3 O pen Trench Installation With Sand Bed
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Table of Contents 3.1 Procedure Description........................................................................................ 1 3.2 Product Description........................................................................................... 2 3.3 Quality Assurance for egeplast egelen® Pipes..................................................... 3 3.4 Technical Information......................................................................................... 5 3.4.1 Product Data Sheet for egelen® Drinking Water Pipes...........................................................................5 3.4.2 Product Data Sheet for egelen® Gas Pipes...........................................................................................6 3.4.3 Product Data Sheet for egelen® Sewage Pressure Pipes.........................................................................7
3.5 Installation Guidelines for egeplast egelen® Pressure Pipes................................... 8 3.5.1 General Information�������������������������������������������������������������������������������������������������������������������������8 3.5.2 Installation........................................................................................................................................8 3.5.3 Joining Techniques.............................................................................................................................8 3.5.4 Accessories.......................................................................................................................................8
3.6 RFP Forms......................................................................................................... 9 3.6.1 RFP Form for egelen® Drinking Water Pipe...........................................................................................9 3.6.2 RFP Form for egelen® Gas Pipe......................................................................................................... 10 3.6.3 RFP Form for egelen® Sewage Pressure Pipe....................................................................................... 11
3.7 Recycling and Environmental Protection.............................................................12
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3 O pen Trench Installation With Sand Bed
3.1 Procedure Description
Defined pipeline zone required When installing a pipeline by the open-trench method, the pipeline zone is precisely defined. The construction of the pipeline trench is subject to a number of regulations, including DIN 4124 „Excavations and Trenches“, which precisely stipulates the specifications for workspace width and installation. These ensure that the soil surrounding the pipe is prepared in such a way that the pressurised medium-bearing pipe is protected from external influences. DIN EN 805 and DVGW Directive W400-2 stipulate embedding the pipe in sand or fine gravel.
Fig 3-1
Surface notching Point loads
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DVGW Worksheet W400-2 stipulates for this purpose a maximum particle size of 22 mm for round materials and 11 mm for crushed stone sand and chip mixes. Only in this way can point or linear loads on the pipe caused by unsuitable materials in the pipe trench be prevented.
3 O pen Trench Installation With Sand Bed
3.2 Product Description
egelen® Drinking Water Pipes · Gas Pipes · Sewage Pressure Pipes · Industrial Pipes The egeplast egelen® pipe is a standard pressure pipe manufactured from high-density polyethylene (PE 100, optionally PE 80). In addition to its high dimensional accuracy, great flexibility and light weight are the quality characteristics of this pipe.
egeplast egelen® pipes are produced in sizes ranging from OD 16 mm to OD 1200 mm.
In addition to the advantages mentioned, egelen® pipes made of PE 100 allow:
egelen® pipes made of PE 100 (or PE 80) offer the following technical advantages:
• A reduction in wall thickness for an unchanged inside pressure load compared with PE 80, resulting in a saving in pipe material and a higher medium flow rate
• Long service life • High flexural creep modulus • High notched impact strength • Easy weldability • High resistance to rapid crack propagation • RAL/DVGW certified quality
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• Alternatively, an increase in the operating pressure with the same wall thickness • Alternatively, an increase in the safety margin egeplast egelen® pipes can also be supplied with an extremely resistant protective coating for use with trenchless installation techniques and renovation procedures. Please refer to Chapter 5 “Trenchless Installation and Renovation” and Chapter 6 “Detecting the installed Pipeline and Checking Integrity” for additional information.
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3 O pen Trench Installation With Sand Bed
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3.3 Quality Assurance for egeplast egelen® Pipes can be made from the PE raw material that can satisfy the requirements on the building site for gas or water supplies, and for sewage disposal. The European standards are different according to application: EN 12201 describes drinking water pipes; EN 1555, gas pipes; and EN 13244, sewage pipes. To allow a better assessment of the material, the DVGW has, in Worksheet GW 335, selected the parameters associat-
The quality of the PE piping produced is critically dependent not only on the raw materials used, but also on the techniques utilised in its production: Material Polyethylene has been continually developed since it was first used as a pipe material in 1957. A balanced property profile is important for application as a pipe material. A wide range of material properties is monitored so that a pipe
ed with the quality of the material (Table 3-1 (=Tab. 6 from GW 335)) and pipes (see Tab. 3-2 (=Tab. 7 from GW 335)), and hence with their approval for use in the areas of gas and water supply. Worksheet GW 335 describes the requirements for polyethylene piping which is assumed to be loaded solely by internal pressure; i.e. the piping is bedded in sand in an open trench installation.
Testing of the Materials PE 80 and PE 100 Property
Melt index
Requirement
as per specifications
Test Procedure EN ISO 1133:1999
Min. 1 x per week as well as on
Condition T
every change of material and on
5 kg, 190°C 10 minutes
every dimension check
Loss on drying
≤ 0.1%
Infrared method
per charge
Homogeneity
≤ grade 3
ISO 18553
per charge
Density
≥ 930 kg/m3
Colour
as per DVGW GW 335 Part A2 as per DVGW GW 335 Part A2
Resistance to weathering
Thermal stability Microbiology Fast crack growth Gas resistance Hygiene Odour and taste Slow crack growth
DIN EN ISO 1183-2, DIN EN ISO 1872-1
per charge regularly
Black as per ISO 6964,blue and
DIN EN 12201-1
yellow as per DIN EN 921 and fol-
DIN EN 1555-1
lowing DIN EN ISO 6259-1
>20 minutes at 200 C
DIN EN 728
per charge
DVGW W 270
approval testing
ISO 13477
1 x annually
DVGW GW 335 Part A2
approval testing
DIN EN 10204
approval testing
DIN EN 10204
per charge
Notch test DIN EN ISO 13479
annually
as per KTW recommendation as well as DVGW GW 335 Part A2 as per DVGW GW 335 Part A2 DIN EN 12201-1, DIN EN 1555-1 as per DVGW GW 335 Part A2 DIN EN 12201-1, DIN EN 1555-1 as per KTW recommendation as well as DVGW GW 335 Part A2 as per KTW recommendation as well as DVGW GW 335 Part A2 as per DVGW GW 335 Part A2 DIN EN 12201-1, DIN EN 1555-1
FNCT Slow crack growth
-
ISO 16770 80 C, 4 N/mm2, 2% Arkopal
Tab 3-1
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Frequency
regularly
No testing required by the regulatory codes
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3 O pen Trench Installation With Sand Bed
Production egeplast is a member of the Quick Switch partnership. The QuickSwitch system, patented by egeplast, allows the external diameter of the extruded piping to be varied accurately over multiple dimensions during the running extrusion process. Furthermore, it works with cooling sections of up to 85 m length, which leads to extremely
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gentle cooling of the pipe. Only in this way is it possible to guarantee compliance with the narrow tolerances needed for electrofusion welding of moulded fittings. This has a similarly positive influence on the internal tensions created in the pipe during the manufacturing process, and hence also its shrinkage. A maximum of 3% change after
warm storage is specified in Worksheet GW 335. The shrinkage of egeplast pipes lies at ca. 1%. Adherence to dimensions and tolerances, described in the current body of regulations, is an absolute must. For this reason, egeplast operates with hundred percent ultrasound monitoring of the produced pipes.
Additional Testing of the Finished Piping Property
Requirement
Test Procedure
Frequency
as per DVGW GW 335 Part A2 Labelling
DIN EN 12201-2
visual inspection
regularly every 2 hours
DIN EN 1555-2 Texture
as per DVGW GW 335 Part A2
visual inspection
regularly every 2 hours
Colour
as per DVGW GW 335 Part A2
visual inspection
regularly every 2 hours
Warm storage
as per DVGW GW 335 Part A2
Homogeneity
as per DVGW GW 335 Part A2
visual inspection
1 x per week
Thermal stability
>20 minutes at 200 C
DIN EN 728
1 x per week
as per DVGW GW 335 Part A2
80 C, 165 h;
on every start
DIN EN 12201-2
PE 80 s = 4.6N/mm2
at least 1 x per week
DIN EN 1555-2
PE 100 s = 5.5N/mm2
Internal pressure creep test
Melt index
Hygiene
max. 20% variation from the raw material as per KTW recommendation as well as DVGW GW 335 Part A2
1 x per week
EN ISO 1133:1999
on every change and on every
Condition T
dimension check
5 kg, 190°C 10 minutes
at least 1 x per week
DVGW W 270
1 x annually
FNCT Slow crack growth
-
ISO 16770 80 C, N/mm2,
-
2% Arkopal HESSEL Point loading test
-
PA PLP 2.2-2 2004-05 80 C, 4 N/mm2, 2% Arkopal
Tab 3-2
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3 O pen Trench Installation With Sand Bed
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3.4 Technical Information 3.4.1 Product Data Sheet for egelen® Drinking Water Pipes
Dimension:
OD 16 mm – OD 1200 mm
Pipe construction:
PE 100: Royal blue for SDR 17 and SDR 11 or black with blue stripes
Alt. PE 80: Black with blue stripes for SDR 11 and SDR 7.4
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Material:
PE 100, alternatively PE 80
Approval:
DVGW, KIWA, DS, SVGW, ÖVGW, SIS, DIN-Gost, Belgaqua,WIS, DWI, KIWA-Gas, IGNG, VUSAPL-NITRA, SFS
Standards:
DIN EN 12201, DIN 8074/75
Welding group:
003–010
Finish:
With smooth ends
Labelling:
With coloured metre marking
Delivery form:
• • • •
Regulatory code/installation methods:
DVGW W400-1/2; DIN EN 805; DIN 4124
6, 12 or 20 m straight lengths (up to max. 30 m) Bundled coils of 100 m (up to OD 160/180 mm) Custom lengths on request Larger lengths on drums
3 O pen Trench Installation With Sand Bed
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3.4.2 Product Data Sheet for egelen® Gas Pipes
Dimension:
OD 16 mm – OD 1200 mm
Pipe construction:
PE 100: Orange-yellow for SDR 17, SDR 17.6 and SDR 11 or black with orange stripes
Alt. PE 80: Black with yellow stripes or yellow for SDR 17, SDR 17.6 and SDR 11
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Material:
PE 100, alternatively PE 80
Approval:
DVGW, KIWA, DS, SVGW, ÖVGW, SIS, DIN-Gost, Belgaqua, WIS, DWI, KIWA-Gas, IGNG, VUSAPL-NITRA,SFS
Standards:
DIN EN 1555; DIN 8074/75
Welding group:
003–010
Finish:
With smooth ends
Labelling:
With coloured metre marking
Delivery form:
• • • •
Regulatory code/installation methods:
DVGW G 472; DIN EN 805; DIN 4124
6, 12 or 20 m straight lengths (up to max. 30 m) Bundled coils of 100 m (up to OD 160/180 mm) Custom lengths on request Larger lengths on drums
3 O pen Trench Installation With Sand Bed
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3.4.3 Product Data Sheet for egelen® Sewage Pressure Pipes
Dimension:
OD 16 mm – OD 1200 mm
Pipe construction:
PE 100: Black with brown stripes for SDR 33 to SDR 7.4
Alt. PE 80: Black with brown stripes for SDR 33 to SDR 7.4
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Material:
PE 100, alternatively PE 80
Approval:
The egelen® sewage pressure pipes bear the DIN Certco DINplus mark of conformity in accordance with ZP 14.3.1.
Standards:
DIN EN 13244; DIN 8074/75
Welding group:
003–010
Finish:
With smooth ends
Labelling:
With coloured metre marking
Delivery form:
• • • •
Regulatory code/installation methods:
Recommended: by analogy to DVGW W400-1/2; DIN EN 805; DIN 4124
6, 12 or 20 m straight lengths (up to max. 30 m) Bundled coils of 100 m (up to OD 160/180 mm) Custom lengths on request Larger lengths on drums
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3 O pen Trench Installation With Sand Bed
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3.5 Installation Guidelines for egeplast egelen® Pressure Pipes Supplement to the installation instructions for PE pressure pipes A 135 and A435 from the Kunststoffrohrverband e.V. in Bonn
3.5.1 General Information
3.5.2 Installation, Open Trench Method With a Sand Bed
egeplast egelen® pipes are manufactured according to EN standards and DVGW directives and carry, depending on their application, the DVGW registration number or the DIN Certco mark of conformity.
Pipes are to be checked for sound condition and full laOpen with Sand Bed belling in accordance with the DVGW regulations before laying in the pipe trench. Grooves, scratches, and laminar abrasions on the pipes of up to 10 % of the minimum wall thickness are permissible. Pipes with damage exceeding this extent may not be installed.
Scope of application The installation instructions apply to soil covered egeplast egelen® pipes made of HDPE in accordance with DIN 8074 and DIN 8075 for use as drinking water and sewage pressure pipelines, and as gas pipelines. The pipe joints and pipeline components must be rated for use with their respective operating pressures.
The standards for assessment of the fill base are set by ZTVA-StB 97 from the German Road and Transportation Research Association in Cologne as well as by DIN 4022 and DIN 18196.
3.5.3 Joining Techniques
3.5.4 Accessories
Weldability of PE 80/PE 100 pipes with moulded fittings Welding together of egeplast PE 80/ PE 100 pipes, and with standardised moulded fittings, is possible for HDPE using the
The market offers a complete range of accessories for pipelines made of polyethylene. Adapters from PE to the various materials used in pipeline networks are available from multiple manufacturers. In principle, the alternative of creating a connection using a flanged joint is always available.
• Butt fusion welding method • Electrofusion welding method according to the parameters given by the DVS Guideline 2207, Part 1, Edition 09/2005. Proof of suitability as required by the DVS guidelines (weld creep factor in accordance with DVS 2203-4) has been provided.
For detailed information on moulded fittings and adapters see Chapter 1.7 „Technical Fundamentals – Connecting to the Network“
For detailed information on joining techniques see Chapter 1.5 “Technical Fundamentals – Joining Techniques”
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The pipe trench is to be dug out in accordance with DIN 4124 (trench profile and sheeting) and DIN 1998 (layout of pipelines in public areas). The minimum covering for gas pipelines is 0.6 to 1.0 m, although the covering can be reduced to 0.5 m for sections up to ca. 2.0 m long which do not carry a heavy load (front gardens, pavements). Drinking water and sewage pressure pipelines are to be laid at a depth of 1.0 to 1.8 m (according to climate and ground conditions) safe from frost. Applicable to the construction of water conduits is, furthermore, DVGW Worksheet W400-2.
3 O pen Trench Installation With Sand Bed
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3.6 RFP Forms 3.6.1 RFP Form for egelen® Drinking Water Pipe Preliminary note: Drinking water pipe in accordance with DIN 8074/8075, DIN EN 12201 made of PE 100, pipe colour royal blue or black with blue stripes, verified in accordance with DVGW GW 335 Part A2. All necessary pipeline joints created by means of either electrofusion welding or butt fusion welding are to be made according to the requirements of the applicable DVS technical guidelines. The piping is to be stored and transported on the building site in compliance with the KRV guidelines.
Product:
egeplast egelen® drinking water pipe PE 100 or equivalent
Manufacturer:
egeplast Werner Strumann GmbH & Co. KG Robert-Bosch-Str. 7 D-48268 Greven Tel.: +49.2575.9710-0 Fax: +49.2575.9710-110 e-mail:
[email protected] http://www.egeplast.de
Specification of services:
egeplast egelen® drinking water pipe with dimensions:
mm, SDR
O delivered as straight lengths of 6 / 12 m
O delivered as bundled coils in lengths of m
eliver running metres and install professionally D according to DIN and appropriate installation guidelines as drinking water pipe: € / running metre
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3 O pen Trench Installation With Sand Bed
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3.6.2 RFP Form for egelen® Gas Pipe Preliminary note: Gas pipe in accordance with DIN 8074/8075, DIN EN 1555 PE 100, pipe colour yellow-orange or black with yellow stripes, verified in accordance with DVGW GW 335 Part A2. All necessary pipeline joints created by means of either electrofusion welding or butt fusion welding are to be made according to the requirements of the applicable DVS technical guidelines. The piping is to be stored and transported on the building site in compliance with the KRV guidelines.
Product:
egeplast egelen® gas pipe PE 100 or equivalent
Manufacturer:
egeplast Werner Strumann GmbH & Co. KG Robert-Bosch-Str. 7 D-48268 Greven Tel.: +49.2575.9710-0 Fax: +49.2575.9710-110 e-mail:
[email protected] http://www.egeplast.de
Specification of services:
egeplast egelen® gas pipe with dimensions:
mm, SDR
O delivered as straight lengths of 6 / 12 m
O delivered as bundled coils in lengths of m
Deliver running metres and install professionally according to DIN and appropriate installation guidelines as gas pipe: € / running metre
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3 O pen Trench Installation With Sand Bed
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3.6.3 RFP Form for egelen® Sewage Pressure Pipe Preliminary note: Sewage pressure pipe in accordance with DIN 8074/8075, DIN EN 13244 made of PE 100, pipe colour black with dark brown stripes, verified in accordance with DIN Certco ZP 14.3.1 and labelled with the DIN Certco DINplus mark of conformity. All necessary pipeline joints created by means of either electrofusion welding or butt fusion welding are to be made according to the requirements of the applicable DVS technical guidelines. The piping is to be stored and transported on the building site in compliance with the KRV guidelines.
Product:
egeplast egelen® sewage pressure pipe PE 100 or equivalent
Manufacturer:
egeplast Werner Strumann GmbH & Co. KG Robert-Bosch-Str. 7 D-48268 Greven Tel.: +49.2575.9710-0 Fax: +49.2575.9710-110 e-mail:
[email protected] http://www.egeplast.de
Specification of services:
egeplast egelen® sewage pressure pipe with dimensions:
mm, SDR
O delivered as straight lengths of 6 / 12 m
O delivered as bundled coils in lengths of m
Deliver running metres and install professionally according to DIN and appropriate installation guidelines as sewage pressure pipe: € / running metre
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3 O pen Trench Installation With Sand Bed
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3.7 Recycling and Environmental Protection
Fig 3-2
Polyethylene is an organic material and consists only of carbon and hydrogen. It has a wholly neutral impact on the environment. PE, being a thermoplastic, can be remelted an almost unlimited number of times and processed into new products. Pipe off-cuts and discarded plastic pipe material, which, for example, accumulate during the installation of plastic pipe systems, should therefore be recycled if at all possible.
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Fig 3-3: Recycling box
At the start of 1994, the Kunststoffrohrverband (KRV), together with the Gütegemeinschaft Kunststoffrohre (GKR), had already introduced a national collection and recycling system for plastic materials, which is free of charge for the trade and its customers and incorporates an obligation to take back these materials. This environmentally conscious system eliminates dumping or incineration together with the high costs which arise from disposal by these methods.
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Recycling boxes are provided on a loan basis to the customer as collection containers. The plastic pipe material, at least partially cleaned, is then thrown into these boxes. Once the boxes have been filled, their collection and exchange for empty boxes is arranged. Only boxes which are filled exclusively with plastic pipe material are taken. The recycling boxes are then brought, via regional collection points, to a recycling plant in which the collected pipe material is sorted, cleaned, and cut into small pieces to be employed subsequently for other uses.
