HDPE PIPELINES

4-Feb-20 This is a proprietary document of Saisanket 1

 JOINTING OF HDPE

• Fusion welding is commonly used in HDPE and is a permanent type of joint

• The pipes shall be brushed through out to remove any soil deposited or stone their in

• Pipes shall be laid in dry condition and under no circumstances they shall rest on slushy bedding

• Clearance of required depth & width on both sides shall be provided, at the joint which shall be refilled from
sides after the joint is made

• For road crossing or river crossing the pipe shall be laid 2 meter below the bed level and encasing should be
done

• Pipe after transporting to the exact place should be cut square by the hacksaw blade

• The face of the pipe should be slightly scrapped prior to the fusion welding to remove oxidized layer

• Ensure the leveling of pipes is maintained at the time of fusion welding

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 JOINTING OF HDPE

• The heating mirror / pan should be heated up to 200 deg. c and the surface of the pan should be 210 + or – 5
deg. C

• The heating pan should be metallic plate which is heated up to the required temperature either by electrical
coil embedded inside or by blow torch

• The fusion welding of pipe should be held in either side of the heating mirror / pan with Teflon paper on each
side

• The contact pressure of 0.2 kg/cm2 in either side if the pipe should be maintained

• Initial heating time for achieving the molten rim, varies from 1 to 5 min depending on the pipe wall thick &
size.

• Pipes should be removed from the heating mirror / pan, when the rim of the molten material is formed and
ensure that the rim formation is not excessive.

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 JOINTING OF HDPE

• Immediate joint should be made by the application of moderate pressure of approx. 1 to 2 kg/cm2 for 2 to 3
sec.

• while joining, the pressure should be maintained until the joint is lukewarm

• After the pressure is relieved, the joint should be allowed to cool completely

4-Feb-20 This is a proprietary document of Saisanket 4

 JOINTING OF HDPE

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 JOINTING OF HDPE

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 JOINTING OF HDPE

• HDPE Pipes butt fusion welding.mp4

• HDPE JOINTING BY ELECTROFUSION.mp4

4-Feb-20 This is a proprietary document of Saisanket 7

 HYDRO TESTING

• After Completion of each section of pipeline, it shall be tested for water tightness before being covered in.

• This can be done by closing each end by means of valve, blank flange, cap or plug and filling the pipe with
water.

• The pressure shall be raised gradually by means of a hydro testing pump till the pressure is at least one and
half times the working pressure.

• A pressure to be specified by the authority for a durationof one hour.

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 HYDRO TESTING

Sample Test Medium

S.No IS No. Pipe Sample Details Test Duration
Size Temp. of heating

For HDPE pipes

110+2 60 /120/240 minutes

HDPE Pipes for 200±20m
1. IS 4984:1995 ( for 8mm/8 to 16mm/16mm Air
Water Supply m
and above thick pipe)

IS 14151 : (part- HDPE pipe for 200±20m 110+2

2. 60 min Air
I) 1999 Sprinkler irrigation m

Irrigation 200±20m
IS 12786:1989 100+2 60 min Air
3. Equipment-PE Pipes m
for Irrigation Laterals

4-Feb-20 This is a proprietary document of Saisanket 9

 HYDRO TESTING

4-Feb-20 This is a proprietary document of Saisanket 10

 LAYING AND BACKFILLING OF HDPE PIPES

4-Feb-20 This is a proprietary document of Saisanket 11

 LAYING AND BACKFILLING OF HDPE PIPES
• Foundation - A foundation is required only when the native trench bottom does not provide a firm working
platform for placement of the pipe bedding material.

• Initial Backfill - This is the critical zone of embedment soil surrounding the pipe from the foundation to at least 6
inches over the pipe.

• Bedding - In addition to bringing the trench bottom to required grade, the bedding levels out any irregularities
and ensures uniform support along the length of the pipe.

• Haunching - The backfill under the lower half of the pipe (haunches) distributes the superimposed loadings.

• Primary Initial Backfill - This zone of backfill provides the primary support against lateral pipe deformation. To
ensure such support is available, this zone should extend from trench grade up to at least 75 percent of the pipe
diameter.
 When the pipe will be permanently below the ground water table, the primary initial backfill should extend
to at least 6 inches over the pipe.

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 LAYING AND BACKFILLING OF HDPE PIPES

• Secondary Initial Backfill - The basic function of the material in this zone is to distribute overhead loads and to
isolate the pipe from any adverse effects of the placement of the final backfill.

• Final Backfill - As the final backfill is not an embedment material, its nature and quality of compaction has a
lesser effect on the flexible pipe.
 However, arching and thus a load reduction on the pipe is promoted by a stiff backfill.
 The final backfill should be free of large rocks, organic material, and debris to avoid concentrated loadtings.

• Concrete slabs over pipes - when pipes are laid below roads (which may be subjected to heavy traffic loads),
trenches should be covered with reinforced concrete slabs

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 LAYING AND BACKFILLING OF HDPE PIPES

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 LAYING AND BACKFILLING OF HDPE PIPES

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 CHECKLIST FOR HDPE LAYING AND JOINTING

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