mscl handling instal manual 2007

S I N T A K O T E ® S T E E L P I P E L I N E S

Handling & InstallationReference Manual

SINTAKOTE®

Steel pipelinesystems

S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S

5

Section Page1. Transportation ........................................................................................12

2. Site Preparation ......................................................................................13

3. Unloading and Handling ........................................................................14

4. Stacking and Storage ............................................................................16

5. Stringing..................................................................................................19

6. Trenching ................................................................................................21

7. Bedding ..................................................................................................23

8. Laying and Jointing ................................................................................24

9. Backfilling................................................................................................40

10. Fittings ....................................................................................................43

11. Anchorage of Pipelines ..........................................................................44

12. Hydrostatic Field Test ............................................................................46

13. Commissioning Water Pipelines ............................................................48

AppendicesAPPENDIX A

Field Repair and Joint Reinstatement of SINTAKOTE ..................................49

APPENDIX B

Field Repair and Joint Reinstatement of Cement Mortar Lining ....................58

APPENDIX C

Field Application of Electrical Cables to CP Lugs ..........................................61

APPENDIX D

General Data ..................................................................................................63

Contents

DisclaimerThis manual has been prepared by Tyco Water to assist qualified Engineers

and Contractors in the use of the Company’s product, and is not intended

to be an exhaustive statement on pipeline design, installation or technical matters. Any conclusions, formulae and the

like contained in the manual represent best estimates only and may be based on assumptions which, while

reasonable, may not necessarily be correct for every installation.

Successful installation depends on numerous factors outside the Company’s control, including site preparation and

installation workmanship. Users of this manual must check technical developments from research and field

experience, and rely on their knowledge, skill and judgement, particularly with reference to the quality and suitability

of the products and conditions surrounding each specific installation.

When pipeline construction is being carried out for any water authority, as Principal, that water authority’s standards,

specifications or drawings, if at variance to any recommendation made in this manual, override the recommendations

made in the manual.

The Company disclaims all liability to any person who relies on the whole or any part of this manual and excludes all

liability imposed by any statute or by the general law in respect of this manual whether statements and representations

in this manual are made negligently or otherwise except to the extent it is prevented by law from so doing.

The manual is not an offer to trade and shall not form any part of the trading terms in any transaction. Tyco Water

trading terms contain specific provisions which limit the liability of Tyco Water to the cost of replacing or repairing

any defective product.

© Copyright Tyco Water Pty Ltd

This manual is a publication of TycoWater Pty Ltd, and must not becopied or reproduced in whole or partwithout the Company’s prior writtenconsent. This manual is and shallremain the Company’s property andshall be returned to the Company onits request. The Company reservesthe right to make changes to anymatter at any time without notice.Fifth edition published 2007

4

S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S

List of Figures & Tables Figure 1.1- Securing pipes for transport..........................................................................12

Figure 3.1- Twin slings or spreader bar ..........................................................................15

Figure 4.1 - Pipe support ................................................................................................16

Table 4.1 - Minimum pipe support area ..........................................................................16

Figure 4.2 - Pipe bearing area ........................................................................................17

Figure 4.3 - Stacking pipes using timber bolsters.............................................................17

Figure 5.1 - Single stringing of pipes................................................................................20

Figure 5.2 - Multiple stringing of pipes ............................................................................20

Figure 6.1 - Trench excavation machinery ........................................................................22

Figure 7.1 - Bedding layer minimum depth ........................................................................23

Figure 7.2 - Spreading bedding ......................................................................................23

Figure 8.1 - Jointing systems ..........................................................................................24

Figure 8.2 - Pulling SINTAJOINT pipes “home” to joint ......................................................25

Figure 8.3 - Fitting rubber rings into sockets ....................................................................27

Figure 8.4 - Alignment of pipes during jointing..................................................................28

Table 8.1 - Permissible misalignment and offsets during entry ........................................29

Figure 8.5 - Temporary construction and permanent SINTAJOINT deflection ....................30

Figure 8.6 - Axial offset measurement created by joint deflection ......................................31

Figure 8.7 - External inspection of assembled SINTAJOINT ..............................................32

Figure 8.8 - Welded ball and socket or slip-in joint field assembly ....................................33

Figure 8.9 - Raised face type flanges ..............................................................................34

Figure 8.10 - Matched o-ring type flanges ........................................................................34

Figure 8.11 - Star pattern tightening sequence ..................................................................34

Table 8.2 - Recommended gasket composition for transport of general domestic liquids including brine and sewage ..........................................................................35

Table 8.3 - Recommended Bolt Torques for Steel Flange Class 14 (AS4087 Fig B7) ......36

Table 8.4 - Recommended Bolt Torques for Steel Flange Class 21 (AS4087 Fig B8) ......37

Table 8.5 - Recommended Bolt Torques for Raised Face Steel Flange Class 35 (AS4087 Fig B9) ..........................................................................................38

Figure 9.1 - Zones of backfill and compaction..................................................................40

Figure 9.2 - Ring deflection limits ....................................................................................42

continued...

Contents (continued)

66 7

List of Figures & Tables (continued)

Figure 10.1 - Common fittings - welded pipelines ..............................................................43

Figure 10.2 - Common fittings - SINTAJOINT pipelines ......................................................43

Figure 11.1 - Anchor blocks for horizontal thrust restraint....................................................44

Figure 11.2 - Anchor blocks for vertical thrust restraint ......................................................45

Figure 11.3 - Pier support for above ground SINTAJOINT pipelines ....................................45

Figure 12.1 - Static head allowance for hydrostatic test with alternative pressure gauge locations..............................................................................46

Figure A.1 - Flow chart for determining appropriate SINTAKOTE repair method..................49

Figure A.2 - Joint region for Drader welding repair ..........................................................53

Figure A.3 - Drader gun assembly ..................................................................................54

Figure A.4 - Drader gun tip selection................................................................................55

Figure A.5 - Build up of material on cut end ....................................................................56

Figure A.6 - Care required when trimming ........................................................................56

Figure B.1 - Typical cement mortar lining crack greater than 2mm.....................................60

Figure B.2 - Enlarge crack to 4 - 6mm ............................................................................60

Figure B.3 - Completed repair ........................................................................................60

Table D.1 - SINTAKOTE Thicknesses..............................................................................63

Table D.2 - Cement Mortar Lining (CML) Thickness ........................................................63

Table D.3 - SINTAKOTE Steel Pipe Bores and Weights ..................................................63

Table D.4 - Manufacturing test pressure and rated pressure of MSCL pipes ....................67

Contents (continued)

S I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E SS I N T A K O T E ® S T E E L P I P E L I N E S

Risk & Safety Tyco Water is a strong advocate of Safety in the Workplace and believes that safety is paramount

All contracts and installers should commit to providing a work enviornment where everyone in the

The safe handling and installation of the SINTAKOTE Pipeline System in all applications relieson all personnel having a high level of safety awareness, reducing risk and improving site preparations

Steps to SafetyResponsibilities for Workplace safetyBe aware who has specific responsibilities

Plan to Work SafelyIdentify tasks and procedures, which control the risks arising from work activities

Involve EmployeesDisplay information in your workplace concerning health & safety. All employees should talk about ways to contribute to decisions that affect their safety in the workplace.

Develop ProceduresIdentify hazards in your workplace and assess any risks associated with them. (Mitigate these hazards through developing processes to eliminate or control).

Inform and Train EmployeesInform employees about hazards in their job

Monitor and ReviewAdjust, review and address any workplace or legislative changes. Processes change, staff changeand so may the risks.

Plant & EquipmentRegularley assess, inspect equipment and maintain records.Ensure appropriate Licenses are held for Plant in use

The above steps may be undertaken throughout and continued through the On-Site Inductions,Toolbox Meetings, or Site Assessments.

Remember you may have Principal Contractor's obligations whereby you may be responsible for:

Injury or accidents to members of the public; employees and other on site contractors, at or neara construction site or workplace.

in all that we do.

workplaced is safe at all times and recognise people as their greatest asset.

and planning.

9

SINTAKOTE Training Program

The SINTAKOTE(R) Quality Pipeline Installation Program was introduced by Tyco in 1989 and, to date, over 4,000 Water Industry personnel have participated. This program assesses individuals

through compentency-based training and assessment, the application of an adherence to Quality, Safety, Environmental and Risk Systems.

In line with Tyco Water's commitment to continuous improvement, the program is accredited by theVocational Education and Training Board of NSW (VETAB NSW).

The program has been running for many years and is recognised as an Industry Leader. The Accreditation can be seen as a QA measure to ensure training for steel pipeline systems meets the most

appropriate specifications.

The basis for the Program and the Accreditation is the Tyco Water Handling and Installation Manual

and the Pipeline Installation Quality System, commonly known as the PIQS Manual.

Tyco Water Training & Auditing - Registered Training Organisation

Services -On-Site Auditing

Technical & Systems Support

Pre Qualification of Installers

On Site and Off Slite Training

Benefits

To Customer -Confidence in installers

Quality Installation

Reduce Unscheduled Maintenance

Traceability

Confidence in Asset Performance

Asset Longevity

Lower risk rating

To Installer -Certification of workersAbility to tender for more work

Lower risks

Increase efficiencies

Confidence in work

Less Re-work

Lower Injury Rates

8


10

Tyco Water embraces environmental protection and ensures its operations comply withrelevant environmental legislation.

Accordingly, Tyco Water as well as SINTAKOTE pipeline Installers and Contractors have a

You are expected to take all reasonable and practical measures to ensure that:-n Waste (spoil, concrete, off-cuts, etc) is minimised and disposed of in the correct manner

Environmental

n Water quality is not affected and contaminated run-off from site is prevented.

Risk Management.

n Soil erosion and sediment control is reduced

n Soil does not become contaminated (either from imported fill or excavation material.

and to assess the likelihood and severity of harm that may arise from such hazards. The

n Care is taken when handling and using hazardous substances

Australian Risk Management Standard AS 4360 contains greater details regarding the Risk

n The effect on air quality is minimised, through dust and pollution control measures.

Legislation in all states and territories requires an employer to identify all hazards in their workplace

n Mininimise disturbance to existing flora and fauna. Restore vegitation on completion of the works.

Management Process.

.

n Disruptions to surrounding services are to be minimised.

n Noise emissions are kept within required limits.

n Traffic and the movement of plant & equipment around the site does not impact the environment.

and doing something about it.

n Vibration to adjacent buildings and area should be minimised

Risk Management mean Looking at the Work and ProcessesYou Are About to Undertake

n Impact on heritage and archaeological sites should be minimised.

that could cause injury (entrapment), Making a Judgement on the Consequence and

n Report any environment incidents to environmental authorities or units.

Likelihood of what could happen as a result (death or injury to persons in an excavation),

Further details can be gained from state government, Environment Agencies, LocalCouncils and also from industry bodies..

responsibility to ensure your work activites do not harm the environment.

,

.

.

.


11

This manual has been prepared by

Tyco Water Pty Ltd.

It is intended to provide guidance on the

field practices of handling and installation of

SINTAKOTE steel pipelines.

Adherence to these guidelines should

ensure that the SINTAKOTE steel pipeline

system will have the capacity to perform in

excess of one hundred years.

There may be aspects of handling and

installation not covered in this manual which

may become subject to revision. For this

reason and in the interests of continuous

improvement, feedback on the manual

is encouraged.

Inquiries or contributions should be directed

to the Manager Marketing,

Steel Pipeline Systems,

Tyco Water,

PO Box 141,

Fairfield NSW 1860

Australia.

Or email [email protected]


1. Transportation S I N T A K O T E ® S T E E L P I P E L I N E S

12 | C H A P T E R 1

Secure the loadAll pipes must be secured by straps or other

suitable means to prevent movement during

transit and be in compliance with all local and

state regulations regarding load restraint.

Protect the pipe and coatingFactory installed toms are installed in some

pipes sizes and should be maintained in place

until after installation.

All supports, restraints and packing bearing on

pipe surfaces should be covered or wrapped

with material suitable to prevent chafing and

shock damage during transit.

In the case of rail transport, end protection

should be provided against shunting shocks.

Rubber mats, carpet etc. are suitable for this

purpose.

If bolsters are utilised only two per pipe length

should be used. Each should be placed 0.2

to 0.25 of the length from each pipe end

(outside quarter points). See Figure 1.1

The width of bolster must provide sufficient

area of support to protect the pipe coating.

A minimum bolster width of 150mm is required.

Double scalloped bolsters should be used to

separate layers of stacked pipe and pipes in the

same row spaced so that they do not touch.

Scallops must be cut to suit the outside

diameter of the pipe and have a minimum

saddle angle of 90 degrees.

The bottom bolsters should be securely

anchored to the floor or side of the road truck

or rail carriage. The load should be strapped

securely at a minimum of two locations, not

more than 500 mm from the bolsters and

using webbing straps with a minimum lashing

capacity of 2000kg. Multiple straps may be

necessary at each location. See Figure 1.1.

The strapping should be securely anchored

with approved ratchet type devices and

should be checked for tension at regular

intervals not exceeding 300 kilometres of

travel. Chains shall not be used to tie down

pipes or piles.

500mm

Bolster locations0.2 to 0.25 of the pipe length from each end

500mm

Figure 1.1 Securing pipes for transport

PPE is it on

This may be varied to suit vehicle loadrequirements.

P P E i s i t o n

C H A P T E R 2 | 13

Good site preparation maximises safety and

can save time and money

Site checksWhile preparing sites remember to check for :

Vehicle access� road conditions

� warning signs

� traffic control

� load limitations

� all weather access

Storage compounds� convenience of location

� security

� site dunnage availability

� protection from weather

Stacking areas� uneven surfaces that may require grading

� stability in bad weather

� clear of grass in case of fire

� overhead power lines

� other services

General � local traffic

� overhead powerlines

� location of other services

2. Site Preparation

Spreader bar


14 | C H A P T E R 3

R e m e m b e r p u b l i c s a f e t y a t y o u r s i t e , e v e n w h e n y o u a r e n o t t h e r e !

Personnel involved in unloading and handling

should wear personal protection equipment as

required by the Occupational Health and Safety

Act. Such as hardhat, safety shoes, safety

glasses, high visibility vest and other equipment.

Attention to the following items improves

efficiency of the operation, maximises safety

and minimises risk of damage.

Steel pipes are not susceptible to breakage but

poor handling can result in damaged coatings

and/or linings and damage to the pipe ends.

Damage to pipeline components will be

prevented by;

� adequate support and restraint during

transportation to site.

� proper use of handling equipment

� use of suitable handling equipment

� correct site storage

� unloading on even ground

� correct handling of load

When factory fitted cathodic protection (CP)

lugs are provided, extra care must be taken

to ensure that the lugs are not damaged and

that pipes are not bumped together as the

lugs may damage coating on adjacent pipes.

Before unloadingChoose a central storage site for general use,

storage of small components, gaskets, etc.

Choose and prepare suitable pipe storage

sites along the pipeline route.

If possible, select unloading and storage

areas which are clear of overhead powerlines.

Make sure the truck is on level ground before

releasing the straps.

Unloading(See also Section 5: Stringing)Immediately upon receipt, all items should be

visually examined for damage to;

� the pipe itself, particularly the ends

� cement mortar lining

� external coating

� rubber rings

� lubricant containers

All repair work should be carried out promptly.

Refer Appendices A: Field repair and joint

reinstatement of SINTAKOTE and B: Field

repair and joint reinstatement of cement

mortar linings.

Check that the correct quantities of materials

have been received.

Unload the truck evenly to keep it stable.

Lifting operationsAll lifting operations must meet legal and

occupation, health and safety requirements

applicable to the site.

Qualified personnel must be employed for

crane operation.

When unloading by mobile crane, a licensed

dogman must be present.

Lifting should be done smoothly without

sudden jerking motions. Pipe movement

should be controlled by use of guide ropes

and care taken not to bump other pipes or

equipment. See Figure 3.1.

Lifting and placing must be carried out so that

the stability of the pipe stack, crane or vehicle

is maintained.

3. Unloading and Handling

Twin sling

Guide ropes

Guide ropes

Figure 3.1 Twin slings or spreader bar

C H A P T E R 3 | 15

When conditions are suitable, forklifts

may be used. The contact surfaces of

the tynes must be protected with thick

rubber with a minimum durometer hardness

(Shore D) of 45.

Choosing equipmentWhen choosing lifting equipment consider

� pipe weights

(Appendix D: General data; Table D.3)

� type of stacking

� outreach

� site conditions

AccessoriesSlingsPipes should be handled one at a time.

R e m e m b e r p u b l i c s a f e t y a t y o u r s i t e , e v e n w h e n y o u a r e n o t t h e r e !

Use twin slings, spreader bar or other

approved lifting devices. See Figure 3.1

Slings and lifting devices must comply

and be used in accordance with the

appropriate safety requirements.

The slings shall be of nylon or synthetic

material of sufficient width that shall not

damage the coated surface of the pipe or

pipe fitting.

Vacuum Lifting DevicesVacuum lifting devices are available to lift

pipes. These should be used in accordance

with the manufacturer’s specifications.

HooksHooks should not be used for lifting pipes

or fittings.

It is recommended that pipes be supported on

sawdust filled bags or sand mounds. The

supports should be positioned to ensure that

each pipe is stable. For long term storage, sand

mounds should be protected from erosion.

The entire pipe must be kept clear of the

ground to protect the coating from damage.

It is recommended that pipes be separated

from each other for ease of inspection and to

minimise the potential for damage during

handling.

Stacking heights forlong term storagePipes 610 mm OD and larger should be

stored in single layers only. Pipes less than

610 mm OD may be stacked. To prevent

damage to the SINTAKOTE and for safety and

handling reasons pipe stacks must not

exceed 2m in height.

Stacks should never be higher than they

are wide.

Timber bolsters of minimum cross section

dimensions: 150mm wide x 150mm clear

depth between scallops, should be used to

separate layers. The scallops shall have a

minimum saddle angle of 90 degrees.

In termite infested areas, timber bolsters may

not last unless the area is treated. Otherwise,

the bottom bolster should be made from

steel. Bottom bolsters must also be placed on

firm ground and must be level.


16 | C H A P T E R 4

R e m e m b e r p i p e s c a n e a s i l y b e r o l l e d a n d m o v e d . M a k e s u r e t h e y a r e s e c u r e ! R e m e m b e r p i p e s c a n e a s i l y b e r o l l e d a n d m o v e d . M a k e s u r e t h e y a r e s e c u r e !

Table 4.1- Minimum pipe support area

Minimum Support Bearing Area

Pipe Length

6m 9m 12 – 13.5m

mm2 mm2 mm2

≤ 813 10,000 10,000 10,000

>813 to ≤1403 10,000 15,000 20,000

>1403 to ≤1753 15,000 20,000 30,000

> 1753 20,000 30,000 40,000

CP Lugs ifprovided

Figure 4.1 - Pipe support Figure 4.2 - Pipe bearing area

Figure 4.3- Stacking pipes using timber bolsters.

4. Stacking and Storage

2 supports 2.5 to 3.0 metres or 0.2 to 0.25 of the pipe

length from each end

Storage areaThe storage area should

� have a firm foundation for pipe stacks

and vehicle operation

� have suitable access for

road vehicles

� be free of overhead power lines

wherever possible

� be barricaded if necessary

Pipe supportCoated pipes should at all times be supported

clear of the ground. Beware of protruding

rocks and uneven ground.

If pipes are provided with factory fitted CP

lugs ensure that pipes are stored with lugs at

the top.

The pipe should be supported at two

locations 0.2 to 0.25 of the pipe length from

each end. See Figure 4.1.

Each support shall provide adequate bearing

area. The bearing area on the pipe should not

be less than that shown in Table 4.1. See

Figure 4.2.

Sawdust bags Soil mounds

Bolster locations 2.5 to 3.0 metres or 0.2 to 0.25 of the pipe length from each end.

C H A P T E R 4 | 17

500mm 500mm


18 | C H A P T E R 4

R e m e m b e r p i p e s c a n e a s i l y b e r o l l e d a n d m o v e d . M a k e s u r e t h e y a r e s e c u r e ! T h e s a f e w a y i s t h e c o r r e c t w ay!

StorageSmall fittings, rubber rings and lubricant

should be stored in a secure convenient area.

Lubricant must not be stored for lengthy

periods in direct sunlight.

Rubber rings should be stored in bags,

out of the sun and away from petroleum

products. They should be stored in

a manner that prevents them from being

subject to high compressive or

tensile strains.

Rubber rings should be used within 12

months. If rubber rings are stored for longer

periods they should be discarded.

Storage of CementMortar Lined PipesCement mortar lining may crack and

possibly disbond when stored in hot, dry

conditions. The longer the storage period in

such conditions, the wider the cracks will

be and the greater the extent of any

disbondment (drumminess).

Cracks up to 2mm in width (as allowed in AS

1281, “Cement Mortar Lining of Steel Pipes

and Fittings”) are acceptable for pipes

conveying potable water as these cracks

close and heal on exposure to water.

When pipes greater than 800mm in diameter

are stored for more than a few weeks in hot,

dry conditions, cracks may develop in excess

of the 2mm allowable under AS 1281 and the

lining may disbond.

In such circumstances precautions should be

taken such as end capping (to reduce airflow

and thus rate of cracking) and adding water

to the pipes (to reduce the width of cracks).

Guidelines for repair when cracks or

disbondment exceeds 2mm are found in

Appendix B - Field repair and joint

reinstatement of cement mortar lining.

5. Stringing

Before pipe deliveryPlan stringing before arrival of the pipe

and consider:

� the construction programme

� the ground conditions, and

� the safety of workers and the

general public

Where to stringPipe should be located to minimise

handling during the laying operation.

Pipes should be properly supported.

Refer Section 4: Stacking and storage.

Large fittings and valves should be put

adjacent to where they will be needed.

Small fittings, gaskets, nuts and bolts

should be kept in a secure storage area

until they are needed.

What equipment to useCranes, forklifts or other appropriate

equipment approved by the relevant State

Occupational Health & Safety Authority may

be used.

Always use approved slings and accessories.

For large pipes, twin slings should be used,

Refer to Section 3: Unloading and handling;

Accessories.

Guide ropes should be used to control the

pipe. See Figure 3.1.

Method of stringing pipesKeep pipes close to the ground while they are

being moved.

Pipes should be near enough to the trench for

the laying crew, but far enough away so they

don’t interfere with equipment access, trench

digging or excavated spoil.

When single stringing, pipes should be in line

with the trench with sockets facing the

direction of laying such that when laying, a

spigot is inserted into an already laid socket.

This is the recommended technique for

jointing and allows the entry of the spigot into

the socket to be more easily seen and

controlled. It also minimises the risk of

scooping bedding material into the joint and

onto mating surfaces. See figure 5.1.

C H A P T E R 5 | 19


When laying pipe on steep slopes,

construction should start at the bottom and

proceed up hill. In this way the weight of the

pipes is used to advantage when jointing.

Pipes should thus be strung with sockets

facing uphill. See Figure 5.1.

When multiple stringing, groups of pipes

should be in line with the trench with their

sockets all facing the direction of laying.

Groups of pipes should be separated by the

distance covered by the number of pipes in

the group. See Figure 5.2.

Figure 5.1- Single stringing of pipes

Figure 5.2- Multiple stringing of pipes

Pipes strung with socketsfacing direction of laying

20 | C H A P T E R 5

T h e s a f e w a y i s t h e c o r r e c t w a y !

6. Trenching

Before excavationLocate and mark other underground utility

service lines. Check whether the water table

needs to be lowered with dewatering

equipment. Assess trench stability and

shoring requirements.

How wide should thetrench be?The trench width should be as narrow as

practicable, consistent with the need to

ensure;

� proper laying and jointing of the pipe, eg.

joint stations for welder in welded joint

pipelines,

� application of joint wrapping for welded

joint pipelines,

� where a change in direction is being made

at a joint, the trench should be wide enough

to allow the joint to be made with the pipes

aligned. The pipe should then be deflected

after jointing,

� proper haunch support and compaction of

the backfill in accordance with the design

specification,

� use of common size backhoe / excavation

bucket widths which are 300, 450, 600, 750,

900, 1100 and 1200 mm.

T r e n c h i n g . I f u n s u r e ? S h o r e !

How deep should thetrench be?The depth of the trench will depend on a

number of factors in addition to pipe diameter.

Other considerations include:

� location of other services, particularly in urban areas,

� future change in levels due to roadregrading or other civil works,

� required cover,

� valve pits etc.

The minimum depth of cover recommended

is 600 mm provided none of the other

considerations require a greater depth.

In rocky ground, the trench should be

excavated at least 50 mm deeper than

required and replaced with compacted

bedding as described in Section 9:

Backfilling.

Where the ground below the bedding is

unstable, additional excavation should be

made and backfilled as described in

Section 9: Backfilling.

CHAPTER 6 | 21

As a guide, the following trench minimum widthsare reasonable:

OD + 400mm for pipe diameters ≤450mmOD + 600mm for pipe diameters > 450mm , ≤900mmOD + 700mm for pipe diameters > 900mm , ≤1500mm0.25 x ODmm for pipe diameters >1500mm


Figure 7.1- Bedding layer minimum depth

7. Bedding

Figure 7.2- Spreading bedding

50mm min

Lift pipesuch thatbase of

pipe is attop of

bedding

Back hoe Excavator Trencher

Figure 6.1- Trench excavation machinery

How to excavateUsually an excavator or backhoe with bucket

attachment is used. Only authorised people

should operate this equipment. A trencher

may be used if conditions permit. This can be

a faster method. See Figure 6.1

SafetyIf working under power lines check with the

electricity supply authority and the government

safety authority. You may need to;

� arrange for overhead cables to be diverted

or protected with insulating covers,

� arrange for electricity to be cut off,

� put up goal post type barriers or,

� use luffing stops on the machine

Remember there is greater sag in power lines

on hot days.

Barricades should be used if there is a danger

of anybody falling into the trench.

Occupation, Health and Safety regulations

must be observed.

Shoring the trenchIt is generally necessary to shore the trench if

it is deeper than 1.5 metres. Refer to the

relevant authority on safe excavation practice.

It may still be necessary to use shoring in

trenches less than 1.5 metres deep if there is

a risk of trench wall collapse as a result of;

� poor soil strength,

� vibration from machinery,

� use of explosives,

� placement of spoil adjacent to the

trench / and/or materials, or

� water inflow.

22 | C H A P T E R 6

T r e n c h i n g , i f u n s u r e ? S h o r e ! F e n c e o f f w o r k a n d s t o r a g e a r e a s .


C H A P T E R 7 | 23

Why Bedding ?Bedding evenly supports the pipe and protects

the external coating.

Bedding should be spread evenly along the

trench with socket holes or welding stations

provided at each joint. The socket holes should

be deep enough to stop the socket of the pipe

bearing any weight. Welding stations should

also be big enough to allow welding and

wrapping at welded joints.

Bedding in wet orunstable groundIn wet or unstable ground, it may be necessary

to dig the trench deeper and backfill with gravel

to form a foundation layer. A barrier geotextile

material may then be placed over this and the

bedding material placed on top. The geotextile

material specified will prevent fine sand and soil

moving into the spaces between the gravel and

subsequent loss of support for the pipe.

Bedding in rockThe trench should be excavated to ensure that

there is space for a minimum of 50 mm

compacted bedding beneath the pipe and to

accommodate appropriate joint stations for

welding and reinstatement if required.

What to use for beddingBedding should be granular material such as

sand with no stones or sharp objects. The

maximum particle size should not exceed 13.2

mm. If the natural soil is not suitable, bedding

should be brought in.

The bedding layer under the pipe should be at least

50 mm thick when compacted See Figure 7.1.

How to put bedding into a trenchBedding is usually put into a trench with a front

end loader or backhoe. It should be evenly

spread along the trench. See Figure 7.2.

Bedding should be compacted to ensure a firm,

even base for pipe laying.

Allowance for slingwithdrawalConsideration should be given to making a

small depression in the bedding where slings

used to lift the pipe will come to rest after

lowering and jointing.

This will allow slings to be withdrawn from under

the pipe more easily.


After assembly

Figure 8.2- Pulling SINTAJOINT pipes“home” to joint

SINTAJOINT Common flange joint

Figure 8.1- Jointing systems

24 | C H A P T E R 8

R e p o r t a n d r e c o r d a l l i n c i d e n t s . R e p o r t a n d r e c o r d a l l i n c i d e n t s .

GeneralThe majority of water pipelines are laid below

ground. However there are also above ground

applications, such as at pumping stations,

treatment works, over creeks, along bridges or

where the cost of trenching is too expensive.

Work is often carried out in congested

conditions. Observe good housekeeping and

safe working practices to avoid injury. Inspect all

lifting and pulling equipment regularly for signs

of wear and deterioration.

All occupational health and safety requirements,

including confined space legislation, should be

complied with and take precedence over

working methods recommended herein.

Joint TypesA number of common jointing configurations

are available for steel pipe:

� Rubber ring joint, SINTAJOINT

� Expanded and collapsed or spherical

slip-in welded joint,

� Ball and socket welded joint,

� Butt welded joint

� Butt welded joint with band or collar

� Flanged joint

See Figure 8.1

SINTAKOTE pipes and fittings are factory

formed/assembled for site installation without

further site adjustment. Where, as a result of

site conditions or damage to pipe, pipes must

be cut to length on site, the following should

be noted:

Pipes with welded joints can be cut and joints

welded in accordance with this Section.

Pipe ends to be joined should be prepared in

accordance with site welding procedure and

joint areas reinstated in accordance with

Appendices A and B,

SINTAJOINT pipe, where cut, can only be

joined by welding in accordance with above.

Do not attempt to use a cut end in a rubber

ring joint.

SINTAPIPE pipe should not be cut for jointing.

Normally design is carried out to avoid the

need for cutting on site.

Where SINTAKOTE pipe with welded joint,

SINTAJOINT or SINTAPIPE is to be cut and

installed with a free end in a corrosive

situation, such as in sewer manholes, it is

recommended that a Tyco Water

representative is consulted.

8. Laying and Jointing

Spherical slip-on joint Ball and socket joint

Plain butt jointButt joint with collar


Jointing Equipment

Anchor slingReversed eye, synthetic webbing slings or

round slings (of endless fibre construction) are

recommended for use in the assembly of

SINTAJOINT pipes. Woven synthetic slings must

be sheathed to prevent penetration of the fabric

by grit, abrasion and deterioration. The slings are

fitted to the pipe using a “choker” hitch and in

this configuration the sling is rated to the SWL

limit marked on the webbing. See Figure 8.2.

Assembly forces will vary depending on the

relative dimensions of the ends being joined,

and to a lesser extent, the diameter and wall

thickness of the pipe.

It is expected that these forces would be

between 20 and 50 kN.

The length of the sling is generally pipe

circumference plus 400 mm.

PullerA winch block of 30-50kN pulling capacity

fitted with hooks on both ends is adequate.

Rubber matsTypically 500 x 500 x 6 – 12 mm thick pieces of

conveyor belt or similar should be placed

between equipment and pipe where the coating

is likely to be damaged during joint assembly.

RagsTo clean sockets and spigots immediately

before joint assembly.

Inspection of PipeBefore LayingGeneralAll pipes are factory inspected, however,

damage may occur in handling, transport or

site storage. Pipes must be reinspected on

site before laying. The inspection should

include pipe coating and lining and pay

particular attention to pipe ends on

SINTAJOINT pipes.

Pipe endsPipe ends must be inspected visually

for any damage that may have occurred

during transport, site storage or handling.

SINTAKOTE at pipe endsShould the coating or lining of the pipe ends

(socket or spigot end) be damaged, it must be

repaired in an approved manner

C H A P T E R 8 | 25


26 | C H A P T E R 8


before the pipe is laid. See Appendix A for

methods of assessment of damage to

SINTAKOTE and methods of repair .

Testing of SINTAKOTEAll surfaces coated with SINTAKOTE are

factory tested for pin holes and other defects.

SINTAKOTE is a tough coating with a high

resistance to handling and transport damage.

However coating damage can occur through

poor handling or incorrect storage.

To ensure that the highest quality coating

system is placed in the ground, it is

recommended that field high voltage

holiday inspection be carried out on all

coated surfaces. SINTAKOTE can be

tested at high voltage without any

detrimental effect on coating properties.

The voltage for the testing should be set at

12,000V -14,000V and testing undertaken in accordance with AS3894.1 or AS4321“Fusion-bonded medium-density polyethylene

coating & lining for pipes and fittings”. Note

that the safety procedures detailed in the

Standard must be strictly followed.

With SINTAJOINT pipes, the earth should

be clamped to a metal plate, laid on the

cement mortar lining. The 12,000V-14,000V test voltage is specified for all coating and

lining thicknesses.

For SINTAPIPE pipes, ie. pipes that are

totally coated and lined with Sintakote, the

method specified in AS4321 shall be used.

Rubber ringsThe rings must be visually inspected for any

damage which may have occurred after

leaving the manufacturer. Damaged rings

must not be used.

LubricantInspect lubricant tins for damage and

replace if contaminated. Use only the

lubricant supplied by Tyco Water.

Laying and Jointing of PipeSINTAJOINT pipeThe laying of SINTAJOINT (RRJ) pipes is

simple and very high laying rates can be

achieved. The equipment is inexpensive,

light and easily handled.

To ensure high laying rates and watertight

joints, attention to detail and the

following recommended laying practices

are essential.

The guidelines below are additional to other

good practices which should be observed

when preparing a trench, storing and laying

steel pipes and backfilling.

The pipe is manufactured to close

tolerances assuring a consistent joint profile.

The rubber rings are also supplied to a strict

specification, for dimensions, hardness

and formulation.

These features produce joints with

assembly properties easily recognised

by the laying team. The ease of spigot

entry and the jointing force are so

consistent that the laying crew quickly

identifies any significant variation.

An additional check for correct joint

assembly can then be made.

C H A P T E R 8 | 27

The recommended method for joint

assembly is to pull the pipe being laid into

the socket of the previously laid pipe, using

anchor slings and winch blocks or pullers.

See Figure 8.2.

Another joint assembly method is easing the

pipe into the joint by slewing the excavator or

crane. This method is acceptable, provided it

does no damage to the pipe, including the

external coating or internal lining.

The slewing action must be controlled to ensure

alignment of the pipe. Care must be taken not

to drive the spigot past the witness mark as this

may damage the coating and/or lining.

If the pipe is to be cathodically protected,

it will be supplied with cathodic protection

lugs on both the socket and spigot. Ensure

the pipe is installed with these located at the

very top of the pipe, to enable connection

of joining cable across the joint.

PreparationStart with the free socket end of the previous

assembly which should be sitting over a

scooped out area of bedding.

Measure out the location where the next

socket end will fall in the trench, and scoop

out the bedding so that after laying there will

be sufficient clearance for the socket.

Fit the anchor sling behind the socket.

Rubber ringClean the inside of the socket with a clean

rag, then fit the rubber ring. Always inspectthe rubber ring for damage or tears prior to

inserting in the socket. The rubber ring is

first placed in the invert and then inserted into thegroove by progressively placing it and compressing

until the last part snaps in the groove. See Figure 8.3

The ring is slightly over length and this must be evenlydistributed by pre-compressing the rubber progressively

as it is fitted into the groove. A simple clamp can

A simple clamp can assist with holding the ring firmallowing two hands free to fit the balance of the ring.

The placement of rubber rings in pipes larger

then 1000mm OD may require two people.

LubricationLift the next pipe and fit an anchor sling over the

spigot positioning it about 2 metres from

the end.

Clean the spigot while it is suspended in theslings.

lubricant supplied by Tyco Water suitable for

use with SINTAKOTE pipe.

On the spigot, the lubricant should be sparingly applied to the area from the spigot end to the witness

mark, providing 100% cover.

Lubricate the internal socket lip, the rubber ring and the spigot end of the pipe to be inserted. Use only

Figure 8.3- Fitting rubber rings into sockets


�

�

Figure 8.4 - Alignment of pipes during jointing

Experience has shown that this is a criticalaspect of rubber ring joint field assemblyprocedures. Using an incorrect lubricant maycause failure of the rubber ring or SINTAKOTE.

The lubricant must cover every exposed partof the internal surface of the socket lip and

rubber ring. Unlubricated areas can cause the

rubber ring to be displaced from the groove.

Care should be taken to ensure lubricantdoes not get behind or under the rubber ring.

High temperatures may cause the lubricant tolose its consistency and become very fluid.Only lubricate the spigot end when operating

in high temperatures. High temperatures mayalso cause premature drying of the lubricantafter application. Lubricant should thereforebe applied immediately before jointing the pipes

In cold conditions it may be necessary to warm the lubricant to a brushable consistency by

standing the lubricant container in warm water.

Joint assembly with puller

Align the pipe with the previously laid pipe.

This alignment is necessary to ensure that the

rubber ring is not displaced from its seat

during joint assembly. See Figure 8.4.

Where field conditions prevent straight axial

entry the spigot can still be entered with a

maximum deflection shown in Table 8.1.

Jointing will be easier with smaller deflection.

Hook on the puller between the anchor slings,

and before applying the pulling force, place

protective mats under the puller and hooks to

prevent damage to the coating.

Carefully pull joint into full entry position.

The witness mark should be visible and inline

with the face of the socket.

28 | C H A P T E R 8


C H A P T E R 8 | 29

When in line with the witness mark, hold in

position for a moment to allow the rubber ring

to go back to its original profile. Failure to do so

will result in the pipe ‘popping back’.

Do not over engage to compensate for this.

The final entry position for undeflected joints is

ideally at the line with a tolerance of ±5mm.

Insufficient entry that exposes the line by more

than 5mm after relaxation could result in a

leaking joint (Note that when the pipe is

deflected, the entry line may be exposed by up

to a maximum of 25mm). Entry greater than the

line will not lead to a leaking joint but may

prevent deflection of the joint. In addition,

if entered the full amount, this may result in

damage to the spigot end if the pipe “bottoms”.

With the puller load on, deflect the pipe

to the required grade and direction on the

sand bedding.

The maximum permanent deflections for

SINTAJOINT pipes are shown on Figure 8.5.

Please Note: If more precise figures are

required, please contact a Tyco Water Regional

Marketing Office.

The puller load must not be released until

sufficient backfill is placed around the pipe to

ensure that joint movement will not occur.

Care should be taken when withdrawing slings

from under bedded pipes to avoid damage to

the SINTAKOTE from sling eyes or hooks.

See Section 7: Bedding; Allowance for

sling withdrawal.

Important note for concavechanges in direction

To satisfy the requirement that rubber ring joints

be assembled with the pipes axially aligned, the

free end of a pipe just laid in a concave trench

must be raised, so increasing the deflection of

the previously assembled joint.

The joint design allows for this temporary

‘over deflection’ which, must not exceed

the limits shown on the joint drawing.

See also Figure 8.5.

Similar remarks apply when laying pipes on

changes in direction.

This temporary ‘over deflection’ in concave

changes in grade is achieved by lifting the

pipe end and placing a padded packer (a bag

filled with sand or sawdust) under it.

After completion of the next joint assembly the

packer is removed to allow the pipe to rest

back on the bedding.

The packer is then transferred to the free end

of the pipe just laid and the operation is

repeated.

Table 8.1 - Permissible misalignment of offsets during entry

Pipe size Max permissible Max permissibleOD misalignment offset (mm) pipe

(mm) (degrees) length (m)

6m 9m 12m 13.5m

less than 813 0.5 50 75 100 112

813 or larger 0.25 25 40 50 56


0 0.50 1.00 1.50 2.00 2.50 3.00

Deflection Angle (degrees)

6m 9m 12m 13.5m

800

700

600

500

400

300

200

100

0 ��

�

�

�

�

�

�


C H A P T E R 8 | 3 1

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

�

��

�

�

�

�

Figure 8.6 – Axial offest measurement created by joint deflection.

30 | C H A P T E R 8


1700

1600

1500

1400

1300

1200

1100

1000

900

800

700

600

500

400

300

200

3.5° 3° 2.5° 2° 1.5° 1° 0.5°

Tem

pora

ry c

onst

ruct

ion

defle

ctio

n

Per

man

ent d

efle

ctio

n

D. O

utsi

de d

iam

eter

in m

illim

etre

s

θ Deflection angle in degrees Figure 8.5- Temporary construction and permanent SINTAJOINT deflection.

θ

� = % OD

Maximum deflectionsRRJ: 2%Welded joint: 3%Note: Vertical deflection shown left is greatlyexaggerated for clarity of termsBedding reaction

Pipe section after backfilland compaction loading

Pipe section before backfill and compaction

During this operation, to ensure that the

‘over deflected’ joint does not come apart,

it will be necessary to leave the puller load

on at the joint and use a second puller to

assemble the new joint.

After removal of the temporary ‘over-

deflection’, place a quantity of backfill over

the pipe before releasing the puller load.

Remove the pipe handling sling and if the

pipe is laid on a down grade, place a quantity

of backfill over the middle part of the pipe

and also compact backfill at the sides to stop

joint separation.

The placement of the backfill for pipes

negotiating concave changes in grade, or

changes in grade, or changes in direction,

must be delayed until the assembly as

described above is completed.

Remove pulling gear and prepare for jointing

the next pipe.

Inspection of assembled jointBy observing the required pulling force and

ease of spigot entry up to the witness mark,

laying teams quickly develop the skill to assess

correct joint assembly. These assessments are

generally very reliable, however correct

assembly should be verified by inspection.

The following inspection methods are

recommended to check that each joint is

correctly assembled.


Figure 8.7- External inspection ofassembled SINTAJOINT

2. Lower onto bed to give correct entry and complete weld.

32 | C H A P T E R 8


External check (see Figure 8.7)

Gap: Visual inspection of the gap between the

lip of the socket and the spigot end surface. It

should be uniform and in the range 0–1.5mm.

Entry: Entry witness marks applied by the

manufacturer and those applied during laying are

to confirm entry is correct and no disassembly

movement has occurred after laying.

Internal checkWhen regulations and pipe sizes allow entry

to the pipe, the assembled joint should be

inspected from inside the pipe.

This inspection gives the assurance that

the rubber ring remains properly seated

in its groove.

It must be ensured that no part of the

rubber ring protrudes past the spigot end

of the pipe.

On smaller pipe lengths, where access is not

practicable, inspection from the end of the

pipe using appropriate lighting, must be

performed on each joint.

Telescopic or video equipment may be used.

This procedure should detect most instances

of rubber ring displacement.

Joints indicating rubber ring displacement or

excessive gapping must be pulled apart,

cleaned of all lubricant and re-assembled

using a new rubber ring.

Summary of Important Pointsfor Laying and Jointing:

SINTAJOINT PipesUse recommended assembly equipment and

a method which allows the laying team to

develop a feel for correct joint assembly.

Use light gear which can be handled easily.

Use protection for the coating if there is any

possibility it could be damaged by equipment.

Inspect the pipe ends for damage before

assembly.

Inspect the joint and rubber ring. Ensure they

are clean and lubricate them correctly just

before the assembly.

Use the correct joint assembly procedures.

Inspect the assembled joint to confirm

successful and correct spigot entry.

If movement of the assembled joint is

possible, take appropriate precautions.

Only lubricants specifically recommended for

use with SINTAKOTE should come in contact

with the coating.

Be sure the laying crew have a current drawing

of the joint as supplied for the contract.

Figure 8.8- Welded ball and socket or slip-in joint field assembly

C H A P T E R 8 | 33

Welded jointsWhen welding, ensure adequate ventilation to

draw off welding fumes.

Clean the ends of the pipe with a wire brush

or power brush to remove surface rust etc.

Lay pipes with sockets facing the direction of

laying. It’s easier to locate a pipe spigot

correctly into a socket than a socket over a

spigot. There is also less chance of entrapping

soil in the joint as the spigot is pushed home.

Pick up the pipe, refer Section 3: Unloading

and handling.

Lower the pipe into the trench and insert

the spigot end into the socket. The pipe

should be inserted angled slightly down

toward the spigot. The top of the joint is then

tack welded and the pipe lowered onto the

bedding to give correct entry. See Figure 8.8.

The maximum allowable deflection for slip-in

joints is in the range 20 to 30. For ball and

socket welded joints, the maximum

allowable deflection is 30.

In general, only a single fillet weld is required

for sealing and structural purposes.

Pipe sizes 813 mm OD and larger may

require a seal weld internally to allow an air

leak tightness test of the weld.

The gap between cement mortar linings at

joints should be filled with cement mortar

for pipe sizes 813 mm OD and larger. Refer

Appendix B - Repair of cement mortar

linings and reinstatement of field joints.

For smaller sizes, design should ensure

joint configurations which permit cement

linings to abut.

Provide external coating at all joints using a

heat shrink sleeve (preferred) or tape field

joint coating systems. Refer Appendix A:

Field repair and joint reinstatement of

SINTAKOTE.

Where a SINTAKOTE pipe is cut for welding,

the pipe should be stripped back to the

steel for a minimum distance of 75 mm

each side of the weld.


14

10

62 15

3

134

8

1612

9

15

7

11

Figure 8.12 Star pattern tighteningsequence

Fig 8.10 Matched o-ring type flangesFig 8.9 Raised face type flanges

34 | C H A P T E R 8


Flanged jointsFlanged joints are completely rigid and should

not be used for applications where movement

of the pipeline is expected, unless special

provision is made to accommodate it by, for

example, the inclusion of expansion joints.

Flanged joints are used mainly for above

ground applications, e.g. pumping stations,

water and sewage treatment plants and for

industrial pipework. They are also used to

facilitate the installation and removal of valves

in SINTAJOINT and welded pipelines and for

valve bypass arrangements.

For assembly of flanged joints no field welding

or other special equipment is required. Flange

dimensions are normally in accordance with

AS 4087 and are currently supplied in Class

14, Class 21 or Class 35.

For access covers and other blank flange

joints Tyco Water recommends the use of o-ring type gaskets because of their low

requirement for assembly stress and trouble

free operation. O-ring flanged joints have

these same advantages in other flanged joint

situations but it must be remembered that the

use of o-ring type flanges requires full

knowledge of all of the mating components to

avoid a joint situation with two o-ring groove

ends joining each other. The correct matching

is shown in Figure 8.10.

C H A P T E R 8 | 35

Where it is not possible or desirable to use

o-ring type flanges, Tyco Water recommends

the use of raised face steel flanges. See Figure

8.9. The use of flat-faced steel flanges is not

preferred except when the mating flange is cast

iron. This situation may occur at a pump

housing, but current practice is for most pipeline

components to be manufactured in steel or

ductile iron. Experience has shown that

flat-faced flanges are generally more susceptible

to sealing problems and successful sealing is

heavily dependent upon assembly technique.

Where the required flange sizes are larger than

DN 1200 or are outside the normal pressure

rating, special flanges must be designed. In this

situation o-ring type flanges are recommended

as being the best option for medium to high

pressure situations.

GasketsGaskets may be either elastomeric or

compressed fibre type. Elastomeric gaskets are

only recommended for the Class 16 flanges.

Compressed fibre gaskets are recommended

for Class 21 and Class 35 flanges.

Compressed fibre gaskets can also be used

with Class 16 flanges but will require the use of

high strength bolts because of the higher initial

compression necessary.

Table 8.2 details the recommended type of

gasket to be used for various classes of raised

face steel flanges. Generally full face gaskets

(that incorporate holes for the flange bolts) can

be used with raised face flanges as only the

raised face area inside the bolt holes is

clamped. The full face gasket enables better

location of the gasket compared to a ring type

gasket. (If rigid compressed fibre type gaskets

are used the use of ring type gaskets is normal)

For other liquids, temperatures or pressures

contact a Tyco Water Regional Marketing Office.

Flange bolts and assembly torqueBolting used on flanges is usually galvanised

steel or stainless steel. Commercial grade bolts

are used with the Class 14 flanges and rubber

gaskets while high strength studs and nuts are

required for use with compressed fibre gaskets.

Poor assembly technique is by far the greatest

single cause of flange joint failure and use of the

correct technique and selection of the suitable

bolt torque is vital. Table 8.3, 8.4 or 8.5 may be

used as a guide for determining the final torque

setting for any flange within the specified range.

Table 8.2 - Recommended gasket composition for transport of general domesticliquids including brine and sewage

Maximum Maximum Gasket CompositionOperating Pressure TemperatureMPa °C

1.6 50 Solid EPDM Rubber 3mm thick

3.5 80 Composit Fibre 1.5mm thick


TABLE 8.3 Recommended Bolt Torques for Raised Face Steel Flanges Class 16 with Compressed Fibre Gaskets Gasket - Full Face 1.5mm TEADIT NA1000 Compressed Fibre. Grade 8.8 Galvanised Steel Studs and Nuts, or Stainless Steel Studs and Nuts, Property class 80

C H A P T E R 8 | 3736 | C H A P T E R 8

R e p o r t a n d r e c o r d a l l i n c i d e n t s S a f a n i l i t y

36 | C H A P T E R 8

S a f e t y

1. 'Lightly oiled' refers to the application of a goodquality lubricating oil and is the usual as receivedcondition of fasteners.2. 'Well lubricated' refers to the application ofmolybdenum disulphide or Koprkote grease.3. The estimated torques provided in the table arebased on the friction factor (k) indicated. Where otherfactors apply, alternative torques should be calculated.4. Required bolt tensions and estimated torques havebeen assumed using established engineering principles.However, variation in installation procedures may result

in different requirements.5. Common pipe sizes not included are 559, 762,889, 914, 1086, 1124, & 1145For these sizes, raised face flanges with elastomericgaskets are not recommended due to eitheroverstressing of the gasket when tightening bolts toachieve gasket sealing or excessive flange deflectionunder pressure. If these pipe sizes are used theflanged joints may not be suitable for full test pressureO-ring grooved flanges are more suited to these pipesizes for Class 14 flanges.

Estimated Torque

Lightly Oiled Well Galvanised, or Lubricated Flange Pipe No. Bolt Bolt Well Lubricated Galvanised DN OD of Size Tension Stainless Steel Steel Bolts Studs or Bolts Studs or Bolts k = 0.22 k = 0.15 mm kN Nm Nm

100 114 4 M16 75 265 180

150 168 8 M16 75 265 180

200 178, 190, 219 8 M16 75 265 180

225 235, 240 8 M16 75 265 180

250 257, 273 8 M20 95 420 285

300 290, 305, 324, 337 12 M20 95 420 285

350 337, 356 12 M24 140 740 505

375 368 12 M24 140 740 505

400 406, 419 12 M24 140 740 505

450 457 12 M24 140 740 505

500 502, 508, 559 16 M24 140 740 505

600 610, 648, 660 16 M27 175 1040 710

700 700, 711, 762 20 M27 175 1040 710

750 800, 813 20 M30 210 1390 945

800 813, 889 20 M33 260 1890 1290

900 914, 959, 965, 972 24 M33 310 2255 1535

1000 1016, 1035, 1067, 1086 24 M33 260 1890 1290

1200 1200, 1219, 1283, 1290 32 M33 260 1890 1290 1. 'Lightly oiled' refers to the application of a good

quality lubricating oil and is the usual as received condition of fasteners.

2. 'Well lubricated' refers to the application of molybdenum disulphide or Koprkote grease

3. The estimated torques provided in the table are based on the friction factor (k) indicated.

. Where other factors apply, alternative torques should be calculated.

4. Required bolt tensions and estimated torques have been assumed using established engineering principles. However, variation in installation procedures may result in different requirements.

5. Common pipe sizes not included are 1124, 1145

For these sizes, raised face flanges with elastomeric gaskets are not recommended due to either overstressing of the gasket when tightening bolts to achieve gasket sealing or excessive flange deflection under pressure. If these pipe sizes are used the flanged joints may not be suitable for full test pressure O-ring grooved flanges are more suited to these pipe sizes for Class 16 flanges.

6. Full face flanges not recommended. If used, gasket should be ring type 3mm TEADIT NA1000 Compressed Fibre.

Gasket - Full Face 1.5mm TEADIT NA1000 Compressed Fibre for raised face flanges. - Ring type 1.5mm TEADIT NA1000 Compressed Fibre for flat face flanges. Grade 8.8 Galvanised Steel Studs and Nuts, or Stainless Steel Studs and Nuts, Property class 70

Estimated Torque

Lightly Oiled Well

Galvanise Lubricated

Flange Pipe No. Bolt Bolt Well Lubricated Galvanised

DN OD o f Size Tension Stainless Stee l Steel

Bolts Studs or Bolts Stud s or Bolts

k = 0.22 k = 0.15

mm kN Nm Nm 100 114 8 M16 40 145 100

150 168, 178 12 M20 75 330 225

200 190, 219 12 M20 75 330 225

225 235, 240, 257 12 M24 80 425 290

250 257, 273, 290 12 M24 80 425 290

300 305, 324, 337 16 M24 80 425 290

350 356, 368 16 M27 115 685 470

375 406, 419 16 M27 115 685 470

400 419 20 M27 115 685 470

450 457, 502, 508 20 M30 115 760 520

500 559 24 M30 115 760 520

600 610, 648, 660 24 M33 190 1380 945

700 700, 711,762 24 M33 190 1380 945

750 800, 813 28 M33 190 1380 945

800 889 28 M33 190 1380 945

900 914, 959, 965, 972 32 M36 190 1505 1030

1000 1016, 1035, 1067, 1086 36 M36 190 1505 1030

1200 1124, 1145, 1200, 1219 40 M39 310 2660 1815

1200 1283, 1290 40 M39 310 2660 1815

1. 'Lightly oiled' refers to the application of a good quality

lubricating oil and is the usual as received condition of fasteners. 4. Required bolt tensions and estimated torques have been

assumed using established engineering principles.2. ' Well lubricated' refers to the application of molybdenum

disulphide or Koprkote grease. result in differenct requirements.However, variation in installation procedures may

3. The estimated torques provided in the table are based on the

friction factor (k) indicated. Where other factors apply, alternative torques should be calculated.

.

TABLE 8.4 Recommended Bolt Torques for Steel Flanges Class 21 with Compressed

Fibre Gaskets


TABLE 8.5 Recommended Bolt Torques for Raised Face Steel Flanges Class 35 with

Compressed Fibre Gaskets

Gasket - Full Face or Ring type 1.5mm TEADIT NA1000 Compressed Fibre Grade 8.8 Galvanised Steel Studs and Nuts, or Stainless Steel Studs and Nuts, Property class 70

Estimated Torque

Lightly Oiled Well Galvanised, or Lubricated

Flange Pipe No. Bolt Bolt Well Lubricated Galvanised DN OD of Sizes Tension Stainless Steel Steel

Bolts Studs or Bolts Studs or Bolts k = 0.22 k = 0.15 mm kN Nm Nm

100 114 8 M16 40 145 100

150 168, 178 12 M20 75 330 225

200 190, 219 12 M20 75 330 225

225 235, 240 12 M24 80 425 290

250 257, 273 12 M24 80 425 290

300 290, 305, 324 16 M24 80 425 290

350 337, 356 16 M27 115 685 470

375 368, 406 16 M27 115 685 470

400 406, 419 20 M27 115 685 470

450 457 20 M30 115 760 520

500 502, 508 24 M30 115 760 520

600 559, 610, 648 24 M33 190 1380 945

700 660, 700, 711 24 M33 190 1380 945

750 762, 800, 813 28 M33 190 1380 945

800 813 28 M33 190 1380 945

900 889, 914, 959 32 M36 210 1665 1135

1000 1016, 1035, 1067, 1086 36 M36 210 1665 1135

1200 1219, 1283, 1290 40 M39 300 2575 1755 1. 'Lightly oiled' refers to the application of a good quality

lubricating oil and is the usual as received condition of fasteners.

4. Required bolt tensions and estimated torques

have been assumed using established engineering principles.

2. 'Well lubricated' refers to the application of molybdenum disulphide or Koprkote grease.

However, variation in installation procedures may result in different requirements.

3. The estimated torques provided in the table are based on the friction factor (k) indicated. Where other factors apply, alternative torques should be calculated.

38 | C H A P T E R 8


C H A P T E R 8 | 39

Jointing instructions for flanged joints

1.Use a scraper or wire brush to thoroughly

clean the flange faces to be jointed, ensuring

there is no dirt, particles or foreign matter,

protrusions or coating build-up on the mating

surfaces.

2. Ensure that the mating threads of all nuts

and bolts are clean and in good condition.

3. Evenly apply a suitable lubricant (e.g.

molybdenum disulphide) to all mating threads,

including the nut load bearing face and washer.

4. Align the flanges to be joined and ensure

that the components are satisfactorily

supported to avoid bending stress on the

flanged joint during and after assembly.

5. Insert four bolts in locations 1 to 4 as

indicated in Figure 8.11 and position the

insertion gasket on the bolts, taking care not to

damage the gasket surface.

6. Offer the adjoining flange to the bolts, taking

care to maintain support and alignment of the

components.

7. Tighten nuts to finger tight and check

alignment of flange faces and gasket.

8. Insert the remaining bolts and tighten nuts to

finger tight.

9. Estimate the required bolt torque considering

bolt type and allowable tension, flange type and

rating, gasket material and max/min

compression, and the pipeline’s maximum

pressure (operating/test pressure). Refer to

tables 8.3, 8.4 or 8.5 for recommended torque

values.

10. Tighten nuts to 20% of estimated torque

using the star pattern; see Figure 8.11.

11. Tighten to 50% of estimated torque using

the same tightening sequence.





14. Repeat the tightening procedure on all nuts

until little or no movement can be achieved on

each nut. (particularly important on elastomeric

gaskets)

• Grade 8.8 galvanised steel or grade 316

property class 80 stainless steel stud bolts

are recommended for use with composite

fibre gaskets.

• Bolt tensions need to counter the force due

to expected internal pressure and to provide

an adequate sealing stress without exceeding

the maximum allowable gasket stress at the

time of installation.

• The application of excessive torque at the

time of installation may overstress the gasket

causing crushing or extrusion, which can lead

to leakage at operating pressures.

• The surface conditions of the threads as a

result of rust, plating, coating and lubrication are

the predominant factors influencing the torque /

tension relationship. However, there are many

others including thread fit, surface texture and

the speed and continuity of tightening.

• The flange faces are assumed to have a

surface roughness of Ra = 10 -12.5 µm.

• A torque wrench is most commonly utilised

to achieve the required bolt tension, however

in critical applications an hydraulic tensioner

should be used.


150 to300mm

50mm min under pipe barrel

600mm minZONE C

ZONE B

ZONE A

9. Backfilling

40 | C H A P T E R 9

F a t i g u e i t d o e s h a p p e n ? F a t i g u e i t d o e s h a p p e n ?

Figure 9.1- Zones of backfill and compaction

The materials used for backfilling the trench

and their compaction should be specified by

the designer. Proper support and protection of

the pipe should be considered together with

the future ground loading and activity.

For small diameter pipe laid in an area where

surface settlement is not a problem, minimum

backfill compaction is normally adequate.

However as the depth of cover increases or

where vehicle traffic occurs, and especially for

large diameter thin wall pipes, the degree of

compaction becomes critical to ensure the

long term performance of the pipeline.

Zones of backfill andcompactionThe soil surrounding the pipe can be

considered as three Zones shown in

Figure 9.1.

Zone A - Bedding

A minimum 50 mm thick compacted beddinglayer of sand, non cohesive native soil or

imported fill (100% less than 13.2mm) should

be provided under the pipe as bedding.

Bedding material may need to be imported or

may be present after excavation.

Bedding provides even support for the pipe

along its entire length and protects the

SINTAKOTE.

Zone B - Backfill for haunchsupport, side support and overlay

The haunch and side support areas provide

support for the pipeline and prevent sharp

objects imparting high loads onto the pipeline

coating. Backfill should consist of non-cohesive

native soil, free from stones and sharp objects

larger than 25 mm or imported fill, sand or

rounded gravel not greater than 20mm.

C H A P T E R 9 | 41

The degree of compaction required will

depend on the loading for which the pipeline

has been designed and the ring stiffness of

the pipe.

Ring stiffness depends on the pipe wall

thickness and diameter; a thick walled small

diameter pipe is stiffer than a thin walled large

diameter pipe. An indication of stiffness can

be taken from the diameter/steel wall

thickness ratio or D/t.

For steel pipes equal to or less than 914mm

OD, with a D/t less than 120, only moderate

compaction is required to achieve the

necessary support. Pipes with D/t values

greater than 120, or greater than 914 mm

OD, need more support from the side fill to

carry the soil and traffic loads and the level of

compaction specified should reflect this.

When high levels of compaction are specified

for these low stiffness pipes, it is essential

that backfill be well compacted between the

sides of the pipe and the trench. Particular

care should be taken in compacting the

material under the haunches of the pipe. The

backfill should be built up in 150 mm layers

evenly on both sides of the pipe.

Backfilling in layers should proceed until there

is an overlay of at least 150 mm above the

top of the pipe. This layer provides a zone of

material to prevent sharp objects imparting

high point loads on the coating.

When a pipeline is to be cathodically

protected, material should not be too high in

electrical resistivity as this will reduce the

effectiveness of the protection. Generally

sand or soil is suitable. Stone and gravel can

be too high in resistivity. Hence a well graded

mix of sand and gravel should be used on

cathodically protected lines where imported

backfill is required.

Zone C - Overburden trench fill

Material in this zone builds the trench up tothe original ground level and the materials

used and extent of compaction

depends on the allowable future surface

settlement. Under road pavements the

load bearing capacity of the ground surface is

important and backfill must be

compacted in layers all the way to the

surface.

Where the trench is across open land,

the compaction requirements of this zone

are not normally so important and the surface

can usually be built up to allow for some

future settlement.

The material used in Zone C, would normally

be the excavated trench material, but where

a high degree of compaction is needed in

bad natural ground, imported material may be

required.


Hockey Stick

1 metre shortMitred Bend

Reducer Tee Air valve or Scour Flanged Offtake

Eccentric Reducer Tee Angle Branch Y-Piece

Concentric Reducer Mitred Bend0° to 22.5°

Mitred Bend22.5° to 45°

Mitred Bend45° to 90°


� = % OD

Maximum deflectionsRRJ: 2%Welded joint: 3%Note: Vertical deflection shown left is greatlyexaggerated for clarity of termsBedding reaction

Pipe section after backfilland compaction loading

Pipe section before backfill and compaction

42 | C H A P T E R 9

F a t i g u e i t d o e s h a p p e n ? O b e y t h e s i t e r u l e s

Figure 9.2- Ring deflection limits

CompactionThe level of compaction to achieve in-situ

ground conditions, may require 65% Relative

Density for sand or 90% Standard Proctor

Density for clay type (cohesive) soils.

Soil density is usually specified as “Standard

Proctor Density” for clay type soils and

“Relative Density” for granular soils

(cohensionless).

Standard tests are available for determining

the density of compacted soils.

Ring deflection limitsTo ensure serviceability of the pipeline, ring

deflection must be limited as described below

and shown in Figure 9.2.

During construction these limits may need to

be lowered where service loads contribute

significantly to ring deflection.

Sintajoint (RRJ)

For SINTAJOINT pipe a safe service ringdeflection limit of 2% of the pipe OD is

recommended. This is to ensure that the

annular gap between spigot and socket is not

so distorted as to cause significant reductions

in gasket contact pressure.

Welded JointsFor pipes with welded joints and cement

mortar lining, a safe service ring deflection limit

of 3% of the pipe OD is recommended.

This is to avoid possible repetitive flexing of

the pipe and fraying of the lining.


Good planning at the design stage can result in

improved installation efficiency. This is particularly

true for pipelines requiring numerous fittings.

For fully welded lines, fittings should be

ordered to suit and can be fabricated from

SINTAKOTE pipe.

For rubber ring joint pipelines, consideration

needs to be given to anchorage at change in

direction, dead ends, tapers or tees. See

Section 11: Anchorage of pipelines.

For rubber ring pipe joints under maximum

allowable deflection (see Figure 8.6)

thorough compaction of the embedment

zone on the outside of the joint is

required.

For directional changes greater than that

achieved by deflection of a pipe joint, fittings

are required.

For common use fittings see Figures 10.1 and

10.2.

10. Fittings

Figure 10.1- Common Fittings - welded pipelinesNote that Tees, Angle Branches and Y-Pieces may require reinforcing as indicated.

Figure 10.2- Common Fittings - SINTAJOINT pipelinesNote that reducers may require a thrust flange.

C H A P T E R 1 0 | 43


Anchor block for horizontal bend

Anchor block for horizontal taperAnchor block for horizontal tee

11. Anchorage of Pipelines


C H A P T E R 1 1 | 45

Figure 11.3 - Pier support for above ground SINTAJOINT pipelines

Hold down over bearing material

Bearing material toaccommodate

expansion movementwhere necessary

Anchor block for vertical slope Anchor block for vertical bend

Figure 11.1- Anchor blocks for horizontal thrust restraint

Static thrustsAll pressure pipelines having unanchored

flexible joints, require anchorage at changes of

direction, changes in diameter, tees, valves

and at blank ends to resist the thrusts

developed by internal pressure.

Additional dynamic thrusts are created by

moving water but are usually negligible unless

the flow velocity is extremely high.

Anchorage of buriedmainsAnchorage to resist thrusts must be designed

for the maximum pressure expected in the

main in service or during test. Anchorage can

be provided in several ways:

� Anchor blocks,

� Ties to concrete blocks, or

� Pipe surface friction

The most common method is the use of

concrete anchor blocks. These should be

poured immediately after excavation for the

block to ensure that the soil bearing strength

does not deteriorate. Where possible

concrete anchor blocks should be of such a

shape as to allow sufficient space for the

joints to be pulled apart, pipe or fittings

replaced and reassembled.

Anchor blocks forhorizontal thrust-buriedmainsThe horizontal thrust developed in buried

mains must be transferred to the undisturbed

soil of the trench wall by anchor blocks poured

against the soil face. The thrust is distributed

over the total bearing area of the block to

ensure that the safe bearing pressure of the

trench wall is not exceeded. See Figure 11.1

Anchor blocks forvertical thrust restraint.Downward vertical thrusts are transferred to

the undisturbed ground by anchor blocks in

the same manner as horizontal thrusts.

44 | C H A P T E R 1 1

B e a w a r e o f y o u r s u r r o u n d s B e a w a r e o f y o u r s u r r o u n d s

Upward vertical thrusts are counteracted by

the weight of the concrete anchor block.

If the water table in the area is likely to reach

the level of the anchor block, the submerged

weight of the block must be sufficient to

counteract the thrust. If the natural ground is

of sufficient strength ie., rock, special anchor

blocks can be cast into the rock to resist

upward thrust forces. See Figure 11.2

Ties to concrete blocksTies are rarely used except where there is

limited space or lack of bearing area behind

the pipe fitting.

Pipe surface frictionThrust resistance can be achieved by utilising the

skin friction between the pipe and soil surround.

This requires the welding or harnessing of several

pipe lengths, the length of which must be

determined by the pipeline design engineer.

Above ground pipesFor above ground applications all steel pipes

must be supported and anchored. Where

relative movement of the pipe support and

anchorage is likely, the bearing materials should

be chosen to allow for this. See Figure 11.3

Figure 11.2- Anchor blocks for vertical thrust restraint


Location A Location BTest pressure 200m Test pressure 175m

200m test pressure required at Location AGauge at A should read 200mGauge at B should read 175m

25m static head

Pipeline section under test

12. Hydrostatic field test

Figure 12.1- Static head allowance for hydrostatic test with alternative pressure gauge locations

A pipeline is subjected to a field pressure test

primarily to check that all joints are watertight.

At the same time the test checks the integrity

of all fittings and appurtenances, as well as

construction work such as anchorages.

It is recommended that a hydrostatic test iscarried out on the first 200m of pipe laid to

confirm that laying practices are effective.

Where concrete anchor blocks are installed,a reasonable time must be allowed for the

concrete to cure before testing commences.Cement mortar lined pipe should becompletely filled with water of approved

quality and allowed to stand for at least 24

hours. This permits maximum absorption of

water by the lining and release of any air.

Additional water should be added to replace

the quantity absorbed.

The pipeline should be filled slowly to

prevent water hammer and to minimise

entrapment of air. If the pipeline section to

be tested is not provided with isolation

valves then the ends must be fitted with

bulkheads. Pipes or bulkheads must be

fitted with the necessary outlets forincoming water and outgoing air.

The hydrostatic test usually commences

after the 24 hour standing period.

The water pressure should be raised to the

specified field test pressure, such

pressure being measured at the lowest

point of the section under test.

Alternatively a static head allowance may

be made between the lowest point and the

point of the section under test.

See Figure 12.1.

46 | C H A P T E R 1 2

T a k e t h e c o r r e c t a t t i t u d e t o s i t e T a k e t h e c o r r e c t a t t i t u d e t o s i t e

C H A P T E R 1 2 | 47

Field hydrostatic test pressures are specified

by the design Engineer after consideration of

the working pressure of the pipeline.

The test pressure should be maintained for at

least 2 hours.

If the pressure has dropped at the end of the

test, the volume of water needed to restore

the original pressure should be measured.

The test should be repeated a number of

times with any make-up volume being

measured. This make-up volume may result

from pipe movement and compression of

small quantities of entrapped air. Some

leakage may be permitted to accommodate

field constructed mechanical joints, and seals

on fittings and appurtenances.

Allowable make-upvolumeAny allowable make-up volume should be

specified by the designer.

A generally accepted make-up volume rate is;

Allowable make-up rate (L/hr) =

1.4 x 10-7x D x L x H

Where D = Pipe OD (mm),

L = Pipeline length (m),

H = Average test head(m)

If the specified allowable make-up volume is

exceeded the following procedure should be

followed.

Ensure that all air has been expelled and the

24 hour standing period has elapsed.

Check all valves for full closure and sealing.

Check all mechanical joints, gibaults and

flanges. Bolts should be uniformly tight and full

sealing achieved.

If subsequent testing still results in

unacceptable make-up volume, the ground

above the line should be inspected for signs

of obvious leakage. If none are apparent the

line should be tested in halves with the failing

section being subsequently halved and tested

until the leak is located.


Choose either heat shrinksleeve (preferred) or tape

wrap field joint coating

Use either adhesivepatch, heat shrink

sleeve or tape wrapcoating method

Repair is atSINTAJOINT ends,use Drader welding

repair method

Isrepair

a welded field

joint?

Isrepair

away fromSINTAJOINT

ends?

Isrepair area

>10,000mm2?(100 x 100mm)

Prior to commissioning ensure the removal of

any solid material from the inside of the

pipeline including rubbish, dirt, welding stubs

and other foreign matter.

This may be achieved by placing a swab or

“pig” through the line or in the case of larger

diameter pipes, by operators travelling through

the line. Only soft foam swabs (with no

scouring pad attachments) should be used on

seal coated pipelines.

A pipeline which will carry potable water

should be sterilised with chlorinated water in

accordance with the water authority’s

requirements.

13. Commissioning water pipelines

48 | C H A P T E R 1 3

D e f i n e r e s p o n s i b i l i t i e s

A P P E N D I X A | 49

Mild steel cement mortar lined pipe is

supplied with SINTAKOTE, a fusion bonded

medium density polyethylene coating for

welded or rubber ring jointing. Fittings may be

fabricated from SINTAKOTE pipe, but are also

available as SINTALINK fittings, entirely coated

with SINTAKOTE.

In order to determine whether or not a

damaged area requires repair the following

assessment should be made:-

Continuity test at 12kV. If a holiday is

detected then repair.

Determine the coating thickness. If less than

1.0 mm then repair.

Figure A.1 has been devised to determine the

best method for field repair of SINTAKOTE for

buried service at ambient temperature. Heat

shrink sleeves are the preferred method of

protection of field welds.

Enclosed are the procedures for heat shrink

sleeve coating (A1), tape wrap coating (A2),

adhesive patch repair (A3), Drader gun welding

repair (A4) and SINTAPIPE end repairs (A5).

The use of petrolatum tape protection

systems is not recommended for the repair or

field joint coating of SINTAKOTE. This is

primarily due to their very poor resistance to

soil stresses.

The techniques detailed in this Appendix do

not apply to pipelines operating at

temperatures above 30 0C, nor do they apply

to piles/pipelines used in above ground

situations. For repair/joint coating of these

pipes contact Tyco Water.

Figure A.1 - Flow chart for determiningappropriate SINTAKOTE repair method

APPENDIX A - Field repair and Joint

Reinstatement of SINTAKOTE®

Choose either heat shrinksleeve (preferred) or tape

wrap field joint coating

YES

YESYES

NO NO

NO


The application of heat shrink sleeves will give

the optimum field protection. However,

personnel applying sleeves need to be fully

trained and experienced.

Recommended SleevesThe recommended sleeves are:

1. Raychem WPCB available from Petro Coating Systems Pty. Ltd. The primer is Petrocote primer.

2. CANUSA KLS available from Denso PtyLtd. The primer is Denso Primer.D.

Application procedure

1. Bevel the edges of the SINTAKOTE so that

there is a tapered transition of at least 5 mm

between the full coating thickness and the

exposed steel.

2. Remove any corrosion products on the

steel and abrade the steel surface

(if necessary) to produce a clean, non-

corroded, roughened surface. Suitable

abrasives are emery paper or a steel file.

3. Prepare the area to be repaired (to be

free from dirt, dust and other contaminates)

in accordance with the recommendations

of the shrink sleeve manufacturer.

4. Using 120 grit emery or sandpaper slightly

roughen the SINTAKOTE around the repair

for a minimum distance of 100 mm from

the edge of the repair. Solvent wipe the

SINTAKOTE with a clean cloth (isopropanol

is a suitable solvent for cleaning).

5. Apply the shrink sleeve in accordance with

the application procedures of the manufacture.

If preheating cannot be achieved, brush apply

a thin film of primer to any steel not coated with

SINTAKOTE and onto the SINTAKOTE for a

distance of 100 mm. Do not apply the primer

prior to preheating. Ensure that the sleeve

overlaps the SINTAKOTE for a minimum width

of 100 mm. Note that the specified preheat

and postheat is necessary to ensure

satisfactory bonding of the sleeve. A roller

should be used to eliminate voids from under

the sleeve.

6. The repair should be visually inspected to

ensure that it is in intimate contact with the

pipe and that a bead of mastic has exuded

from each end of the sleeve for the full pipe

circumference. (If this is not in evidence

additional heating is required).

Procedure A1 - Heat Shrink Sleeve Coating Method

50 | A P P E N D I X A


Procedure A2 - Tape Wrap Coating Method

This tape system provides a thick coating repair

or field joint coating with similar impact resistance

to that of SINTAKOTE. Thinner coating systems

may not provide the same degree of protection.

The outerwrap of a thin PVC tape is provided to

reduce soil stresses as far as is possible with a

tape wrap system. A heat shrink sleeve

repair/joint protection is recommended for

optimum resistance to soil stresses.

Recommended tape wrapThe following tape system or equivalent is

recommended:-

Primer - Denso Densolen HT primer or

Denso Primer D.

Primary tape - Denso Ultraflex 1500 tape with

a minimum 55% overlap.

Secondary tape - Denso MP/HD tape with a

minimum 10% overlap.

These products are available from Denso

(Aust.) Ltd.

Application procedureThe method of application should be in

accordance with the tape manufacturer’s

recommended procedures with the following

additions:-

PreparationUse a knife to remove all burrs/stubs from the

parent coating. For coating repair, slightly

roughen the SINTAKOTE for 100 mm from the

edge of the repair using 120 grit emery.

The steel and coating area should be clean

and dry before application of the primer.

Procedure1. Cut out a piece of tape (Ultraflex 1500)

to fit into the bare steel area. (This is used

for repair, it is not necessary for field

joint coating).

2. Using a brush, apply a thin even coat of

primer onto the steel and onto the

SINTAKOTE by 100 mm.

3. Allow the primer to tack dry (approx.

10mins). Insert into the repair the cut piece

of tape.

4. Spirally apply the tape (Ultraflex 1500)

to the repair area ensuring a 100 mm

overlap onto the SINTAKOTE. The overlap

of tape layers should not be less than

55% of tape width.

5. Spirally apply the outerwrap (Denso

MP/HD) to completely cover the first layer

of tape coating. The overlap of layers

should not be less than 10% of the

overwrap width.

6. Some tension should be applied

when applying the tapes to ensure

that air voids, wrinkles etc. are not

present after wrapping.


Jointing Region200mm

Jointing Region

This method is recommended for repair areas

up to 10,000 mm2 (ie 100 x 100 mm). It is

only recommended for field use. The method

uses a mastic filler, a heat fused repair patch

and an overwrap tape. The tape overwrap is

provided to reduce the effect of soil stresses

on the patch coating. A heat shrink sleeve

coating is recommended for optimum

resistance to soil stresses (see A1). Note that

rolls of Perp material should not be left in the

sun as the product can heat up and cause

the layers in a roll to fuse together.

Recommended MaterialsThe following system or equivalent is

recommended:

� Filler - Raycem Perpfiller

� Patch - Raychem Perp

� Overwrap - PCS PVC250 overwrap

Products available from Petro Coating Systems.

Application ProcedureRecommended adhesive repair patches

1. Clean and dry the area to be repaired (free

from dirt, dust and other contaminates). At all

the coating interfaces with bare steel, the

coating must be bevelled to an angle of ≤300

to the steel.

2. Cut a patch from the Perp roll big enough

to extend 80mm beyond the damaged area on

all sides. The corners of the Perp patch should

be rounded to at least a 30mm diameter.

3. Slightly roughen the SINTAKOTE around

the repair for a minimum distance of 80 mm

from the edge of the coating damage, using

120 grit emery. Solvent wipe the SINTAKOTE

with a clean cloth (acetone and isopropanol

are a suitable solvents for cleaning).

4. Preheat the entire region to be covered by

the patch (including the exposed bare metal), to

a minimum temperature of 600C, with a yellow

flame from a propane/air gas torch. The

temperature can be measured with a melt stick.

5. Place a pre-cut piece of Perpfiller to cover

the area of exposed steel. Heat the mastic

and smooth it with a flame heated paint

scraper type blade to cover all bare metal and

to exclude all air. Do not smear the mastic

over the SINTAKOTE. Any excess mastic

should be removed so that the mastic just fills

the damaged region.

6. Apply a yellow flame to the SINTAKOTE to

warm the surface.

7. Apply a yellow flame to the adhesive side

of the Perp until it appears glossy.

8. Immediately apply the patch to the

damaged area centering the Perp with respect

to the damage.

9. Heat, using the gas torch, from the centre

of the Perp, and use rubber coated or Teflon

roller to eliminate any entrapped air. Continue

heating and rolling until adhesive is observed

exuding from all areas of the Perp.

10.Ensure the area to be tape wrapped is

clean and free from any dirt/contamination.

If in doubt, solvent wipe.

11.Spirally apply the Denso MP/HD tape

around the full circumference of the pipe, with

tension applied, to completely cover the patch

repair and overlap it by at least 80mm on all

sides. The tape overlap should not be less

than 10% of the tape width.


Procedure A3 - Adhesive patch repair method Procedure A4 - Drader welding repair method (for field repair at SINTAJOINT pipe ends only)

For use only where damaged SINTAKOTE

surfaces occur in the jointing region shown

in Figure A2. The Shrink Sleeve method or

Adhesive Patch method should be used

where damage occurs away from the joint

region.

This method is the only approved method for

repairing the spigot end and socket end of

SINTAJOINT pipe or fittings.

When properly executed, this method will

ensure good fusion between the filler material

and existing SINTAKOTE.

QualificationsEach operator who is to make repair welds

upon coatings should be suitably practised

and should be able to achieve adequate

fusion in practice welds. Such welds can be

evaluated by removing full thickness

sections perpendicular to the weld.

These sections can then be bent one way

and then the other, through an angle of

approximately 300, to place the internal

and external surfaces of the coating in

tension. Any lack of fusion indicate an

unsatisfactory weld.

Welding equipment1. Drader extrusion welder and suitable

welding tips. Refer Figure A.3 & A.4.

2. 240 V extension lead and power supply

3. Air supply 550 to 700 kPa (80 to 100 psi)

4. Thick leather gloves

5. Wraparound tip

Figure A.2 - Joint Region for Materials Drader welding repair 1. A 4 mm nominal diameter extruded

medium density polyethylene filler rod supplied

by Tyco Water. (SINTAKOTE filler rod).

2. Clean cotton rags and isopropanol cleaning

solution.

General Instructions1. The Drader Injectiweld can produce sound

weld deposits of various shapes that are

effectively bonded to the original surface

provided the correct technique is used.

2. Temperature setting – The welder unit

should be preset to 270ºC initially and no

further adjustment is necessary.

3. Select the correct tip and fit to the gun as

follows:

Remove the retaining nut with the tool

provided. This will require the gun to be

switched on and heated up for a few minutes.

Remove the previous tip being careful to

locate the aluminium washer that is fitted

between the tip and the body of the gun.

4. Figure A.3 shows the gun with tip removed.

Always replace the washer: Failure to replace the

washer before fitting the new tip will allow

extruded material to be forced down these holes

and possibly damage the heater and/or sensor.




Barrel

GunHandle

SensorIndexing Pin

Heater

AluminiumWasher

Figure A.3 – Drader gun assembly


5. Apply a small amount of the ‘Heat transfer’

paste to the top of the washer and the

threads of the body to enable them to be

easily removed later. Place the gun on a

horizontal surface so that it is pointed up and

place the tip over the end so that it fits snugly

over the washer and pin. Occasionally the tip

may not engage correctly because the

locating holes are filled of plastic. In this case

wait until the tip heats up and melts the plastic

in the holes. Ensure that the tip sits firmly on

the washer and place the retaining nut over

the tip and push it down until it engages the

thread (use thick gloves and/or cotton rags to

prevent burning hands – all of these

components will get hot).

6. Never place the tip into the retaining nut

first and screw it onto the gun. This could

break off the locating pin making it very

difficult to repair.

7. Screw the retaining nut up tight with the tool

provided. This process may need to be repeated

a few times as the components heat up and the

retaining nut expands. (It may also be necessary

to heat up the gun to replace a tip later).

8. Fit the Ø4 mm plastic wire into the hole at

the base of the gun and rotate the feed nut to

engage the wire. The wire should not be able

to be pulled out from the gun when correctly

engaged. Never operate the feed trigger

without plastic wire being engaged. This could

result in damage to the feed mechanism.

Various concave tips for wraparound end repairThese specially developed tips are designed

to repair the Sintajoint wraparound ends in a

single pass. They produce a finished end that

generally only needs one side trimmed,

(outside of the spigot or inside of the socket)

The technique used for the repair of end

damage requires a determination of the

extent of the damage. Small damage such as

punctures or dents might be repaired with a

number of tips including the Cone tip, Ball

end tip, the 3/16’ Fillet weld tip or one of the

butt weld tips.

Large damage which involve more than 25

mm long repairs to the end will be best

repaired with the concave tip that suits the

particular plate thickness.

These tips are identified as W06 for 6 mm

pipe wall thickness, W08 for 8 mm pipe wall

thickness etc. The following procedure

describes the use of these concave tips.

If there is a split in the coating away from the

end of the pipe this should be first repaired with

a butt weld tip before attempting this repair.

Operators who attempt this repair technique

should have attended a Sintakote repair

training course and be certified as being

competent in the use of the equipment.

1. Clean the affected area to ensure that all

the dust and foreign matter is removed from

the repair area. Use a file or knife to remove

any coating that may be sticking out.

2. The transition area from full thickness at the

start and finish of the defect should be tapered

over about 40 mm to enable the tip to travel

smoothly without catching on any step. This is

best done with a sharp knife or rasp.

3. Fit the Concave tip that suits the pipe wall

thickness to the gun. Experience has shown

that it is better to fit the tip so that the groove

is horizontal when the gun is held out with the

handle vertical. This means that the gun

travels sideways and gives the operator a

better view of the repair area both in front of

and behind the weld.

4. Ensure that the heating tip has reached the

correct temperature and that the LED is flashing.

5. Test the feed rate by pressing the trigger

for several seconds until a quantity of plastic

extrudes out of the end of the tip. Adjust the

feed rate to give a moderate flow (no more

than 2 pulses per second has been found to

give good results). Remove the extrudate with

a knife or suitable tool.

Figure A.4 - Drader gun tip selection 6. Determine the line of weld that the repair

should be laid along and place the welding

tip about one tip length before the transition

to the defect. This ensures that any lack of

bond on start up is outside the original

defect area. The gun should be held so that

it remains straight out from the pipe end but

angled sideways (about 150) in the direction

of the weld as determined by the angle of

the tip, keeping the full face of the tip in

contact with the end of the pipe at all times.

Make certain that the surface beneath

the tip begins to melt before commencing

the weld.

7. Hold down the trigger and start moving the

welder the required direction at a constant

speed to ensure smooth feeding of the

weld pool.

8. Use a travel speed that will give good build

up of material and good coverage of the

coating on both sides (see Figure A.5). Failure

to get good fusion on either or both sides will

result in further more complicated repairs.

(Generally good fusion will result when the

build up on either side of the end is about the

same). If there is still poor fusion then the

travel speed is too fast.

9. It is important to complete the line of weldwithout stopping until the tip is beyond thedefect area otherwise a new transition willhave to be prepared before restarting repairs.



Welding tip

Plastic depositOutside

Trim excessive material

Figure A.6 – Care required when trimmingFigure A.5 – Build up of material on cut end

Procedure A5 - Wraparound reinstatement of SINTAPIPEafter field cutting

EquipmentRefer to Procedure A.4

MaterialsRefer to Procedure A.4

General InstructionsRefer to Procedure A.4

Various concave tips for wraparound end reinstatement

1. Identification Marks W05, W06, W08, W10,

W11 etc. for 5,6,8,10 and 11 mm wall

thickness pipes.

2. These specially developed tips are designed

to reinstate the Sintakote around the end in a

single pass. It will produce a sound repair that

is bonded to the external and internal coating.

10. When the run is completed angle the

gun so that it is perpendicular to the end of

the pipe and continue to extrude material as

the tip is withdrawn from the surface. This

will reduce any plasticised defects caused

by the tip.

11. When the weld has solidified the excess

material can be removed using a suitable

tool, being careful not to cut below the

original surface level (see Figure A.6).

12. Remove material from the end in the start

and finish zone where double thickness has

been applied.

13. Do not remove any material from the end

in the defect zone. (Wood rasps and planer

can be used for this purpose). It is only

necessary to remove excess material from

the outside of the spigot. It is better to

remove the excess from both the inside

(necessary) and outside of the socket to give

a better appearance.

14. Visually examine the finished area for

defects and repair if necessary using a

suitable tip.

15. Check the repair using a High Voltage

Holiday Detector. Repair any defects and retest.


It is assumed that the pipe has been cut

with a suitable machine and is presented

with the coating and lining flush with the

end of the pipe.

Operators who attempt this repair technique

should have attended a Sintakote repair

training course and be certified as being

competent in the use of the equipment.

1. Clean the affected area with isopropanol to

ensure that all the dust and foreign matter is

removed. Use a file or knife to remove any

coating that may be sticking out.

2. Fit the Concave tip that suits the pipe wall

thickness to the gun. Experience has shown

that it is better to fit the tip so that the groove

is horizontal when the gun is held out with the

handle vertical. This means that the gun

travels sideways and gives the operator a

better view of the repair area both in front of

and behind the weld.

3. Ensure that the heating tip has reached the

correct temperature (i.e. the LED is flashing.)

4. Test the feed rate by pressing the trigger for

several seconds until a quantity of plastic

extrudes out of the end of the tip. Adjust the

feed rate to give a moderate flow (no more

than 2 pulses per second has been found to

give good results). Remove the extrudate with

a knife or suitable tool.

5. The gun should be held so that it remains

straight out from the pipe end but angled

sideways (about 15º) in the direction of the

weld as determined by the angle of the tip.

Keep the full face of the tip in contact with the

end of the pipe at all times. Make certain that

the surface beneath the tip begins to melt

before commencing the weld.

6. Hold down the trigger and start moving

the welder the required direction at a

constant speed to ensure smooth feeding of

the weld pool.

7. Use a travel speed that will give good build

up of material and good coverage of the

coating on both sides (see Figure A.5). Failure

to get good fusion on either or both sides will

result in further more complicated repairs.

(Generally good fusion will result when the

build up on either side of the end is about the

same). If there is still poor fusion then the travel

speed is too fast.

8. It is recommended to complete as much

welding as possible without stopping as a

new transition will have to be prepared for

each start. The start area must be feathered

back to the surface to remove any unbonded

areas and to provide a smooth area for

finishing the weld.

9. To complete the run make sure that the

bead finishes past the initial start area to

ensure a complete seal.

10. When the weld has solidified the excess

material can be removed using a suitable tool

being careful not to cut below the original

surface level (see Figure A.6).

11. Visually examine the finished area for defects

and repair if necessary using a suitable tip.

12. Check the repair using a High Voltage

Holiday Detector. Repair any defects and retest.

The finished end should now be suitable for

the attachment of a pipe coupling.



58 | A P P E N D I X B

APPENDIX B

Field Repair and Joint Reinstatement of Cement Mortar LiningThe cement mortar lining of steel pipes in

factory production is carried out in

accordance with Australian Standard

AS 1281- Cement mortar lining of steel pipes

and fittings using a centrifugal process. This

method ensures a dense, low water cement

ratio mortar in close contact with the steel. In

the factory all pipes are end capped and held

for several days to enable the mortar to cure.

Pipe fittings are lined in the factory either using

a centrifugal mortar applicator, by hand lining

or by a combination of centrifugally lined pipe

with the joints reinstated by hand. Lined

fittings are end capped and allowed to cure

before delivery.

In order to determine whether or not the

mortar requires repair the following procedure

should be followed:-

1. Use a 2.0 mm feeler gauge and see if it

can be inserted to a depth greater than half

the thickness of the lining. If it can, the mortar

should be repaired as described in B2.

2. Use the feeler gauge to determine if the

mortar has disbonded to give a gap in excess

of 2 mm between the mortar and the steel

pipe. This can be measured by attempting to

insert the feeler gauge into the gap (at the

ends of pipe) or to check if the step between

adjacent sections of the lining (at a crack) is

greater than 2 mm. If the disbondment is

greater than 2 mm break out the disbonded

lining and repair as described in B1.

Disbonded (drummy) linings are acceptable

provided the above criteria are not exceeded

or if potable water is placed inside the pipe

and water absorption leads to total loss of the

drumminess.

Cement mortar lining repairs and pipe joint

reinstatement are usually done by hand

application of the cement mortar.

The procedures detailed herein aresummarised as follows:-

1. Lining repair using premixed materials.

2. Epoxy repair of cement mortar lining cracks.

A P P E N D I X B | 59

Procedure B1 - Cement mortar lining repair method

Using EZILINE Premixed Materials (for field repair/joint reinstatement)

The EZILINE Mortar Mix is a high performanceproduct specifically designed for compatability

and use in reinstating the field joints and repairof Tyco Water cement mortar lined steel pipes

Materials

Available from Tyco Water in kit form.

Dry Mix - Part AType SR blended cement in compliance

with AS 3972 and sand in full compliance

with AS 2758.1.

Liquid - Part B

The liquid is a high performance acrylic

modifier.

Primer - Liquid Part B is used undiluted asthe primer.

For safe use of the product, refer to the

MSDS.

7. The mortar should be protected fromexcessive heat, water and sub-zero temperaturesduring the first 24 hours from placement. It

least 7 days prior to service.

Application Instructions1. Ensure all surfaces are free of grease

oil, paint and loose or flaking materials.

and fittings. 2. Wet the adjacent mortar, leaving

the surface damp, but with no excess/pooledwater

3. Brush apply a primer coat of Part B (liquid)

to cover the steel and adjacent mortar.

Note do not dilute. The mortar can be applied when this coat is wet or dry, but must be

applied the same day, otherwise apply another

prime coat.

4. Thoroughly manually mix Part A (do not usea cement mixer) and as much of Part B required to form a stiff workable mixture.Do not add water. Ensure there is no dry mixture present. Note the working time reduces with temperature,and is apporx. 20 minutes at 300C.

5. Apply the mortar, compacting it into placeto the level of the adjacent mortar.

6. Finish with a metal trowel to provide a smootheven finish.

should be allowed to fully dry/cure for at

8. Open bags of mortar not used within 24 hoursshould be discarded thoughtfully.

9. Dispose of packaging and waste materialappropriately after use.

Epoxy grout

4 – 6mm

Steel pipe

Crack

Cementmortar lining


This method is applicable to repair of cracks

in cement mortar lined (CML) pipes. It is used

to repair cracks that are greater than the

2.0mm width allowed in AS 1281.

MaterialsThe following materials are suitable:-

Epirez construction products - Epirez 633

solventless epoxy paste. Epirez advises that this

product meets the requirements of AS/NZS 4020

for contact with drinking water, or Hilti (Aust) Pty.

Ltd. CA 273 solventless epoxy paste.

PreparationThe CML should be dry at the time of

undertaking the repair.

Enlarge the crack to a width of 4 to 6mm

using a 100 mm angle grinder (or equivalent)

fitted with a diamond tipped cutting blade

nominally 3.2mm in width. The depth of the

groove should be set at 2mm less than the

lining thickness. The depth should be

checked with a ruler.

Application1. Mix the resin and hardener components of

the epoxy paste thoroughly in the specified

ratio. Mix a reasonable quantity of product to

ensure that the mix ratio is achieved. Only

mix an amount that can be placed within 20

minutes. Discard all product that is not used

within 20 minutes. The minimum application

temperature is 5ºC. For large repairs the

easiest method of application is to fill

an empty caulking gun container and apply

with a caulking gun. This method pushes the

epoxy into the groove to completely fill the

space and exclude air.

2. With a spatula or knife applicator press theepoxy into the groove to exclude all air.Slightly overfill as shown in the diagram.

Allow to cure for at least 24 hours prior to

exposure of the epoxy to water.

Figure B.3 - Completed repair

Figure B.1 - Typical cement mortarlining crack greater than 2mm.

Figure B.2 - Enlarge crack to 4 – 6mm

Procedure B2 - Epoxy repair of cement mortar lining cracks


60 | A P P E N D I X B

to CP LugsField Application of Electrical Cables

A P P E N D I X C | 61

APPENDIX C

M a t er ia ls

• Cable cutter suitable for 25 mm2 copper cable (ALM type ME 11-65, Wattmaster ME 60 or equivalent.)

• Hand crimping tool (Wattmaster MK 80, Utilux No 20 or equivalent. (See picture below.)

Note: Hydraulic type crimpers are not suitable for crimping this style of lug.

• Cable (19/1.35 (25 mm2) single core double insulated P.V.C.

• Shrink tube 100 long (Raychem WCSM 28/9 / 1200)

• Knife or stripping tool (For cable and 9.5 mm dia lug)

• Battery operated hand drill and 6.5 mm bit (17/64”)

• Solvent (Methylated Spirits, isopropanol or acetone) and clean rags

• Propane/Butane heating torch with primus 2956 burner or equivalent

P r o c e d u r e

1. When making the joint make sure that both lugs are aligned as close as possible (Fig 1), preferably, at the top of the pipe.

Fig. 1

2. Strip the Sintakote for a distance of 25 mm from the end of the lug by cutting around the full circumference of the lug and twisting the loosened Sintakote cap. (See Fig 2)

Fig. 2 Using the battery drill on low speed insert the 6.5 mm drill bit into the hole in the end of the lug to remove any residual Sintakote and clean the inside copper surface.

62 | APPENDIX C

3. Cut the length of cable to the required length (distance between the lugs including room to bend the cable) using the cable cutters. Bare both ends of the cable for a distance of 20 mm taking care to avoid damaging the ends of the copper cable. See Fig 3

Fig. 34. Slide two lengths of shrink

tube over the cable and insert the ends into the hole on the lugs of each pipe.

5. Adjust the screw on the crimp tool for 25 mm2 cable and while holding the cable firmly into the lug make a crimp close to the end of the lug. The crimp must be made from the top with the tool at 90º to the pipe surface Repeat this operation adjacent to the first crimp. (see Fig. 4)

Fig 4(In the diagram above the crimp appears on the top of the lug for illustration purposes – in practice it will be on the sides of the lug).

6. Clean the surface of the lug and at least 50 mm of cable next to the lug using methylated spirits and a clean rag.

7. Slide the shrink tube down to the surface of the pipe and using a low flame heat the sleeve around the location of the crimp join as shown in Fig 5. Move the flame outwards towards the cable end of the tube whilst heating the tube all around. When this is completed a small amount of adhesive/sealant will squeeze from the end of the tube.

Fig. 5 Repeat this operation

towards the pipe end until sealant squeezes out from that end. See Fig 6

Fig. 6 8. Repeat procedure 6 and 7

on the other lug and cable end to complete the joining operation.




A P P E N D I X D | 63

114 4.8 1.6 9 86.4 19.9 19.4 0.1 na na na

114 4.8 1.6 9 86.4 19.9 19.4 0.1 na na na168 5 1.6 9 140 31.0 30.2 0.2 0.3 na na190 5 1.6 9 162 35.3 34.4 0.2 0.3 na na

219 5 1.6 9 191 41.0 40.0 0.2 0.4 na na240 5 1.6 9 212 45.1 44.0 0.3 0.4 na na257 5 1.6 9 229 48.5 47.2 0.3 0.4 na na273 5 1.6 9 245 51.6 50.3 0.3 0.5 na na290 5 1.8 12 256 61.0 59.4 0.4 0.5 na na

305 5 1.8 12 271 64.3 62.6 0.4 0.6 na na324 4 1.8 12 292 60.8 59.1 0.4 0.5 na na324 4.5 1.8 12 291 64.6 62.9 0.4 0.6 na na324 5 1.8 12 290 68.4 66.7 0.4 0.6 na na324 6 1.8 12 288 76.0 74.2 0.5 0.7 na na337 4 1.8 12 305 63.4 61.6 0.4 0.6 na na337 4.5 1.8 12 304 67.3 65.5 0.4 0.6 na na337 5 1.8 12 303 71.3 69.5 0.4 0.6 na na337 6 1.8 12 301 79.1 77.3 0.5 0.7 na na344 4 1.8 12 312 64.7 62.9 0.4 0.6 na na344 4.5 1.8 12 311 68.8 66.9 0.4 0.6 na na344 5 1.8 12 310 72.8 71.0 0.4 0.7 na na344 6 1.8 12 308 80.8 79.0 0.5 0.7 na na356 4 1.8 12 324 67.1 65.2 0.4 0.6 na na356 4.5 1.8 12 323 71.3 69.4 0.4 0.6 na na356 5 1.8 12 322 75.4 73.5 0.5 0.7 na na356 6 1.8 12 320 83.8 81.9 0.5 0.8 na na

406 4 1.8 12 374 76.8 74.6 0.5 0.7 0.9 1.0406 4.5 1.8 12 373 81.6 79.4 0.5 0.7 1.0 1.1406 5 1.8 12 372 86.4 84.2 0.5 0.8 1.0 1.2406 6 1.8 12 370 96.0 93.8 0.6 0.9 1.2 1.3406 8 1.8 12 366 114.9 112.8 0.7 1.0 1.4 1.6419 4 1.8 12 387 79.3 77.1 0.5 0.7 1.0 1.1419 4.5 1.8 12 386 84.3 82.1 0.5 0.8 1.0 1.1

Stee

l out

side

di

amet

er (m

m)

Stee

l wal

l th

ickn

ess

(mm

)

SIN

TAKO

TE

thic

knes

s (m

m)

Cem

ent m

orta

r lin

ing

thic

knes

s (m

m)

Cem

ent m

orta

r lin

ing

bore

(mm

)

Mas

s pe

r met

re

SKC

L (k

g/m

)

Mas

s pe

r met

reU

CC

L (k

g/m

)

6.0

9.0

12.0

13.5

APPENDIX D

General Data

Pipe OD SINTAKOTE Thickness(mm) (mm)

≤273 1.6

>273 to 508 1.8

>508 to 762 2.0

>762 2.3

Pipe OD CML Thickness(mm) (mm)

≤273 9 ± 3

>273 to 762 12 ± 4

>762 to 1219 16 ± 4

> 1219 to 1829 19 ± 4

Table D.1 – SINTAKOTE Thicknesses

Table D.3 – SINTAKOTE Steel Pipe Bores and Weights

Table D.2 – Cement Mortar Lining (CML) Thickness

SKCL PIPE Weight (tonnes)Pipe Length (m)



64 | A P P E N D I X D

419 5 1.8 12 385 89.2 87.0 0.5 0.8 1.1 1.2419 6 1.8 12 383 99.1 96.9 0.6 0.9 1.2 1.3419 8 1.8 12 379 118.7 116.5 0.7 1.1 1.4 1.6457 4.5 1.8 12 424 92.2 89.7 0.6 0.8 1.1 1.2457 5 1.8 12 423 97.6 95.1 0.6 0.9 1.2 1.3457 6 1.8 12 421 108.4 106.0 0.7 1.0 1.3 1.5457 8 1.8 12 417 129.9 127.4 0.8 1.2 1.6 1.8

502 4.5 1.8 12 469 101.5 98.8 0.6 0.9 1.2 1.4502 5 1.8 12 468 107.4 104.8 0.6 1.0 1.3 1.5502 6 1.8 12 466 119.4 116.7 0.7 1.1 1.4 1.6502 8 1.8 12 462 143.1 140.4 0.9 1.3 1.7 1.9508 4.5 1.8 12 475 102.7 100.0 0.6 0.9 1.2 1.4508 5 1.8 12 474 108.8 106.1 0.7 1.0 1.3 1.5508 6 1.8 12 472 120.8 118.1 0.7 1.1 1.4 1.6508 8 1.8 12 468 144.8 142.1 0.9 1.3 1.7 2.0559 4.5 2 12 526 113.6 110.3 0.7 1.0 1.4 1.5559 5 2 12 525 120.3 117.0 0.7 1.1 1.4 1.6559 6 2 12 523 133.6 130.3 0.8 1.2 1.6 1.8559 8 2 12 519 160.1 156.8 1.0 1.4 1.9 2.2

610 4.5 2 12 577 124.2 120.6 0.7 1.1 1.5 1.7610 5 2 12 576 131.5 127.9 0.8 1.2 1.6 1.8610 6 2 12 574 146.1 142.5 0.9 1.3 1.8 2.0610 8 2 12 570 175.1 171.5 1.1 1.6 2.1 2.4610 9.5 2 12 567 196.7 193.1 1.2 1.8 2.4 2.7648 4.5 2 12 615 132.1 128.2 0.8 1.2 1.6 1.8648 5 2 12 614 139.8 136.0 0.8 1.3 1.7 1.9648 6 2 12 612 155.4 151.5 0.9 1.4 1.9 2.1648 8 2 12 608 186.3 182.4 1.1 1.7 2.2 2.5648 9.5 2 12 605 209.3 205.5 1.3 1.9 2.5 2.8660 4.5 2 12 627 134.5 130.6 0.8 1.2 1.6 1.8660 5 2 12 626 142.5 138.6 0.9 1.3 1.7 1.9660 6 2 12 624 158.3 154.4 0.9 1.4 1.9 2.1660 8 2 12 620 189.8 185.9 1.1 1.7 2.3 2.6660 9.5 2 12 617 213.3 209.4 1.3 1.9 2.6 2.9660 12 2 12 612 252.2 248.3 1.5 2.3 3.0 3.4

700 4.5 2 12 667 142.8 138.7 0.9 1.3 1.7 1.9700 5 2 12 666 151.3 147.1 0.9 1.4 1.8 2.0700 6 2 12 664 168.1 163.9 1.0 1.5 2.0 2.3700 8 2 12 660 201.5 197.4 1.2 1.8 2.4 2.7700 9.5 2 12 657 226.5 222.4 1.4 2.0 2.7 3.1700 12 2 12 652 267.9 263.8 1.6 2.4 3.2 3.6711 4.5 2 12 678 145.1 140.9 0.9 1.3 1.7 2.0711 5 2 12 677 153.7 149.5 0.9 1.4 1.8 2.1711 6 2 12 675 170.8 166.6 1.0 1.5 2.0 2.3711 8 2 12 671 204.8 200.6 1.2 1.8 2.5 2.8711 9.5 2 12 668 230.2 225.9 1.4 2.1 2.8 3.1711 12 2 12 663 272.2 268.0 1.6 2.4 3.3 3.7762 4.5 2 12 729 155.7 151.2 0.9 1.4 1.9 2.1762 5 2 12 728 164.9 160.4 1.0 1.5 2.0 2.2762 6 2 12 726 183.2 178.7 1.1 1.6 2.2 2.5762 8 2 12 722 219.8 215.2 1.3 2.0 2.6 3.0

Stee

l out

side

di

amet

er (m

m)

Stee

l wal

l th

ickn

ess

(mm

)

SIN

TAKO

TE

thic

knes

s (m

m)

Cem

ent m

orta

r lin

ing

thic

knes

s (m

m)

Cem

ent m

orta

r lin

ing

bore

(mm

)

Mas

s pe

r met

re

SKC

L (k

g/m

)

Mas

s pe

r met

reU

CC

L (k

g/m

)

6.0

9.0

12.0

13.5




762 9.5 2 12 719 247.0 242.5 1.5 2.2 3.0 3.3762 12 2 12 714 292.2 287.7 1.8 2.6 3.5 3.9

800 4.5 2.3 16 759 187.3 181.9 1.1 1.7 2.2 2.5800 5 2.3 16 758 197.0 191.5 1.2 1.8 2.4 2.7800 6 2.3 16 756 216.2 210.7 1.3 1.9 2.6 2.9800 8 2.3 16 752 254.5 249.0 1.5 2.3 3.1 3.4800 9.5 2.3 16 749 283.0 277.6 1.7 2.5 3.4 3.8800 12 2.3 16 744 330.4 325.0 2.0 3.0 4.0 4.5813 4.5 2.3 16 772 190.4 184.9 1.1 1.7 2.3 2.6813 5 2.3 16 771 200.2 194.7 1.2 1.8 2.4 2.7813 6 2.3 16 769 219.8 214.2 1.3 2.0 2.6 3.0813 8 2.3 16 765 258.7 253.2 1.6 2.3 3.1 3.5813 9.5 2.3 16 762 287.8 282.2 1.7 2.6 3.5 3.9813 12 2.3 16 757 335.9 330.4 2.0 3.0 4.0 4.5

914 6 2.3 16 870 247.6 241.4 1.5 2.2 3.0 3.3914 8 2.3 16 866 291.5 285.3 1.7 2.6 3.5 3.9914 10 2.3 16 862 335.2 329.0 2.0 3.0 4.0 4.5914 12 2.3 16 858 378.7 372.5 2.3 3.4 4.5 5.1914 16 2.3 16 850 465.2 458.9 2.8 4.2 5.6 6.3960 6 2.3 16 916 260.3 253.7 1.6 2.3 3.1 3.5960 8 2.3 16 912 306.4 299.9 1.8 2.8 3.7 4.1960 10 2.3 16 908 352.4 345.9 2.1 3.2 4.2 4.8960 12 2.3 16 904 398.2 391.7 2.4 3.6 4.8 5.4960 16 2.3 16 896 489.2 482.6 2.9 4.4 5.9 6.6965 6 2.3 16 921 261.7 255.1 1.6 2.4 3.1 3.5965 8 2.3 16 917 308.1 301.5 1.8 2.8 3.7 4.2965 10 2.3 16 913 354.3 347.7 2.1 3.2 4.3 4.8965 12 2.3 16 909 400.3 393.8 2.4 3.6 4.8 5.4965 16 2.3 16 901 491.8 485.2 3.0 4.4 5.9 6.6

1,016 8 2.3 16 968 324.6 317.7 1.9 2.9 3.9 4.41,016 10 2.3 16 964 373.4 366.5 2.2 3.4 4.5 5.01,016 12 2.3 16 960 421.9 415.0 2.5 3.8 5.1 5.71,016 16 2.3 16 952 518.4 511.5 3.1 4.7 6.2 7.01,067 8 2.3 16 1019 341.2 333.9 2.0 3.1 4.1 4.61,067 10 2.3 16 1015 392.5 385.2 2.4 3.5 4.7 5.31,067 12 2.3 16 1011 443.5 436.3 2.7 4.0 5.3 6.01,067 16 2.3 16 1003 545.0 537.8 3.3 4.9 6.5 7.41,086 8 2.3 16 1038 347.4 340.0 2.1 3.1 4.2 4.71,086 10 2.3 16 1034 399.6 392.2 2.4 3.6 4.8 5.41,086 12 2.3 16 1030 451.6 444.2 2.7 4.1 5.4 6.11,086 16 2.3 16 1022 555.0 547.6 3.3 5.0 6.7 7.51,124 8 2.3 16 1076 359.7 352.1 2.2 3.2 4.3 4.91,124 10 2.3 16 1072 413.8 406.1 2.5 3.7 5.0 5.61,124 12 2.3 16 1068 467.7 460.0 2.8 4.2 5.6 6.31,124 16 2.3 16 1060 574.8 567.2 3.4 5.2 6.9 7.8

1,200 8 2.3 16 1152 384.4 376.3 2.3 3.5 4.6 5.21,200 10 2.3 16 1148 442.2 434.1 2.7 4.0 5.3 6.01,200 12 2.3 16 1144 499.9 491.7 3.0 4.5 6.0 6.71,200 16 2.3 16 1136 614.5 606.3 3.7 5.5 7.4 8.3

Stee

l out

side

di

amet

er (m

m)

Stee

l wal

l th

ickn

ess

(mm

)

SIN

TAKO

TE

thic

knes

s (m

m)

Cem

ent m

orta

r lin

ing

thic

knes

s (m

m)

Cem

ent m

orta

r lin

ing

bore

(mm

)

Mas

s pe

r met

re

SKC

L (k

g/m

)

Mas

s pe

r met

reU

CC

L (k

g/m

)

6.0

9.0

12.0

13.5



Notes: Pipe masses may vary +/- 10 % due to material tolerancesCalculations based on:Steel shell 0.02466(D-t)tCement lining 0.00755T(D-2t-T)SINTAKOTE 0.00296Dts

where D = outside diameter of pipe (mm) t = steel wall thickness (mm)T = cement lining thickness (mm) ts= SINTAKOTE thickness (mm)

Total mass may carry minor round-off error



1,219 8 2.3 16 1171 390.6 382.3 2.3 3.5 4.7 5.31,219 10 2.3 16 1167 449.3 441.0 2.7 4.0 5.4 6.11,219 12 2.3 16 1163 507.9 499.6 3.0 4.6 6.1 6.91,219 16 2.3 16 1155 624.4 616.1 3.7 5.6 7.5 8.4

1,283 8 2.3 19 1229 439.3 430.6 2.6 4.0 5.3 5.91,283 10 2.3 19 1225 501.1 492.4 3.0 4.5 6.0 6.81,283 12 2.3 19 1221 562.7 554.0 3.4 5.1 6.8 7.61,283 16 2.3 19 1213 685.4 676.6 4.1 6.2 8.2 9.31,290 8 2.3 19 1236 441.7 432.9 2.7 4.0 5.3 6.01,290 10 2.3 19 1232 503.9 495.1 3.0 4.5 6.0 6.81,290 12 2.3 19 1228 565.9 557.1 3.4 5.1 6.8 7.61,290 16 2.3 19 1220 689.2 680.4 4.1 6.2 8.3 9.3

1,404 8 2.3 19 1350 481.3 471.8 2.9 4.3 5.8 6.51,404 10 2.3 19 1346 549.1 539.6 3.3 4.9 6.6 7.41,404 12 2.3 19 1342 616.7 607.2 3.7 5.6 7.4 8.31,404 16 2.3 19 1334 751.3 741.7 4.5 6.8 9.0 10.11,422 8 2.3 19 1368 487.6 477.9 2.9 4.4 5.9 6.61,422 10 2.3 19 1364 556.3 546.6 3.3 5.0 6.7 7.51,422 12 2.3 19 1360 624.7 615.1 3.7 5.6 7.5 8.41,422 16 2.3 19 1352 761.1 751.4 4.6 6.8 9.1 10.31,440 8 2.3 19 1386 493.9 484.1 3.0 4.4 5.9 6.71,440 10 2.3 19 1382 563.4 553.6 3.4 5.1 6.8 7.61,440 12 2.3 19 1378 632.8 623.0 3.8 5.7 7.6 8.51,440 16 2.3 19 1370 770.9 761.1 4.6 6.9 9.3 10.41,575 8 2.3 19 1521 540.8 530.1 3.2 4.9 6.5 7.31,575 10 2.3 19 1517 617.0 606.3 3.7 5.6 7.4 8.31,575 12 2.3 19 1513 693.0 682.3 4.2 6.2 8.3 9.41,575 16 2.3 19 1505 844.5 833.7 5.1 7.6 10.1 11.4

1,750 10 2.3 19 1692 686.4 674.5 4.1 6.2 8.2 9.31,750 12 2.3 19 1688 771.1 759.2 4.6 6.9 9.3 10.41,750 16 2.3 19 1680 939.8 927.9 5.6 8.5 11.3 12.7

2,159 10 2.3 na na na na na na na na2,159 12 2.3 na na na na na na na na2,159 16 2.3 na na na na na na na na

Stee

l out

side

di

amet

er (m

m)

Stee

l wal

l th

ickn

ess

(mm

)

SIN

TAKO

TE

thic

knes

s (m

m)

Cem

ent m

orta

r lin

ing

thic

knes

s (m

m)

Cem

ent m

orta

r lin

ing

bore

(mm

)

Mas

s pe

r met

re

SKC

L (k

g/m

)

Mas

s pe

r met

reU

CC

L (k

g/m

)

6.0

9.0

12.0

13.5



559 5 4.8 492 3.9 394559 6 5.8 591 4.6 473559 8 7.7 788 6.2 630

610 4.5 4.0 406 3.2 325610 5 4.4 451 3.5 361610 6 5.3 541 4.2 433610 8 7.1 722 5.7 577610 9.5 7.0 714 5.6 571648 4.5 3.8 382 3.0 306648 5 4.2 425 3.3 340648 6 5.0 510 4.0 408648 8 6.7 679 5.3 544648 9.5 6.6 672 5.3 538660 4.5 3.7 375 2.9 300660 5 4.1 417 3.3 334660 6 4.9 500 3.9 400660 8 6.5 667 5.2 534660 9.5 6.5 660 5.2 528660 12 8.2 834 6.5 667

700 4.5 3.5 354 2.8 283700 5 3.9 393 3.1 314700 6 4.6 472 3.7 377700 8 6.2 629 4.9 503700 9.5 6.1 622 4.9 498700 12 7.7 786 6.2 629711 4.5 3.4 348 2.7 279711 5 3.8 387 3.0 310711 6 4.6 464 3.6 372711 8 6.1 619 4.9 495711 9.5 6.0 613 4.8 490711 12 7.6 774 6.1 619762 4.5 3.2 325 2.6 260762 5 3.5 361 2.8 289762 6 4.3 433 3.4 347762 8 5.7 578 4.5 462762 9.5 5.6 572 4.5 457762 12 7.1 722 5.7 578

800 4.5 3.0 310 2.4 248800 5 3.4 344 2.7 275800 6 4.1 413 3.2 330800 8 5.4 550 4.3 440800 9.5 5.3 545 4.3 436800 12 6.8 688 5.4 550813 4.5 3.0 305 2.4 244813 5 3.3 338 2.7 271813 6 4.0 406 3.2 325813 8 5.3 542 4.3 433813 9.5 5.3 536 4.2 429813 12 6.6 677 5.3 542

114 4.8 8.5 866 6.8 693168 5 8.5 866 6.8 693190 5 8.5 866 6.8 693

219 5 8.5 866 6.8 693240 5 8.5 866 6.8 693257 5 8.5 866 6.8 693273 5 8.5 866 6.8 693290 5 8.5 866 6.8 693

305 5 8.5 866 6.8 693324 4 6.7 679 5.3 544324 4.5 7.5 764 6.0 612324 5 8.3 849 6.7 679324 6 8.5 866 6.8 693337 4 6.4 653 5.1 523337 4.5 7.2 735 5.8 588337 5 8.0 817 6.4 653337 6 8.5 866 6.8 693344 4 6.3 640 5.0 512344 4.5 7.1 720 5.7 576344 5 7.8 800 6.3 640344 6 8.5 866 6.8 693356 4 6.1 618 4.9 495356 4.5 6.8 696 5.5 557356 5 7.6 773 6.1 618356 6 8.5 866 6.8 693

406 4 5.3 542 4.3 434406 4.5 6.0 610 4.8 488406 5 6.7 678 5.3 542406 6 8.0 813 6.4 651406 8 8.5 866 6.8 693419 4 5.2 525 4.1 420419 4.5 5.8 591 4.6 473419 5 6.4 657 5.2 525419 6 7.7 788 6.2 630419 8 8.5 866 6.8 693457 4.5 5.3 542 4.3 434457 5 5.9 602 4.7 482457 6 7.1 723 5.7 578457 8 8.5 866 6.8 693

502 4.5 4.8 493 3.9 395502 5 5.4 548 4.3 439502 6 6.5 658 5.2 526502 8 8.5 866 6.8 693508 4.5 4.8 488 3.8 390508 5 5.3 542 4.3 433508 6 6.4 650 5.1 520508 8 8.5 866 6.8 693559 4.5 4.3 443 3.5 354

Table D.4- Manufacturing Test Pressure and Rated Pressure for MSCL Pipes

Out

side

Dia

met

er (m

m)

Wal

lTh

ickn

ess

(mm

)

Test

Pre

ssur

e(M

Pa)

Test

Pre

ssur

e(m

)

Rate

d Pr

essu

re(M

Pa)

Rate

d Pr

essu

re(m

)

Out

side

Dia

met

er (m

m)

Wal

lTh

ickn

ess

(mm

)

Test

Pre

ssur

e(M

Pa)

Test

Pre

ssur

e(m

)

Rate

d Pr

essu

re(M

Pa)

Rate

d Pr

essu

re(m

)

559 5 4.8 492 3.9 394559 6 5.8 591 4.6 473559 8 7.7 788 6.2 630

610 4.5 4.0 406 3.2 325610 5 4.4 451 3.5 361610 6 5.3 541 4.2 433610 8 7.1 722 5.7 577610 9.5 7.0 714 5.6 571648 4.5 3.8 382 3.0 306648 5 4.2 425 3.3 340648 6 5.0 510 4.0 408648 8 6.7 679 5.3 544648 9.5 6.6 672 5.3 538660 4.5 3.7 375 2.9 300660 5 4.1 417 3.3 334660 6 4.9 500 3.9 400660 8 6.5 667 5.2 534660 9.5 6.5 660 5.2 528660 12 8.2 834 6.5 667

700 4.5 3.5 354 2.8 283700 5 3.9 393 3.1 314700 6 4.6 472 3.7 377700 8 6.2 629 4.9 503700 9.5 6.1 622 4.9 498700 12 7.7 786 6.2 629711 4.5 3.4 348 2.7 279711 5 3.8 387 3.0 310711 6 4.6 464 3.6 372711 8 6.1 619 4.9 495711 9.5 6.0 613 4.8 490711 12 7.6 774 6.1 619762 4.5 3.2 325 2.6 260762 5 3.5 361 2.8 289762 6 4.3 433 3.4 347762 8 5.7 578 4.5 462762 9.5 5.6 572 4.5 457762 12 7.1 722 5.7 578

800 4.5 3.0 310 2.4 248

800 6 4.1 413 3.2 330800 8 5.4 550 4.3 440800 9.5 5.3 545 4.3 436

813 4.5 3.0 305 2.4 244813 5 3.3 338 2.7 271813 6 4.0 406 3.2 325813 8 5.3 542 4.3 433813 9.5 5.3 536 4.2 429813 12 6.6 677 5.3 542

114 4.8 8.5 866 6.8 693168 5 8.5 866 6.8 693190 5 8.5 866 6.8 693

219 5 8.5 866 6.8 693240 5 8.5 866 6.8 693257 5 8.5 866 6.8 693273 5 8.5 866 6.8 693290 5 8.5 866 6.8 693

305 5 8.5 866 6.8 693324 4 6.7 679 5.3 544324 4.5 7.5 764 6.0 612324 5 8.3 849 6.7 679324 6 8.5 866 6.8 693337 4 6.4 653 5.1 523337 4.5 7.2 735 5.8 588337 5 8.0 817 6.4 653337 6 8.5 866 6.8 693344 4 6.3 640 5.0 512344 4.5 7.1 720 5.7 576344 5 7.8 800 6.3 640344 6 8.5 866 6.8 693356 4 6.1 618 4.9 495356 4.5 6.8 696 5.5 557356 5 7.6 773 6.1 618356 6 8.5 866 6.8 693

406 4 5.3 542 4.3 434406 4.5 6.0 610 4.8 488406 5 6.7 678 5.3 542406 6 8.0 813 6.4 651406 8 8.5 866 6.8 693419 4 5.2 525 4.1 420419 4.5 5.8 591 4.6 473419 5 6.4 657 5.2 525419 6 7.7 788 6.2 630419 8 8.5 866 6.8 693457 4.5 5.3 542 4.3 434457 5 5.9 602 4.7 482457 6 7.1 723 5.7 578457 8 8.5 866 6.8 693

502 4.5 4.8 493 3.9 395502 5 5.4 548 4.3 439502 6 6.5 658 5.2 526502 8 8.5 866 6.8 693508 4.5 4.8 488 3.8 390508 5 5.3 542 4.3 433508 6 6.4 650 5.1 520508 8 8.5 866 6.8 693559 4.5 4.3 443 3.5 354

Table D.4- Manufacturing Test Pressure and Rated Pressure for MSCL Pipes

Out

side

Dia

met

er (m

m)

Wal

lTh

ickn

ess

(mm

)

Test

Pre

ssur

e(M

Pa)

Test

Pre

ssur

e(m

)

Rate

d Pr

essu

re(M

Pa)

Rate

d Pr

essu

re(m

)

Out

side

Dia

met

er (m

m)

Wal

lTh

ickn

ess

(mm

)

Test

Pre

ssur

e(M

Pa)

Test

Pre

ssur

e(m

)

Rate

d Pr

essu

re(M

Pa)

Rate

d Pr

essu

re(m

)


1,404 8 3.1 314 2.5 2511,404 10 3.2 327 2.6 2611,404 12 3.9 392 3.1 3141,404 16 5.1 523 4.1 4181,422 8 3.0 310 2.4 2481,422 10 3.2 323 2.5 2581,422 12 3.8 387 3.0 3101,422 16 5.1 516 4.1 4131,440 8 3.0 306 2.4 245

1,440 10 3.1 319 2.5 2551,440 12 3.8 382 3.0 3061,440 16 5.0 510 4.0 408

1,575 8 2.7 280 2.2 2241,575 10 2.9 291 2.3 2331,575 12 3.4 349 2.7 2801,575 16 4.6 466 3.7 373

1,750 10 2.6 262 2.1 2101,750 12 3.1 314 2.5 2521,750 16 4.1 419 3.3 335

2,159 10 2.1 212 1.7 1702,159 12 2.5 255 2.0 2042,159 16 3.3 340 2.7 272

Out

side

Dia

met

er (m

m)

Wal

lTh

ickn

ess

(mm

)

Test

Pre

ssur

e(M

Pa)

Test

Pre

ssur

e(m

)

Rate

d Pr

essu

re(M

Pa)

Rate

d Pr

essu

re(m

)

914 6 3.5 361 2.8 289914 8 4.7 482 3.8 385914 10 4.9 502 3.9 401914 12 5.9 602 4.7 482914 16 7.9 803 6.3 642960 6 3.4 344 2.7 275

960 8 4.5 459 3.6 367960 10 4.7 478 3.8 382960 12 5.6 573 4.5 459960 16 7.5 764 6.0 611965 6 3.4 342 2.7 274965 8 4.5 456 3.6 365965 10 4.7 475 3.7 380965 12 5.6 570 4.5 456965 16 7.5 760 6.0 608

1,016 8 4.3 433 3.4 3471,016 10 4.4 451 3.5 3611,016 12 5.3 542 4.2 4331,016 16 7.1 722 5.7 5781,067 8 4.0 413 3.2 3301,067 10 4.2 430 3.4 3441,067 12 5.1 516 4.1 4131,067 16 6.8 688 5.4 5501,086 8 4.0 405 3.2 3241,086 10 4.1 422 3.3 3381,086 12 5.0 507 4.0 4051,086 16 6.6 676 5.3 5411,124 8 3.8 392 3.1 3131,124 10 4.0 408 3.2 3261,124 12 4.8 490 3.8 3921,124 16 6.4 653 5.1 522

1,200 8 3.6 367 2.9 2941,200 10 3.8 382 3.0 3061,200 12 4.5 459 3.6 3671,200 16 6.0 611 4.8 489

1,219 8 3.5 361 2.8 2891,219 10 3.7 376 3.0 3011,219 12 4.4 451 3.5 3611,219 16 5.9 602 4.7 482

1,283 8 3.4 343 2.7 2751,283 10 3.5 357 2.8 2861,283 12 4.2 429 3.4 3431,283 16 5.6 572 4.5 4581,290 8 3.3 341 2.7 2731,290 10 3.5 356 2.8 2841,290 12 4.2 427 3.4 3411,290 16 5.6 569 4.5 455

Out

side

Dia

met

er (m

m)

Wal

lTh

ickn

ess

(mm

)

Test

Pre

ssur

e(M

Pa)

Test

Pre

ssur

e(m

)

Rate

d Pr

essu

re(M

Pa)

Rate

d Pr

essu

re(m

)

Maximum test pressure =90% of yield stress of

steel, but not greater than 8.5 MPa.

Rated pressure =72% of yield stress of steel,

but not greater than 6.8 MPa.

Yield stress of steel = 300MPa for t<=8.0mm,

250MPa for t>8.0mm.

where t is steel wall thickness (mm).

Working pressure is determined by the designer

after consideration of the Rated Pressure of the

pipe and fittings and taking into account the various

factors such as external loads and transient

hydrostatic conditions.



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