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Australian/New Zealand Standard

Installation of polyethylene pipesystems

AS/NZS

2033:2008

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his document has expired. To access the current document, please go toour on-line service.ease note that material accessed via our on-line subscription services is

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AS/NZS 2033:2008

This Joint Australian/New Zealand Standard was prepared by Joint TechnicalCommittee PL-006, Polyolefin Pipe Systems. It was approved on behalf of theCouncil of Standards Australia on 10 April 2008 and on behalf of the Council ofStandards New Zealand on 9 April 2008.This Standard was published on 19 May 2008.

The following are represented on Committee PL-006:

AUSTAP

Certification Interests (Australia)

CSIRO Manufacturing & Infrastructure Technology

Energy Networks Association

Engineers AustraliaMaster Plumbers, Gasfitters and Drainlayers New Zealand

New Zealand Water and Waste Association

Plastics Industry Pipe Association of Australia

Plastics New Zealand

Water Services Association of Australia

Keeping Standards up-to-date

Standards are living documents which reflect progress in science, technology andsystems. To maintain their currency, all Standards are periodically reviewed, andnew editions are published. Between editions, amendments may be issued.Standards may also be withdrawn. It is important that readers assure themselvesthey are using a current Standard, which should include any amendments whichmay have been published since the Standard was purchased.

Detailed information about joint Australian/New Zealand Standards can be found byvisiting the Standards Web Shop at www.standards.com.au or Standards NewZealand web site at www.standards.co.nz and looking up the relevant Standard inthe on-line catalogue.

Alternatively, both organizations publish an annual printed Catalogue with fulldetails of all current Standards. For more frequent listings or notification ofrevisions, amendments and withdrawals, Standards Australia and Standards NewZealand offer a number of update options. For information about these services,users should contact their respective national Standards organization.

We also welcome suggestions for improvement in our Standards, and especiallyencourage readers to notify us immediately of any apparent inaccuracies orambiguities. Please address your comments to the Chief Executive of eitherStandards Australia or Standards New Zealand at the address shown on the backcover.

This Standard was issued in draft form for comment as DR 07337.

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Australian/New Zealand StandardInstallation of polyethylene pipesystems

COPYRIGHT

Standards Australia/Standards New Zealand

All rights are reserved. No part of this work may be reproduced or copied in any form or byany means, electronic or mechanical, including photocopying, without the written

permission of the publisher.

Jointly published by Standards Australia, GPO Box 476, Sydney, NSW 2001 and Standards

New Zealand, Private Bag 2439, Wellington 6020

ISBN 0 7337 8705 3

Originated as AS 20331977.Previous edition 1980.Jointly revised and designated AS/NZS 2033:2008.Reissued incorporating Amendment No. 1 (October 2008).Reissued incorporating Amendment No. 2 (June 2009).

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PREFACE

This Standard was prepared by the Joint Standards Australia/Standards New Zealand

Committee PL-006, Polyolefin Pipe Systems to supersede AS 20331980.This Standard incorporates Amendment No. 1 (October 2008) and Amendment No. 2 (June

2009). The changes required by the Amendment are indicated in the text by a marginal bar

and amendment number against the clause, note, table, figure or part thereof affected.

The objective of this Standard is to provide uniform procedures for the installation of

polyethylene (PE) pipe systems for both above and below ground applications.

The objective of this revision is to update the Standard with respect to current practice and

publish it as a joint Australian/New Zealand Standard.

This Standard primarily addresses the installation of polyethylene (PE) pipes and fittings

for plumbing, industrial and irrigation applications and is not intended to replace industry

specific installation codes or regulations.

For plumbing applications, reference should also be made to AS/NZS 3500, Plumbing and

drainage (all parts). For above ground applications using structured wall pipes, reference

should also be made to the manufacturer.

For installations conveying gaseous fluids, reference should be made to AS 5601, Gas

installationsand AS 3723, Installation and maintenance of plastics pipe systems for gas, as

appropriate and in New Zealand NZS 5258, Gas distribution.

NOTE: Reference to AS 3723 correct at time of publ ishing, however, future reference wil l be

made to AS 4645, Gas distribution networks, Part 3: Plastics pipe systems.

For water supply and sewerage network infrastructure involving the design and installation

of PE pipe systems, reference should be made to Water Services Association of Australia(WSAA) codes.

For design and installation of buried flexible pipelines, reference should be made to

AS/NZS 2566.1, Buried flexible pipelines Part 1: Structural design and AS/NZS 2566.2,

Buried flexible pipelines, Part 2: Installationor ISO 21138-1.

A bibliography is provided in Appendix A for references that may be used to provide more

detailed explanations or information regarding the installation of PE pipes.

For electrical installations, reference should be made to AS/NZS 3000, Electrical

installations(known as the Australian/New Zealand Wiring Rules).

Australian and New Zealand Standards generally do not

(a) restate the duties of employers, employees, designers and installers; or

(b) determine the applicability of regulatory limitations; or

(c) determine appropriate health and safety practices.

Statements expressed in mandatory terms in notes to tables are deemed to be requirements

of this Standard. Notes to text are for information and guidance only.

The term informative has been used in this Standard to define the application of the

appendix to which it applies. An informative appendix is only for information and

guidance.

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CONTENTS

Page

SECTION 1 SCOPE, DEFINITIONS AND MATERIAL REQUIREMENTS

1.1 SCOPE ........................................................................................................................ 5

1.2 NORMATIVE REFERENCES.................................................................................... 5

1.3 DEFINITIONS ............................................................................................................ 6

SECTION 2 PRODUCTS AND MATERIALS

2.1 SCOPE OF SECTION................................................................................................. 8

2.2 PIPE AND FITTINGS................................................................................................. 8

2.3 HANGERS AND CLIPS ............................................................................................. 9

2.4 PIPE EMBEDMENT AND TRENCH-FILL MATERIALS ........................................ 9

2.5 TOOLS AND EQUIPMENT ....................................................................................... 9

SECTION 3 GENERAL REQUIREMENTS

3.1 SCOPE OF SECTION............................................................................................... 10

3.2 TRANSPORT, HANDLING AND STORAGE ......................................................... 10

3.3 PRE-INSTALLATION INSPECTION ...................................................................... 10

3.4 PROTECTION AGAINST DAMAGE ...................................................................... 11

3.5 REPLACEMENT OF METALLIC WATER SUPPLY PIPELINES.......................... 11

3.6 STATIC ELECTRICITY........................................................................................... 11

3.7 TEMPERATURE CONSIDERATIONS.................................................................... 11

3.8 EFFECT OF WATER HAMMER OR PRESSURE SURGES................................... 13

SECTION 4 JOINTING METHODS4.1 SCOPE OF SECTION............................................................................................... 14

4.2 FUSION JOINTS....................................................................................................... 14

4.3 MECHANICAL COMPRESSION FITTINGS .......................................................... 14

4.4 ELASTOMERIC SEAL JOINTS............................................................................... 14

4.5 FLANGED JOINTS .................................................................................................. 15

4.6 THREADED JOINTS................................................................................................ 15

4.7 REPAIR FITTINGS .................................................................................................. 15

4.8 CONNECTION OF PE PIPES AND FITTINGS TO PIPES AND FITTINGS OF

OTHER MATERIALSOTHER THAN THREADS AND FLANGES ................... 16

4.9 SERVICE CONNECTIONS...................................................................................... 16

SECTION 5 INSTALLATION OF BURIED PIPES AND FITTINGS

5.1 SCOPE OF SECTION............................................................................................... 17

5.2 PIPELINE INSTALLATION USING TRENCHLESS TECHNOLOGY................... 17

5.3 PIPE INSTALLATION IN A TRENCH.................................................................... 17

5.4 PIPE INSTALLATION IN AN EMBANKMENT..................................................... 21

SECTION 6 INSTALLATION OF PIPES ABOVE GROUND

6.1 SCOPE OF SECTION............................................................................................... 22

6.2 INSTALLATION REQUIREMENTS ....................................................................... 22

6.3 SUPPORT OF PIPELINES........................................................................................ 23

6.4 PROVISION FOR EXPANSION ............................................................................. 25

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SECTION 7 TESTING OF PIPE SYSTEM

7.1 SCOPE OF SECTION............................................................................................... 30

7.2 TESTING OF PRESSURE PIPE SYSTEMS............................................................. 30

7.3 TESTING OF NON-PRESSURE PIPELINES........................................................... 327.4 DEFLECTION TESTING ......................................................................................... 34

7.5 CLOSED CIRCUIT TELEVISION (CCTV) INSPECTION...................................... 34

SECTION 8 COMMISSIONING........................................................................................... 37

SECTION 9 COMPRESSED GASES

9.1 SCOPE ...................................................................................................................... 36

9.2 CONTENTS IDENTIFICATION .............................................................................. 36

9.3 PRESSURE RATING (PN, SDR) AND TEMPERATURE RERATING .................. 36

9.4 JOINT TYPES........................................................................................................... 37

9.5 CHEMICAL RESISTANCE...................................................................................... 379.6 UV RESISTANCE .................................................................................................... 37

9.7 PRECAUTIONS........................................................................................................ 37

APPENDICES

A BIBLIOGRAPHY...................................................................................................... 38

B COMMISSIONING GUIDE...................................................................................... 39

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STANDARDS AUSTRALIA/STANDARDS NEW ZEALAND

Australian/New Zealand Standard

Installation of polyethylene pipe systems

S E C T I O N 1 S C O P E , D E F I N I T I O N S A N D

M A T E R I A L R E Q U I R E M E N T S

1.1 SCOPE

This Standard sets out methods for handling, storage, installation, testing and

commissioning of polyethylene (hereinafter referred to as PE) pipelines, above or below

ground, for both pressure and non-pressure applications conveying fluids.

NOTE: Where PE pipelines are to be installed underground the safe installation depths are

calculated by reference to AS/NZS 2566.2.

This Standard applies to PE pipe systems that carry liquids under either pressure or gravity

flow situations and the components of which comply with, but are not limited to, the

following:

(a) AS 2698.2PE rural pipe.(b) AS/NZS 4129Fittings for PE pipes for pressure applications.(c) AS/NZS 4130PE pipes for pressure applications.(d) AS 4176Polyethylene/aluminium and cross-linked polyethylene/aluminium macro-

composite pipes for pressure applications.

(e) AS/NZS 4401PE pipe for soil and waste discharge.(f) AS/NZS 4798(Int)PE maintenance shafts.(g) AS 4799Underground installation within railway boundaries.(h) AS/NZS 5065PE and PP pipes for drainage and sewerage.1.2 NORMATIVE REFERENCES

The following referenced documents are indispensable for the application of this document.

AS

1345 Identification of the contents of pipes, conduits and ducts

1646 Elastomeric seals for waterworks purposes (all parts)

2698 Plastics pipes and fittings for irrigation and rural applications

2698.2 Part 2: Polyethylene rural pipe

4176 Polyethylene/aluminium and cross-linked polyethylene/aluminium macro-

composite pipe systems for pressure applications

4799 Installation of underground utility services and pipelines within railway

boundaries

AS/NZS

2566 Buried flexible pipelines

2566.1 Part 1: Structural design2566.2 Part 2: Installation

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AS/NZS

2648 Underground marking tape

2648.1 Part 1: Non-detectable tape

3500 Plumbing and drainage

3500.0 Part 0: Glossary of terms3500.1 Part 1: Water services

3500.5 Part 5: Domestic

4020 Testing of products for use in contact with drinking water

4129 Fittings for polyethylene (PE) pipes for pressure applications

4130 Polyethylene (PE) pipes for pressure applications

4327 Metal-banded flexible couplings for low-pressure applications

4401 Plastics piping systems for soil and waste discharge (low and high temperature)

inside buildingsPolyethylene (PE)

4793 Mechanical tapping bands for waterworks services*

4798(Int) Polyethylene maintenance shafts

5065 Polyethylene and polypropylene pipes and fittings for drainage and sewerage

applications

ISO/TR

10358 Plastics pipes and fittingsCombined chemical resistance classification table

WSAA

PS-318 Marking tape, detectable

01 Polyethylene pipeline code

05 Sewer inspection reporting code of Australia

NZWWA Pipe Inspection Manual, 2006

1.3 DEFINITIONS

For the purpose of this Standard the definitions in AS/NZS 3500.0 and those below apply.

1.3.1 Embankment and trench zones

Embankment and trench zones as shown in AS/NZS 2566.2.

1.3.2 Fixed point

A point at which axial movement of the pipe or fitting is restrained.NOTE: For example

(a) at the fixed (clipped) part of an expansion joint fitting;

(b) at junctions and bends except where alternative provision for expansion is made

(see Clause 6.4.3(c)); or

(c) at connections to fixtures [except where movement is accommodated at a trap,

(see Clause 6.4.3(d))] and drains [except where movement is possible at the drain

connection (see Clause 6.4.3(b))].

1.3.3 Permeation

The passage or diffusion of a gas, vapour, liquid or solid through a product without the

product being physically or chemically affected.

* In course of preparation.Accessedb

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1.3.4 Shall

Indicates a mandatory requirement.

1.3.5 Should

Indicates a recommendation, i.e. text that is not a mandatory requirement but given for

guidance.

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S E C T I O N 2 P R O D U C T S A N D M A T E R I A L S

2.1 SCOPE OF SECTION

This Section specifies requirements for products and materials used for the installation ofPE pipe systems.

2.2 PIPE AND FITTINGS

2.2.1 PE pipes and fittings

Pipes and fittings installed in accordance with this Standard shall comply with the relevant

Standards given in Clause 1.1.

In Australia, for plumbing and drainage applications, PE pipes and fittings shall be

authorized in accordance with the Plumbing C

ode of Australia (PCA). In New Zealand, for plumbing and drainage applications, PE pipesand fittings shall meet the requirements of the AS/NZS 3500 series of standards.

2.2.2 Chemical resistance

Where the application is for the conveyance of chemicals, information on the suitability of

PE pipe for that application may be found in ISO/TR 10358 or obtained from

manufacturers.

It shall be necessary to assess the effects of external chemical contamination.

For installations in contaminated ground the suitability of PE for that service shall be

determined. Such contamination may take the form of actual attack on the material,

affecting the systems structural integrity, or it may permeate the pipe or fitting, not

adversely affecting structural strength but potentially tainting pipe contents. Suchpermeation might not be an issue for pipes that do not convey drinking water (see

Clause 2.3).

In drainage applications, the tables of chemical resistance may need to be varied to take

account of the concentration of the chemicals, temperature of the liquid, and the duration of

contact (e.g. a laboratory drainage system).

For pipes joined with elastomeric seals consideration shall be given to the chemical

resistance of the seals.

Mechanical joint fittings and their components may also need to be considered.

NOTE: Further guidance on chemical resistance is available from the relevant sources listed in

Appendix A. Alternatively, refer to the pipe manufacturer.

2.2.3 Permeation

Permeation of pipes and fittings by chemicals may be a consideration arising from the fluid

to be transported, or an external influence such as ground contamination.

For PE, as with other materials, including those used for jointing, permeation depends upon

the concentration of the contaminant and its nature.

In instances involving significant levels of contamination, expert advice should be sought.

2.2.4 Elastomeric seals

Elastomeric seals shall comply with the applicable Parts of the AS 1646 series of Standards

and shall be in accordance with the recommendations of the manufacturer of the socketed

pipe or fitting. For drinking and recycled water applications, elastomeric seals shall comply

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2.2.5 Lubricants for elastomeric seals and expansion joints

Lubricants used in conjunction with elastomeric seals shall be those specified by the

manufacturer of the socketed pipe or fitting. For drinking and recycled water applications,

lubricants shall also comply with AS/NZS 4020.

2.3 HANGERS AND CLIPS

Sliding joints, pipe hangers and clips shall be constructed so that, when fully tightened,

longitudinal movement of the pipe is possible without damage to the pipe or fitting.

Anchor clips for fixed points shall be constructed so that, when fully tightened, the fitting

or pipe is securely and evenly clamped to prevent movement. Care shall be taken to ensure

that pipes and fittings are not distorted by over-tightening.

2.4 PIPE EMBEDMENT AND TRENCH-FILL MATERIALS

Embedment and trench-fill materials shall comply with the AS/NZS 3500 series,

AS/NZS 2566 parts 1 and 2 or specific industry standards, as required.

2.5 TOOLS AND EQUIPMENT

Specialized tools and equipment used in the installation, repair, testing and commissioning

of PE pipes and fittings shall be as recommended by the pipe and fittings manufacturers.

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S E C T I O N 3 G E N E R A L R E Q U I R E M E N T S


This Section specifies general requirements for the installation of PE pipe systems and theirhandling, transport, storage and inspection.

3.2 TRANSPORT, HANDLING AND STORAGE

3.2.1 General

PE pipes and fittings shall be transported, handled and stored with care by the installer at all

times to avoid physical damage (e.g. gouging, scoring, scratching, localized deformation,

excessive ovalization or impact damage) that could adversely affect performance.

3.2.2 Transportation

When being transported, pipe shall be supported in a secure manner to prevent damage orexcessive distortion of the pipe.

3.2.3 Storage

The storage area provided for pipe shall

(a) be a flat surface free of any sharp stone or projection, which may cause damage orlocalized deformation to the pipe; and

(b) be suitable for the use of the proposed loading and unloading equipment without therisk of accidental damage to the pipe.

For pipes to AS/NZS 4130 other than plain black pipes, if the total period of exposed

storage outdoors is likely to exceed 24 months, pipes and fittings shall be covered.Pipes and fittings that are not UV stabilized shall be covered at all times or stored indoors.

Stacking of pipes during storage shall be in accordance with the manufacturers

recommendations.

Joint lubricants shall be stored in sealed containers until ready for use.

3.3 PRE-INSTALLATION INSPECTION

3.3.1 Correct supply

Before installation, pipes and fittings shall be inspected to ensure that they are of the type,

size and classification specified for the installation. Any items that are not according to thespecifications shall be replaced.

3.3.2 Cleanliness

Pipes and fittings shall also be inspected to ensure they are free of obstructions and foreign

materials, which might interfere with the performance of the pipeline, and be cleaned if

necessary.

3.3.3 Fitness for use

The outside surfaces of pipes and fittings shall be visually checked for damage immediately

prior to installation. The allowable damage to the external surface shall be up to 10% of the

wall thickness. Kinks in pipe shall not be installed, re-rounded or repaired by reheating.

Pipe and fitting spigot ends, and spigot ends of cut pipe lengths, shall also be checked for

excessive ovality. Excessively oval pipe and fitting spigots ends may be re-rounded.

Pipes may be cut to remove damaged sections and the remaining sections may be used.Accessedb

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3.4 PROTECTION AGAINST DAMAGE

3.4.1 General

Pipework installed in locations or operating under conditions where they may be subject to

mechanical damage shall be suitably protected, including during the construction stage.

3.4.2 Protection from heat

Pipelines shall not be installed adjacent to heat sources, such as boilers, naked flame, hot

water or steam lines, where the temperature of the pipework may exceed the design

temperature of the pipe system.

3.5 REPLACEMENT OF METALLIC WATER SUPPLY PIPELINES

Any work on existing metallic pipe shall be conducted in accordance with the appropriate

Section of AS/NZS 3500.1 or AS/NZS 3500.5.

NOTE: Metallic water pipes often serve as an earth for electr ic systems within the property.

3.6 STATIC ELECTRICITY

Static electric charges may be generated on the surface of PE pipes by the effects of friction

during handling, laying and operation of pipes. Where the discharge of electricity from

static electricity build-up could cause problems (e.g. in explosive atmospheres) steps shall

be taken to ensure that static electricity is not generated or that it can be discharged safely.

3.7 TEMPERATURE CONSIDERATIONS

3.7.1 Pressure re-rating due to thermal effects

3.7.1.1 Temperature of pipe wall

The pressure rating of PE pressure pipe shall be based on the temperature of the pipe wall,

which may be determined from

(a) an assumption of a constant pipe wall temperature typical for continuous service at aset temperature, e.g. cold water service; or

(b) the determination of an average service temperature where temperature variations arelikely to occur in a predictable pattern, e.g. in cavity walls or roof spaces; or

(c) the maximum service temperature less 10C for installations where largeunpredictable temperature variations occur up to a maximum of 80C, e.g. above-

ground installations such as irrigation systems.

For Items (a) (b) and (c), the maximum allowable operating pressure (MAOP) shall be in

accordance with values in Tables 3.1 and Table 3.2.NOTE: The values tabled are for materials typical ly used in Australia and New Zealand.

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TABLE 3.1

MAOP, METRES HEAD

PE 80B

Temperature

C

PN 3.2 PN 4 PN 6.3 PN 8 PN 10 PN 12.5 PN 16 PN 20

20 32 40 63 80 100 125 160 200

25 32 40 63 80 100 125 160 200

30 28 35 55 70 88 109 140 175

35 26 32 50 64 80 100 128 160

40 24 30 47 60 75 94 120 150

45 22 28 44 56 70 88 112 140

50* 21 26 41 52 65 81 104 130

55* 19 24 38 48 60 75 96 120

* At 50 and 55C the extrapolated performance of the pipe cannot be predicted beyond 36 and 24 yearsrespectively based on current data.

TABLE 3.2

MAOP, METRES HEAD

PE 100

Temperature

CPN 3.2 PN 4 PN 6.3 PN 8 PN 10 PN 12.5 PN 16 PN 20 PN 25

20 32 40 63 80 100 125 160 200 250

25 32 40 63 80 100 125 160 200 250

30 30 38 59 75 94 118 150 188 235

35 29 36 56 71 89 112 143 179 224

40 27 34 53 68 84 106 135 169 221

45 25 32 50 64 80 100 127 159 199

50* 24 30 48 60 76 95 121 151 189

55* 23 29 45 57 72 89 115 143 179

* At 50 and 55C the extrapolated performance of the pipe cannot be predicted beyond 36 and 24 years

respectively based on current data.

3.7.1.2 Predictable temperature variations

For installations where predictable temperature variations occur, the average material

temperature shall be determined from Item (a) or Item (b) as follows:

(a) Across the wall of the pipe, the material temperature taken as the mean of the internaland external pipe surface temperatures, where a temperature differential exists

between the fluid in the pipe and the external environmental.

(b) The pressure and temperature condition, where flow is stopped for prolonged periods,shall also be checked. In this event, fluid temperature and outside temperature may

equalize.

(c) With respect to time, the average temperature may be considered as the weightedaverage of temperatures for the proportion of time spent at each temperature under

operational pressures; it shall be calculated from the following equation:

A1

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Tm= T1L1+ T2L2+ + TnLn

where

Tm = average pipe material temperature for the period of time under

consideration, in C

Tn = average pipe material temperature for a proportion of pipe life, in C

L = proportion of life spent at temperature Tn

NOTE: This approximation is reasonable provided the temperature variations from the mean

do not exceed 10C, which is generally the case for pipes buried at depths 300 mm below

finished surface level.

3.7.2 Provision for expansion and contraction

Figure 3.1 shows the thermal linear expansion of PE pipe. PE 80 and PE 100 have a co-

efficient of expansion of 18 105/C.

FIGURE 3.1 THERMAL LINEAR EXPANSION OF PE PIPE

Where a pipe is being buried during hot or cold weather, expansion or contraction of the

pipeline may take place as the pipe adjusts to ground temperature during backfilling. In

these cases, where no elastomeric seal joints are included, final connection and backfillingshould not take place until the pipe is at approximately the normal service temperature. In a

system using elastomeric seal joints this precaution may not be necessary.

For above-ground sanitary plumbing and drainage, in most circumstances the greatest

thermal movements will be caused by variations in environmental temperature because the

duration of most waste discharges is short and the temperature response of the material is

slow. Provision for expansion and contraction shall be in accordance with Clause 6.4.

When a downpipe is connected to a stormwater pipe, or otherwise restrained at the

discharge point, provisions shall be made to allow the pipe to expand and contract.

3.8 EFFECT OF WATER HAMMER OR PRESSURE SURGES

Water hammer or pressure surges are a design consideration.

NOTE: Information on surge and fat igue can be found in WSA 01 Polyethylene Pipeline Code

and other documents (see Appendix A) and PIPA POP 10A and 10B, www.pipa.com.au.Accessedb

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S E C T I O N 4 J O I N T I N G M E T H O D S


This Section sets out requirements for the jointing of PE pipe and fittings in PE pipesystems.

4.2 FUSION JOINTS

Acceptable methods for fusion jointing are electro-fusion, butt-fusion and socket-fusion.

Extrusion welding shall only be used for non-pressure applications.

NOTES:

1 For electro-fusion refer to PIPA POP-001.

2 For butt welding parameters refer to PIPA POP-003.

Only trained and certified operators shall carry out fusion jointing. For guidance refer to

http://www.pipa.com.au/Training.html.

4.3 MECHANICAL COMPRESSION FITTINGS

Mechanical compression fittings for the connection of PE pipes shall be used in accordance

with the manufacturers instructions.

4.4 ELASTOMERIC SEAL JOINTS

4.4.1 Application

Only elastomeric seals and lubricants recommended by the pipe or fitting manufacturer

shall be used.

NOTE: Unrestrained elastomeric seal joints for use with PE are applicable only to low or non-

pressure applications.

4.4.2 Procedure

The following procedure shall apply to joints where the elastomeric seal is incorporated in

the socket:

NOTE: This procedure does not apply to expansion joints (see Clause 6.4).

(a) Where pipes are required to be cut in the field(i) cut the spigot end square and remove all burrs;(ii) chamfer the cut end of the pipe with a taper of approximately 15 to

approximately half the wall thickness, or as specified by the pipe manufacturer;

and

(iii) as appropriate, witness mark the pipe at the distance specified by themanufacturer.

NOTES:

1 A witness mark is normally positioned on the spigot by the manufacturer to show the

optimum insertion depth.

2 Where spigots and sockets are not made by the same manufacturer reference should be

made to the socket manufacturer for the correct marking depth.

(b) Ensure that the inside of the socket is clean.(c) Where elastomeric seals are required to be fitted, clean and fit the seal. Check that the

elastomeric seal sits evenly in the housing.

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(d) Apply the manufacturers specified lubricant to the end of the spigot and chamfer ofthe pipe. Keep the elastomeric seal and its housing free of lubricant, unless otherwise

recommended by the manufacturer.

(e) Align the pipes so that there is no deflection at the joints, then insert the spigot in thesocket and push it home to the witness mark.

(f) Hold the socket end firmly during the jointing to prevent previously assembled jointsfrom moving.

NOTES:

1 Similar procedures apply for making joints where the socket is pushed on to a spigot, e.g.

socketed valves or fittings.

2 After the joint is made, it may be deflected up to the limit specified by the socket

manufacturer.

4.5 FLANGED JOINTS

4.5.1 Application

Flanges may be installed for the jointing of PE pipelines, but their principal application is

for connecting pipes (particularly those with larger diameters) to valves and vessels where

disconnection or strength in tension is required.

4.5.2 Requirements

Flanges are typically PE stub flanges that are fitted with loose metal backing rings.

In all flanged joints a gasket or seal ring shall be provided. The gasket or seal ring type,

thickness and composition shall be selected to suit the application. It shall be resistant to

the fluid that is to be carried through the pipeline.

Metallic components liable to corrode shall be supplied in a corrosion-resistant material

suitable for the intended environment or otherwise protected using an appropriate corrosionprotection system e.g. petrolatum tape wrapping.

NOTE: Refer to PIPA POP-007 for specif ications and dimensional details.

4.5.3 Procedure

Manufacturers requirements for alignment and bolt tightening (torque and sequence) shall

be applied to the joints.

4.6 THREADED JOINTS

4.6.1 Application

Only threads produced by the pipe or fitting manufacturer shall be used. Only threadsealants nominated by the pipe or fitting manufacturer shall be installed.

4.6.2 Procedure

Care shall be taken to avoid over-tightening or damaging joints, and to provide adequate

support to prevent excessive shear forces on threaded joints.

4.7 REPAIR FITTINGS

Various types of repair fittings are available and installation shall be in accordance with the

manufacturers recommendations.

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4.8 CONNECTION OF PE PIPES AND FITTINGS TO PIPES AND FITTINGS OF

OTHER MATERIALSOTHER THAN THREADS AND FLANGES

For pressure and non-pressure applications, mechanical couplings shall be used in

accordance with the manufacturers instructions to join PE pipes (or fittings) to pipes (or

fittings) of other materials.

For gravity or low-pressure applications, metal-banded flexible couplings complying with

AS/NZS 4327 may be installed to join PE pipes (or fittings) to pipes (or fittings) of other

materials having the same or similar nominal diameter.

4.9 SERVICE CONNECTIONS

When tapping bands or saddles complying with AS 4129 or AS 4793 are installed for

service connections, they shall be installed in accordance with the manufacturers

instructions. Such bands shall be suitable for use with PE pipes and be so designed and

constructed that they do not damage the pipe.

Equipment for tapping under pressure may be employed with service connections in

accordance with the fitting manufacturers recommendations.

Ferrules shall not be screwed directly into PE pipes.

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S E C T I O N 5 I N S T A L L A T I O N O F B U R I E D

P I P E S A N D F I T T I N G S


This Section sets out specific requirements for the installation of buried pipes and fittings.

NOTE: For further information refer to AS/NZS 2566, all parts.

5.2 PIPELINE INSTALLATION USING TRENCHLESS TECHNOLOGY

Trenchless technology may be adopted by methods such as directional drilling, thrust-

boring, micro-tunnelling and pipe-jacking.

NOTE: For further information refer to www.ast t.com.au (see Appendix A).

5.3 PIPE INSTALLATION IN A TRENCH

5.3.1 Provision of a trench

The trench shall be excavated, trimmed to the required grade and as narrow as practicable,

taking into account the native soil type and the need to make joints, install fittings and

compact the pipe embedment material. Where required, the trench shall be wide enough to

allow for jointing, compaction and inspection.

The trench depth shall be sufficient to allow for the specified grade, the required depth of

bedding, foundation material if required (see Figure 5.1), and the minimum cover over the

pipe as specified in Table 5.1.

NOTES:

1 The trench should be kept free of water as far as practicable. Surface water should also be

prevented from entering the trench.2 Narrow trenches may be used where the system design permits and person access is not

required.

TABLE 5.1

MINIMUM COVER OVER PIPE

Loading conditionMinimum cover

m

Not subject to vehicular loading 0.30

Subject to vehicular loading

(a) no carriageways;(b) sealed carriageways;

(c) unsealed carriageways

0.450.60

0.75

Pipes in embankments or subject to

construction equipment loads

0.75

5.3.2 Excavation across improved surfaces

For bitumen, asphalt and concrete surfaces, neat straight lines shall be saw cut at least

50 mm beyond the outer limits of the excavation. For paved surfaces, pavers, blocks or

bricks shall be removed by hand, then cleaned and set aside for later replacement. Trench

fill shall be adequately compacted to avoid subsequent subsidence of the reinstated

improved surface.

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5.3.3 Minimum cover

Minimum cover over the pipe shall be as specified in Table 5.1, based on the future finished

surface level.

Where the trench depth is such that the minimum cover specified cannot be provided for

pipelines subject to vehicular loading, additional protection may be specified.Notwithstanding the minimum covers specified in Table 5.1, pipelines shall have sufficient

cover to

(a) ensure any vehicular loading that is in excess of the loading capability of the pipe istransferred to the soil strata beyond the pipeline;

(b) suit the height dimensions (locally) of fittings such as valves and hydrants; and(c) meet the requirements of the road owner (for pipelines in roadways).Where a pipeline may be subject to abnormal loading during construction, temporary (or

permanent) measures shall be taken to ensure that the pipeline is not overloaded.

5.3.4 Buckling under external load and vacuum

PE pipes and fittings subjected to negative pressure or installed below the water table are

subjected to external loads and may buckle. The pipe class selected in the installation shall

be high enough to ensure stability against

(a) the minimum (vacuum) design pressure; and(b) buckling failure when subjected to the maximum external hydrostatic pressure

possible for the deepest pipe in the installation.

Typically consideration shall be given to negative pressures for pipes of SDR greater than

SDR 13.6. In these circumstances advice may be sought from the manufacturer of the pipe.

When grouting is undertaken, the grouting pressures and temperatures should be determinedto ensure that empty pipes do not deflect or buckle beyond acceptable criteria as a result of

grout pressure. Where the contribution of grouting pressure to buckling forces on an empty

pipe is uncertain, grouting should be carried out with the pipe internally pressurized.

5.3.5 Anchorage

For systems with mechanically or fusion restrained joints, anchorage is not usually

necessary. For those without end-load resisting joints, anchorage at changes of direction

and other points of potential pull-out forces shall be provided, e.g. at bends, valves, tees,

etc.

Construction of anchor and thrust blocks shall be in accordance with AS/NZS 2566.1.

When concrete is being placed on a PE pipeline, complete encasement of the pipe shall be

avoided if possible. The maximum encasement shall be 180, unless flexible joints are

provided at each concrete face entered. Where a pipe is completely concrete encased, it

shall be fully wrapped prior to encasement with a compressible material such as geotextile

or polyethylene foam to a nominal thickness of 6 mm.

5.3.6 Encasement in concrete

Where pipes are to be encased in concrete precautions shall be taken to prevent movement,

flotation or deformation of pipes while pouring concrete.

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Where damage to pressure pipe surfaces could occur as a result of differential movement of

the encased pipe, the pipe and fittings shall be protected.

NOTES:

1 Protection may be by wrapping in a compressible membrane e.g. made of polyethylene, PVC,

petrolatum tape or felt.

2 Encasement in concrete may compromise the inherent flexibility of a PE pipeline and shouldonly be used in special circumstances. In unstable ground conditions, the use of geotextile to

form a ground beam (as shown in AS/NZS 2566.2) may provide a superior solution.

5.3.7 Foundations and foundation stabilization

The floor of the excavated trench is required to provide a foundation suitable for the

adopted construction method.

Where the bottom of an excavation is unable to provide a firm foundation with minimum

bearing capacity of 50 kPa (e.g. in clay soils that can easily be penetrated 40 mm with a

thumb or in sand or gravel that makes a footprint more than 10 mm deep) at the required

level without abrupt irregularities or undulations, engineering advice should be sought on

how to provide a satisfactory foundation.

5.3.8 Prevention of flotation

Flotation of the pipe due to groundwater or inundation before completion of filling shall be

prevented.

Flotation of pipes and fittings may be prevented by one or more of the following methods:

(a) Using trench stops.(b) Placing and compacting sufficient height of fill material.(c) De-watering.Where trench de-watering is necessary, embedment and fill material shall be placed andcompacted while de-watering systems are operating.

NOTE: PE has a density less than that of water and pipes can float even when full of water.

5.3.9 Trench floor preparation

On excavation, the trench floor shall be inspected for rock outcrops and soft and loose areas

so that appropriate action can be taken to ensure that the pipe or fitting or other

appurtenance or structure will not be subject to differential settlement in the future.

Where the pipeline is to be laid on the trench floor, the trench shall be free from hard

objects such as stones, sharp projecting rocks and tree roots, and the trench floor shall be

trimmed to provide continuous support for the pipes.

Where rock outcrops are present, the trench floor shall be trimmed and filled with granular

material to restore the design trench floor level limits. Soft and loose areas shall be treated

as specified in Clause 5.3.7.

All fill and all disturbed areas shall be compacted to not less than the density of the natural

ground.

Where the excavation is in unstable or waterlogged ground or rock, or where excessive

excavation occurs, the depth of excavation and bedding preparation shall be as specified to

provide a uniform base to the bedding.

De-watering shall be carried out to below the pipe level until sufficient backfill has been

placed to prevent flotation of the pipe. The trench floor shall be stabilized to provide an

adequate foundation for the bedding.

All debris shall be removed before placement of any bedding material.

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5.3.10 Placement of bedding

Bedding shall be placed and spread so as to provide uniform support for the pipe. Chases

may be provided at sockets, couplings and other appurtenances to achieve uniform support.

The bedding shall not be compacted and the centre of the bedding shall not be walked on

either during or after placement.

The depth of bedding shall be appropriate to the trench floor condition and the diameter and

classification of the pipe. For pipes in clay soils and rock, a graded continuous cushion of

bedding material of minimum thickness 75 mm should be provided at the trench floor.

Where cement mortar is used as bedding, it shall be packed into the space between the

trench floor and the pipe laid in the trench to attain the line, grade and specified minimum

cover over the pipe. Cement mortar-based material shall not be installed as a haunch.

5.3.11 Pipe laying and jointing

Pipes may be jointed at ground level and then lowered into position. If elastomeric seal

joints have been used for jointing, they shall be checked after the pipe is in position to

ensure that the socket is still correctly positioned on the pipe. The manufacturers

instructions shall be adhered to. The pipes may be snaked in the trench to minimize the

effects of thermal movement.

5.3.12 Bending of pipes

For curves of smaller radius, post-formed bends, moulded fittings or purpose-made sockets

shall be used. PE pipes may be bent during pipe laying to allow a pipeline to follow a

curved path.

For profile wall pipes, reference should be made to the manufacturer for bending

requirements.

Generally, a pressure pipeline can be bent without difficulty in the vertical plane to follow

changes in the ground surface. Where it is not possible to bend the pipe by hand, preformed

bends or moulded fittings shall be installed. The form of the trench floor provides support

for the pipes and bending occurs more or less uniformly along the length of the pipes

involved.

Bending in the horizontal plane is more difficult as pipes tend to move in the trench and the

deflection tends to be concentrated in a few places. There is a tendency for excessive loads

and deformation if pipes are not adequately supported. As the structural stiffness of pipes

increases (small SDRs), the forces required to bend a pipe to a designed curvature increase

considerably, and support along the full length of the pipe becomes more important.

The use of pegs or stakes in the trench to define the radius of the designed curve, or to

restrain the pipe during installation, is not permitted. Bending tends to be localized at the

pegs or stakes and, if they are left in the trench when it is filled, highly localized stressesmay cause premature failure of the pipeline.

5.3.13 Pipe embedment

Embedment material shall be placed uniformly along and around the whole length of the

pipe barrel, couplings and other appurtenances in a manner to ensure uniform density of

side support (including haunch support) and overlay without distortion, dislodgment or

damage to the pipeline.

Where a sewer or drain is supported on concrete, overlay material shall not be placed until

the concrete has attained its initial set.

Following pipe placement, the haunch, side support and overlay materials shall be

compacted in layers not greater than 150 mm to uniformly support the pipe.

Compaction equipment or methods that produce horizontal or vertical earth pressures that

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Flooding compaction may be suitable in some types of soil.

Flooding compaction shall be used only beneath non-trafficable areas, in situations where

embedment material is non-cohesive (i.e., no clays) and the surrounding native soil and the

embedment material are completely free draining.

5.3.14 Trench fillTrench fill material shall be placed on the pipe embedment and compacted as specified to

fill the trench, with care taken to avoid impact loading of the pipeline.

For non-pressure pipelines, the voids behind timber ground support in close-timbered

tunnels, drives and shafts should be filled by pressure or gravity grouting using a sand-lime-

cement slurry or pneumatic placement of appropriate trench fill material.

Any deficiencies of trench filling exposed by settlement shall be corrected.

5.3.15 Removal of trench supports, pegs and packing

All levelling pegs or temporary packing, such as wooden blocks, shall be removed from the

trench before pipe laying.

Temporary trench support systems shall be lifted progressively above each layer of

embedment or fill to ensure that each layer is compacted against undisturbed native soil

(trench wall).

5.3.16 Marking tape

Marking tape, where installed, shall be located at the top of the embedment zone (see

Figure 5.1).

Refer to AS/NZS 2648.1 for non-detectable tape. Refer to WSAA PS-318 for detectable

tape.

DIMENSIONS IN MILLIMETRES

FIGURE 5.1 TYPICAL INSTALLATION IN A TRENCH

5.4 PIPE INSTALLATION IN AN EMBANKMENT

Pipe installation in an embankment shall be in accordance with AS/NZS 2566.2.Accessedb

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S E C T I O N 6 I N S T A L L A T I O N O F P I P E S

A B O V E G R O U N D


This Section sets out specific requirements for the installation of pipes above ground.

6.2 INSTALLATION REQUIREMENTS

6.2.1 Grade and alignment

When PE sanitary plumbing systems are being installed, particular care shall be taken to

establish the correct grade and alignment.

6.2.2 Pipe bending

Refer to Clause 5.3.12.

6.2.3 Setting of pipes in concrete

Where a pipe is set in concrete and damage to pipe surfaces could occur as a result of

movement of the pipe relative to its surrounding, a membrane (e.g. of polyethylene, PVC,

petrolatum tape, or felt) shall surround the pipe and fittings to permit movement without

scoring. Where fittings are installed with insufficient space for them to move, expansion

joints shall be provided to accommodate thermal movement (see Clause 6.4).

NOTE: PE pipe may be totally enclosed in concrete without protection where the installation is

designed for total enclosure.

6.2.4 Pipes passing through floors and walls

Any pipe or fitting passing through any floor or wall shall be wrapped with a suitable

flexible material, or a permanent annular clearance of not less than 6 mm shall be providedbetween the pipe or fitting and the floor and wall. Suitable measures shall be taken to

maintain this clearance, and to permit the pipe to be sealed in position without restricting its

axial movement.

6.2.5 Pipe installation in a sleeve or duct

When a pipe is being laid through a sleeve or duct, it shall be suitably protected against

damage from sharp ends or edges on the sleeve or duct. The pipe shall be restrained within

the duct to prevent excessive movement under pressure transients. This may be achieved by

using slippers, a purpose-designed product for installation of pipes in sleeves or ducts, or by

using timber skids strapped to the pipe (see Figure 6.1).

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FIGURE 6.1 TYPICAL INSTALLATION OF DN 560 PE PIPE IN A HOST PIPE (DUCT)

6.2.6 Penetration of fire-resistant structuresWhere fire-resistant structures are penetrated by PE pipe, devices such as intumescent fire

stoppers that will maintain the integrity of the structure in the event of a fire shall be

installed in accordance with the manufacturers instructions.

6.3 SUPPORT OF PIPELINES

6.3.1 Supports

6.3.1.1 General

All supports shall be of fixed or sliding type, and shall be rigidly fixed to the adjacent wall

or floor.

6.3.1.2 Sliding supports

Sliding supports shall provide a guide, without restraint, for the axial movement of pipes

subject to thermal expansion. The support shall allow for a pipe to be surrounded with a

layer of suitable flexible material, or incorporate a plastics coating.

Sliding supports shall be provided in accordance with Table 6.1.

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TABLE 6.1

MAXIMUM SPACING OF SUPPORTS

Recommended maximum spacing of supports, mNominal outside

diameter of pipe Horizontal or graded

pipes Vertical pipes

16

20

25

0.25

0.30

0.35

0.50

0.60

0.70

32

40

50

0.38

0.43

0.45

0.75

0.85

0.90

63

75

90

0.50

0.60

0.67

1.05

1.20

1.35

125

140

160

0.75

0.85

1.00

1.50

1.70

2.00

200

225

250

1.10

1.15

1.25

2.20

2.30

2.50

280

355

1.30

1.50

2.60

3.00

6.3.1.3 Fixed supports

Fixed supports shall restrain movement of the pipe or fitting either by being clamped to the

structure with a fixed bracket or by being set firmly into the structure. Care shall be taken

to ensure that pipes and fittings are not distorted by over-tightening. The support shall be

securely attached to the fitting and located in the clamping groove, if one is provided on thefitting.

Fixed supports shall be provided at every expansion fitting, and at every fitting that

incorporates provision for expansion, to prevent movement of the fittings. This includes the

sockets of all pipes with elastomeric seal joints used in the installation. Where expansion

joints are installed, fixed supports shall alternate with expansion joints throughout the

installation.

6.3.2 Spacing of supports

6.3.2.1 Pressure pipes

Pipes shall be supported at intervals dependent on the density of the fluid being conveyed

and the maximum temperature likely to be reached by the pipe material. The maximum

spacings of supports for all classes of pressure pipe where water at temperatures up to 20C

is being conveyed shall be as given in Table 6.1.

Where ambient temperatures or the temperature of piped fluids are such that the

temperature of the material is likely to be greater than 20C, the support distances shall be

reduced accordingly. For PE pipes where material temperatures are likely to approach 60C

and the pipe is horizontal, the pipe shall be continuously supported; for vertical

installations, the values in Table 6.1 for horizontal support shall be used.

Heavy fittings, such as valves, shall be supported independently and large plastics fittings

(e.g. flanges, particularly those with metal backing rings) shall be supported on each side.

Where pipes are continuously supported, flanged connections and other protrusions shall beallowed room for movement.

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6.3.2.2 Non-pressure pipes

Cold non-pressure pipes (see Clause 6.4.2.2) shall be supported at intervals not exceeding

the distances set out in Table 6.1. For hot pipelines (see Clause 6.4.2.2), the supports shall

be at intervals not exceeding half the distances set out in Table 6.1.

Pipelines shall be supported at, or adjacent to, every bend, including fittings wherepipelines emerge from a wall.

6.4 PROVISION FOR EXPANSION

6.4.1 General

Provision shall be made for thermal movement by fitting expansion joints, unless the

movement can be accommodated by other means as described in Clause 6.4.3. An

expansion joint shall permit an axial movement of the connecting pipe of not less than

10 mm in either direction.

Elastomeric seal joints on pipes may be regarded as expansion joints if recommended as

such by the manufacturer.6.4.2 Maximum spacing of expansion joints

6.4.2.1 General

The maximum spacing of expansion joints depends upon the maximum temperature

differential expected in service and the magnitude of the axial movement that the selected

expansion joint can accommodate.

NOTE: The thermal expansion or contraction of PE pipe is shown in Clause 3.7.2 and Figure 3.1.

6.4.2.2 Cold and hot pipelines

Unless there is alternative provision for thermal movement, pipelines shall be fitted with

expansion joints in accordance with the following:(a) PE pipe systems located within buildings or outside buildings that are out of direct

sunlight and not subject to pipe material temperatures greater than 60C (cold

pipelines) shall be fitted with expansion joints at spacings no greater than 6 m or as

recommended by the manufacturer. Where the length of pipeline between fixed points

is no greater than 1.5 m, provision for thermal movement is not required.

(b) Water supply and sanitary plumbing pipe systems installed for conveying hot fluids(e.g. from dishwashers, washing machines, knife sterilizers etc.) or located outside

buildings in direct sunlight, or in roof spaces, so that the pipe material temperature

might exceed 60C (hot pipelines), shall be fitted with expansion joints at spacings

no greater than 4 m. Where the length of pipeline between fixed points is no greater

than 1 m, provision for thermal movement is not required.

6.4.2.3 Stacks and vertical pipes

Expansion joints shall be located in stacks and vertical pipes

(a) at each floor at which fixtures or branch pipes are connected, and shall beimmediately above the highest branch connection; and

(b) at the base of a stack.This is illustrated in Figure 6.2.

6.4.2.4 Graded pipelines

When required by Clause 6.4.2.2, expansion joints shall be provided in graded pipelinesimmediately upstream of the entrance to a vertical stack (as illustrated in Figure 6.3).

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6.4.3 Alternative provision for expansion

Expansion joints may be omitted in the following locations (as illustrated in Figure 6.4):

(a) Above the highest branch connection on a stack where the stack is free to movethrough a weatherproofed sleeve through the roof.

(b) At a junction, bend or expansion loop in a graded pipeline where the thermalmovement in the pipeline can be accommodated by deflection of the offset leg

without affecting the grade of the pipeline. The minimum length of the offset leg, as

defined by fixed supports, shall conform to the values in Table 6.3.

(c) At a junction or bend in a graded pipeline where the thermal movement in thepipeline can be accommodated at a trap of plastics material, provided that the length

of the pipeline does not exceed 6 m for cold pipelines or 4 m for hot pipelines (see

Clause 6.4.2.2), and the trap is in alignment with the pipeline.

TABLE 6.3

ALTERNATIVE EXPANSION PROVISION

Nominal size

of pipe

mm

Maximum pipe

length

m

Minimum length

of offset leg

ms

40, 50, 63

2.0

3.0

4.0

6.0

0.5

0.6

0.8

1.0

75, 90, 125

2.0

3.0

4.0

6.0

0.75

1.0

1.1

1.2

140, 160

2.0

3.0

4.0

6.0

1.0

1.1

1.2

1.2

6.4.4 Installation of expansion joints

Expansion joints shall be supported at the socket section of the fitting by a fixed support.

Care shall be taken to ensure that expansion fittings are correctly installed in accordance

with the manufacturers instruction and that the pipe is not bottomed in the expansionsocket.

The following procedure shall be adopted where no temperature markings are provided on

the movable part of the fittings:

(a) Insert the pipe in the expansion socket to the full depth and mark the pipe.(b) Withdraw the pipe a distance equal to the temperature engagement depth and mark

the pipe. The temperature engagement depth shall be determined according to the

average environmental or pipe material temperature at the time of installing the

system.

(c) Hold the pipe in this position until the installation is complete.

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LEGEND:

= Expans ion jo in t

= F ixed po int

Expansion jo int

above highest branch

connection (may be omitted

under Clause 6.4.3 (a) )

Clause 6.4.2.2(a)

6 m max. without

expansion joint

(cold pipelines)

Sl id ing support

at a l l f loors

Clause 6.4.2.3(a)

Expansion joint

above highest

branch connect ion

from each f loor

Clause 6.4.2.3 (b)Expansion joint at

base of stack

FIGURE 6.2 EXPANSION JOINTS AND FIXED POINTS IN VERTICAL STACKS

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FIGURE 6.3 EXPANSION JOINTS AND FIXED POINTS IN GRADED PIPELINES

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Clause 6.4.3(a)

Expansion jo int omit ted where

al ternat ive expansion provided

through roof

Clause 6.4.3(c)

Expansion jo int omit ted where

al ternat ive expansion providedby plast ic t rap

Clause 6.4.3(c)

Expansion jo ints omit ted where


l3

l3

L3

L2

L1

l2

l2

l2

l1

L1

L

Clause 6.4.3(c)



Clause 6.4.3(c)



LEGEND:

= P ipe suppor t

= Expans ion jo in t

= F i xed po int

= Expans ion jo in t de le ted

See Table 6.3 for va lues of Land l

FIGURE 6.4 ALTERNATIVE EXPANSION PROVISIONS IN VERTICAL AND GRADED

PIPELINES

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S E C T I O N 7 T E S T I N G O F P I P E S Y S T E M


This Section sets out the requirements for testing pipelines and systems after theirinstallation or repair. Where appropriate, the procedures in AS/NZS 3500 series may be

used as an alternative.

7.2 TESTING OF PRESSURE PIPE SYSTEMS

7.2.1 Pre-test precautions

Above-ground installations shall be tested when all fittings and supports have been

installed.

Pipelines shall be pressure-tested when sufficient time has elapsed to allow curing of

concrete thrust blocks.

NOTE: While it is preferable for all joints in underground pipelines to be left exposed during the

testing procedure, this is seldom practical.

7.2.2 General requirements

Pressure testing PE pipes may require special processes since they may continue to expand

significantly throughout the test period. When a PE pipe is sealed under a test pressure

there may be decay, even in a leak free system, due to the creep response and stress

relaxation of the PE material. Due to this material behaviour, standard pipe testing

procedures used for other pipe materials such as PVC, DI and steel, may not be suitable for

PE pipe.

The following factors can affect a PE pipe pressure test:

(a) Length of section and pipe diameter.(b) Test pressure, rate of pressurisation and duration of the test.(c) Presence of air.(d) Relative movement of mechanical fittings.(e) Level of support from pipe embedment.(f) Accuracy of test equipment.(g) Ambient temperature changes during testing.(h)

Presence of fittings and other materials in the test section.

(i) The presence of leaks.Long test sections may incorporate a large number of joints that should be checked for

leakage. The longer the test section the harder it is to locate a leak. Pipes above about DN

250 cause additional effects to further complicate the test process. Where site or production

reasons require longer lengths to be tested, radio links between test operatives to minimize

the test duration should be employed.

The pipeline or system may be tested as a whole or in sections, depending on test pressure

requirements, the length and diameter of the line, the availability of water, and the spacing

between sectioning valves or blanking ends. The pipeline (or section) shall be properly

supported and, if it includes non end load bearing joints, be anchored to prevent the

movement of pipes or fittings during the test.

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The test section shall be filled with water, taking care to purge all free air from the section.

Where a motorized positive displacement pump is used for the test, it shall be fitted with an

effective form of pulsation damping. Also, to minimize the risk of potentially damaging

over-pressurization occurring, a pressure relief valve shall be fitted. This relief valve shall

be set correctly and have sufficient capacity to limit any possible pressure rise to a

maximum of 100 kPa above the test pressure.The pressure shall be monitored at the lowest part of the pipeline or, if that is not possible,

at some other convenient point and the test pressure adjusted to take account of the

elevation difference between the pipelines lowest point and the test rig. The adjustment

shall be made by subtracting 10 kPa for every metre that the rig is elevated above the

lowest part of the line. The source of any leak shall then be ascertained and any defects

repaired. The pipeline shall then be retested.

The pressure test shall be conducted using two pressure measuring instruments that shall

agree within 5% of gauge reading.

7.2.3 Basic pressure test (Visual)

A test pressure of 1.25 times the operating pressure (but not more than 1.25 times theMAOP of the lowest rated component in the system) shall be applied to the section under

test. The test section shall then be allowed to stand without make-up pressure. Where the

joints are accessible for inspection and there is no evidence of leaks of the test water after

at least 15 minutes under pressure, the section is deemed to have passed the test.

Where the joints are not accessible for inspection and the apparent loss of water is less than

that calculated from the following equation, the section is deemed to have passed the test.

Q0.14LDH

where

Q = allowable make-up water, in litres per hourD = nominal diameter of the test length, in metres

L = length of the test length, in kilometres

H = average test head over length of pipeline under test, in metres

NOTES:

1 The make-up water is not a leakage allowance, but is an allowance to cover the effects of the

test head forcing small quantities of entrapped air into solution. Normally the test should last

for a minimum of 2 h and be concluded within 5 h to 8 h. The make up water requirement

should reduce with time as air goes into solution. Where, after 12 h the make up water still

exceeds the allowable limit, testing should cease and the cause of loss investigated.

2 It is assumed that if the pipeline passes the test, the anchorages are sound.3 Pressure testing against a closed valve should normally only be undertaken when there is no

practicable alternative or when any leakage from the valve can be observed and measured

during the test.

7.2.4 General pressure test (Technical)

7.2.4.1 General

For plastics pipes that are subjected to internal pressure, there will be a progressive drop in

that pressure due to stress relaxation. Accordingly, it may be difficult to assess whether a

pipeline is leaking or simply subject to stress relaxation.

In order to overcome this difficulty, this method is based on the principle that if the

pressure is held constant, there will be a linear relationship between hoop strain andlogarithmic time.

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Variables such as pipe stiffness and soil compaction are irrelevant, as the test result is based

on actual performance during the test. Temperature may be considered constant, as with

other test methods, unless special conditions exist.

7.2.4.2 Test procedure

Maximum system test pressure (STP) shall be at least 1.25 times the maximum workingpressure of pipeline but not to exceed 1.25 times MAOP of lowest rated pipe/fitting in line.

The pipelines shall be tested as follows:

(a) Raise pressure to STP, close off main and allow to settle for at least 12 hours. Duringthis period, pressure will fall as a result of pipe expansion.

(b) Using water of the same temperature as that in the pipeline (3C) restore andmaintain STP,

(c) Measure and record water volume added at 2 h, 3 h, 4 h, and 5 h from start.(d) Conclude test 5 hours after commencement.

For optimum test protocol, the following tolerances are recommended:

(i) Water volume: 10Dlitres, where D= pipe nominal diameter in metres.(ii) Time: 1 min.(iii) Pressure: 1 kPa.Suggested tolerances are included even though the current method does not include

tolerances. Accordingly, they are included as recommendations only.

(e) Calculate the water volume added between the second and third hour, V(3h2h) andthe volume added between the fourth and fifth hour, V(5h4h).

(f) Calculate Vall = 0.14.L.D.H(ref. AS/NZS 2566.2, Clause 6.3)where

Vall = Volume makeup allowance, in litres/hour

L = Test length, in kilometres

D = Pipe nominal diameter, in metres

H = Average test head over pipeline length, in metres

(g) Test passes if V(5h4h) 0.55V(3h2h) + Vall .7.2.5 Joints between test sections

The joints between the new pipeline and existing pipelines shall be subjected to theoperating pressure for at least 1 h and then inspected for leakage. This inspection shall only

be carried out in dry weather or if a suitable shelter is erected over the joints and the area

dried sufficiently to show any dripping or weeping.

7.3 TESTING OF NON-PRESSURE PIPELINES

7.3.1 General

Where specified, new sewers, sanitary and stormwater drainage and other non-pressure

installations shall be pressure tested.

Appropriate methods are described in Clauses 7.3.2, 7.3.3 or and 7.3.4. The tests shall also

be applied to any section of existing pipeline or drain that has been repaired or replaced. Allopenings in the pipeline below the top of the section under test shall be sealed.

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7.3.2 Method 1Hydrostatic test

The pipeline shall be filled with water to a height of not less than 1 m above the natural

ground level at the highest point of the section being tested, or to the flood level of the

lowest sanitary fixture, but not exceeding 5 m at the lowest point of the test section.

The pressure shall be maintained without leakage for at least 15 minutes. The source of anyleak shall then be ascertained and any defects repaired. The pipeline shall then be retested.

NOTE: If groundwater is present, the test pressure should be increased to compensate for the

depth of groundwater at a rate of 10 kPa for every 1 m of groundwater depth above the pipe.

7.3.3 Method 2Low pressure air test

Air shall be introduced slowly by suitable means until a pressure of 50 kPa is obtained. This

pressure shall then be maintained for a period of at least 3 minutes. If no leaks are apparent

at the end of 3 minutes, the air supply shall be shut off and, provided that the pressure of air

contained in the pipes under test does not fall below 35 kPa within 60 s, the pipeline shall

be considered satisfactory. If the pressure is not maintained within the specified limits, the

air shall be re-introduced and the pipeline examined for leaks by pouring a concentrated

solution of soft soap and water over the joints and fittings. The source of the leak shall thenbe ascertained and any defects repaired. The pipelin

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