.
4) It should be possible to connect a fil-
ter socket in the lowest point and
ventilation (air escape) in the summit
to the starting and end points of the
line respectively.
5) Bends, tees, reducers, valves, end
caps etc. should be anchored for the
increased testing pressure.
6) The demands placed by the owner on
possible pressure testing should
appear from the project description
enabling the contractor to take the
necessary measures for pressure
testing.
7) Choice of pipe and fitting material
should be made under reference to
EN1555/12201/1452
When the above conditions have been
fulfilled the next step is the practical
accomplishment of the job, and here the
following points may contribute to pro-
blem-free pressure testing:
Correct transport, storage and hand-
ling of pipes and fittings
Correct excavation, laying, filling and
compaction
Correctly used jointing components
and methods
It is highly important that above mentio-
ned rules are observed as they will
influence the final result of the project.
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PE Pressure Pipes
Laying Instructions

Procedure for pressure 5) After 60 minutes the pressure is meas- Formula 6

testing of pipe systems ured and water is added until the pres-
Below is the procedure for pressure tes- sure is again 1.3 x the nominal pres- a) pressure drop in percentage of initial
ting of pipe systems. The procedure is in sure class (testing pressure). pressure = 2%
accordance with the standard of the 6) The fall in pressure and the amount of b) water quantity in litres/metres = 0.02di
Danish Engineers Union: 'Tightness of water added must not exceed the fol- - 0.001 + ∆V
underground sewer systems" DS 455, lowing limits:
1st edition, January 1985. ∆V = 0.05 x d2 for PVC pipes
∆V = 0.08 X d2 for PE pipes
Before pressure testing the following di = inside diameter
must be observed:
1) End caps are mounted on all ends of After pressure testing the end caps are
the system. The end cap can be an demounted.
end socket or a blank flange. A 90˚C
bend, a ball valve and a 32 mm tensile
resistant coupler are mounted on the
end cap, for mounting of a 32 mm PE
pipe.
2) AII end caps must be anchored.
3) The system must be filled with water at
least 24 hours prior to the start of the
pressure test. Ensure that the system
is entirely ventilated.
4) During the first 6 hours the pressure in
the system must be 1.3 x the nominal
pressure class. This is very important
in order that the result of the test is not
misleading. This part of the test must Figure 25. Diagram of pressure testing of pipeline.
be documentable to the inspection
authorities.
5) There must be access to water on the
testing site.
6) Pressure testing against a valve is at
your own risk.

During pressure testing the following is to

be observed:
1) The actual pressure is measured and
water is added to the system if
required.
2) The system is exposed to a pressure
corresponding to 1.3 x the nominal
pressure class (testing pressure).
3) This pressure is maintained for 2
hours. Supplementary filling of water is
allowed.
4) During the following 60 minutes water
must not be added.

Laying Instructions
TEL. 41
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 PE Pressure Pipes
Anchorage

9. Anchorage

All examples shown in this chapter are Formula 8 Anchorage of bends

based on PVC, but are also applicable for The resulting force for bends can be cal-
PE pipes. The size of the axial force N = p x N1 culated as follows:
depends on the dimension and working
pressure (testing pressure) of the pipe where N1 = axial force at 1 bar [kN] Formula 9:
line and is calculated as follows: α
p = max. pressure occurring in R = 2 x N1 x p x sin —
Formula 7 pipeline [bar] possibly testing 2
pressure
π x dy x p
2
where N1 = axial force at 1 bar [kN]
N = ——————— (table 7)
104 x 4
p = max. pressure occurring in
where N = axial force [kN] pipeline [bar] possibly testing
dy = external pipe diameter [mm] pressure
PE
p = max. pressure occurring in
pipeline [bar] possibly testing α = angle of bend [degrees]
pressure
R = resulting force [kN]
Anchorage of tees, end
caps and valves Figure 26. Diagram showing anchorage
of tee Angle α 11˚ 22˚ 30˚ 45˚ 60˚ 90˚
Fittings exposed to shearing forces k 0.19 0.38 0.52 0.77 1.00 1.41
caused by internal water pressure, e.g.
bands, tees, end caps, reducers and Table of angle constants
valves must be anchored.
The resulting shearing force which the
The shearing force which the anchorage is anchorage is intended to withstand can
intended to withstand can be easily calcu- be easily calculated by using the figures
lated by using the figures in the table in the tables in the following simplified
below in the following simplified formula: formula:
Figure 27. Diagram showing anchorage
Outside Axial force at 1 of tee Formula 10
diameter [mm] bar N1 [kN]
40 0.13 R = k x p x N1
50 0.20
63 0.32 Where k = constant for resulting force
75 0.45 (see table of angle constants)
90 0.64
110 0.95 p = max. pressure occurring in
125 1.23 pipeline [bar] possibly testing
140 1.54 pressure
160 2.00
200 3.15 N1 = axial force at 1 bar [kN]
225 4.00
250 4.90
280 6.16
315 7.80
400 12.60
500 19.60
630 31.20

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PE Pressure
Anchorage
Anchorage block
Figure 28. Diagram of anchorage of bend
Figure 29. Diagram of anchorage of bend
When calculating the area necessary for
the determination of the size of the
anchorage, due consideration has to be
paid to the permissible earth pressure,
which in each individual case has to be
determined by geotechnical surveys. In
most cases it is sufficient to use the
following formula:
σ earth = 200 (kN/m2)
The person in charge of the project
should always make an appraisal of the
relevance of this value.
This width of an anchorage can then be
calculated by means of the following for-
mula:
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Formula 11
R The resulting force will then be:
b= R = 0.77 x 9 x 3.15 = 21.83 kN
h/ σ earth
Now the size of the concrete block can
be calculated by using formula 11:
where b = width of anchorage [m] R
b=
h = height of anchorage [m] hx σ earth
R = resulting force [kN]
σ earth is estimated at [kN/m ] 2
σ earth = permissible earth pres-
sure [200 kN/m2] The height is estimated at:
h = 0.2 (height of pipe)
It is a condition for the strength of the The minimum width must then be:
anchorage that the concrete is cast
against a solid wall of the pipe trench. It 21.83
may, however, sometimes be necessary b= = 0.55 m
to cast against carefully compacted fill. In 0.2 x 200
such case account should be taken in
the calculations of the lower strength of Anchorage of reducer
the fill.
The axial force for reducer is found by
The fitting in question must be protected means of formula 12:
from the damage by the concrete by an
intermediate layer of e.g. plastic film Formula 12
before casting takes place. π x (dy21 x dy22) x p
N=
Example of anchorage of 104 x 4
bend
Conditions: where dy21 = the outside diameter [mm]
of the largest pipe
- Ø 200 x 45º pressure pipe bend
- Testing pressure (maximum pressure) dy22 = the outside diameter [mm]
9 bar of the smallest pipe
Formula 10 is applied as follows:
R = k x p x N1
where k = 0.77 according to table of
angle constants
p = 9 bar
Figure 30. Diagram of anchorage of
N1 = 3.15 according to table of reducer
the previous page
Anchorage
43
 PE Pressure Pipes
Anchorage

Example of anchorage of
reducer

Conditions:

- Ø 200/110 reducer
- Testing pressure (maximum pressure) 9
bar

which is inserted in formula 12:

π x (2002 - 1102) x 9
N=
104 x 4

N = 19.72 kN

The anchorage (concrete block) is

calculated as follows:

h = (is estimated at) 0.2m

σ earth = (is estimated at) 200kN/m2

N
b=
hx σ earth

19.72
b=
0.2 x 200

b = 0.49 m

Figure 31. Diagram of anchorage of

reducer

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PE Pressure Pipes
Handling & Storage

10. Handling & Storage

Handling plastic piping Figure 33

systems
Wavin pressure pipes are supplied in pre-
packed bundles to ensure adequate pro-
tection during transport and storage. The
pipes are supplied with end caps protec-
ting the pipes effectively from dirt entering
the pipes.
Bearers must be placed on the truck
body.
Support the full length of the load.
Always load and unload properly.
Do not tip or throw the pipes from the
carrier.
Handling on site

Figure 34
Small-diameter pipes can easily be
carried without the use of auxiliary
equipment.

Figure 32. Pipes should be handled and
stored in bundles as delivered
from Wavin for as long as
possible.
Figure 35
Do not drag the pipes across the ground
and avoid sharp edges.

Transport
Vehicles for transporting pipes should be
selected in such a way that the pipes lie Figure 36
completely on the floor of the vehicle, Small-diameter pipes can be manually
without jutting out of the vehicle. Sagging placed in the trench.
is to be prevented. Impacts are to be
avoided under all circumstances,
particularly at temperatures near the
freezing point. To protect the pipes and
fittings from damage, they should not
grind against the load area of the vehicle Figure 37
or against the floor of the vehicle during Pipes in larger diameter may necessitate
transportation. Pipes and fittings should slings. Always use at least 2 slings.
be loaded and unloaded with extreme
caution and care. If hoists are used, then
pipe components may not be thrown
from the vehicle into the storage area.

Figure 38
Larger diameters may necessitate a
special lifting bar.

Handling & Storage

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Storage
Storage areas for pipes should be
without gravel and plain. Storage and
stock heights should be selected in such
a way, as to avoid damages or perma-
nent deformations. Pipes with large dia-
meters and small wall thickness should
be equipped with circular stiffeners. Point
and line supports for the pipes should be
avoided.
The recommendation for the permitted
stacking height for PE pipes not stored
on pallets is 1 m. Pipes should be
stacked in layers with sockets placed at
alternate ends of the stack to ensure their
support along the entire length.
If the pipes are stacked on pallets and
are secured against lateral movements,
the stacking height can be increased to
1.5 m. When spacing the pipes the
bearing width of the supports and tim-
bers respectively must be at least 7.5
cm. The distance between the supports
and timbers respectively should be 1-2
m. The outer supports and timbers
respectively are to be arranged 0.5-1.0 m
from the stack end.
The area where pipe components are
stored should provide as much protection
as possible. Pipes should be completely
protected from the effects of oil, solvents
and other chemical substances during
the storage period. The area where the
pipes are to be placed should be covered
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Handling & Storage
with sheeting or cardboard (including the
side supports) in order to avoid damage
caused by protruding rivets and nails.
The influence of weather on stored pipe
components should be kept to a mini-
mum, i.e. the pipe components should
be kept in a warehouse. If the pipes are
stored in the open (construction sites),
then they should be covered with colou-
red or black sheeting to protect them
from the influence of weather (for exam-
ple, UV rays). Wavin PE fittings and val-
ves are packed in PE plastic bags to pro-
tect them from ultraviolet radiation and
dust. We recommend removing the pipes
from the packing only shortly before
installation.
Moreover, one-sided heat exposure
caused by sunshine can lead to
deformations in the pipes.
Maximum permitted storage periods
should be adhered to (for example,
DVGW). The pipe components should be
used in the order of their manufacture
and delivery to ensure appropriate stock
turnover.
1,50 m
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PE Pressure Pipes
Notes

11. Notes

This document gives units of the interna- Dimensions and units

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

In this document, g is supposed to be 10 OD = Outside Diameter

m/s, the fault of approximately 2% being WT = Wall Thickness
neglected. DN means nominal diameter,
PN is nominal pressure.

Notes
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 PE Pressure Pipes
Notes

Pressure system dimensions Explanations of

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

PSI BAR (PN) Mpa Kpa

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

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PE Pressure Pipes
Notes

Notes
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Wavin PE Pressure Product and
Pipe Systems Technical Guide

Meeting your needs

Wavin PE Pressure Pipe Systems form part of a comprehensive
range of plastic pipe systems to provide intelligent solutions for
all building, construction and utilities projects

These include:
Above Ground Projects
Wavin Soil & Waste Systems
Wavin Rainwater Systems
Wavin Electrical Conduit Systems
Plumbing & Heating Projects
Wavin Hot & Cold Water Systems
Wavin Underfloor Heating Systems
Below Ground Projects
Wavin Sewer Systems
Wavin Inspection Chambers & Manholes
Wavin Road Gullies
Wavin Stormwater Infiltration Systems
Wavin Cable Duct Systems
Wavin Land Drainage
Pressure Pipe Projects
Wavin PE Pressure Systems
Wavin operates a programme of continual product development, and therefore reserves the right to modify or amend
Wavin PVC Pressure Systems the specification of their products without notice. All information in this publication is given in good faith, and believed to
be correct at the time of going to press. However, no responsibility can be accepted for any errors, omissions or incor-
Wavin Pipe Relining Systems rect assumptions. Users should satisfy themselves that products are suitable for the purpose and application intended.
05/2006

Wavin Overseas B.V. www.wavinoverseas.com

Rollepaal 19, 7701 BR,
P.O. Box 158, 7700 AD,
Dedemsvaart, The Netherlands
Phone: +31/523-624911
Fax: +31/523-624600
Email: wavin.overseas@wavin.com