Plastic Pipe

Industry Association

Contents

Page
1

General

1.2

Scope of application

Installation Instructions

Transport and unloading

A 785

Storage

Installing pipes and pipelines

10

4.1

Laying operation

10

4.2

Pipe joints

11

4.2.1

Types of couplings

11

4.2.2

Joining the pipes

12

4.2.2.1

Push-on couplings

12

4.2.2.1.1

Angular deflection between adjacent pipes

13

4.2.2.2

Flanged joints

14

4.2.2.3

Steel couplings

15

4.2.3

Making adapters

16

4.2.4

Connecting to other pipe systems

17

Sewerage Systems
Made of Centrifugally
Cast GRP Pipe
For Buried Sewers and Pipelines

4.3

Laying double pipes

19

Laying in slopes

33

4.4

Installing manholes

19

Water reservations

34

Pipe trench

22

8.1

Scope of application

34

5.1

Terms

22

8.2

Design guidelines

34

5.2

Trench geometry

22

8.3

Installing sewers and pipelines

35

5.3

Types of soil

24

8.4

Leak testing in operation

36

5.4

Building materials in the pipe zone

27

Backfilling and compacting

36

5.4.1

General

27

10

Removing the trench lining

40

5.4.2

Native soil

27

11

Leak tests

40

5.4.3

Supplied building materials

27

11.1

Hydrostatic test

41

5.4.3.1

Granular and non-cohesive building materials

27

11.2

Air test

41

5.4.3.2

Hydraulic building materials

28

11.3

Leak test in double pipe systems

42

5.4.4

Building materials for the backfill

30

12

Connections to structures and masonry

43

Pipe zone

30

13

Retrofitting connections
(saddles)

44

6.1

General

30
14

Fitting intermediate lengths

46

6.2

Lower pipe bed

31
15

Repairs

46

6.3

Upper pipe bed

31
15.1

Assessing damage

46

6.4

Embedding pipes

31

6.5

Embedding pipes in concrete

32

15.2

Replacing a defective pipe section

46

15.3

Repair couplings

46

15.4

Repair laminate

47

Installation Instructions for Buried GRP Sewers and

Pipelines

1
15.5

Removing a pipe coupling

47

16

Project questionnaire

48

17

Standards and guidelines

51

General

A pipe system is an engineered structure in which the pipe,

joints, bedding, backfill and cover all contribute to its ultimate
stability and reliability. The pipe stiffness and nature of the soil
together determine system performance, which is a significant
factor in buried installations. The quality of the materials used
and the execution are the most important criteria for the
soundness of the finished pipe structure.
1. 2 Scope of application
These instructions apply to the transport, storage and
installation of pipes and fittings made of glass fiber reinforced
plastics (GRP) on the basis of unsaturated polyester resins (UP)
for non-pressure buried sewers and pipelines.
Only quality-controlled pipes, fittings and seals should be
used. All products approved by the Plastic Pipe Quality
Association are stamped with the RAL mark:
When designing the GRP pipes, the following parameters are
assumed:
- Pipe zone backfilled with a non-cohesive gravel/sand mixture
- Proctor density 90% min.
The trench must be backfilled as described in Section 9 to
ensure that the pipe/soil system functions properly.

2nd edition; A 785/99-3

To make sure that all the important parameters are taken into
consideration during installation, it is advisable to complete the
Project Questionnaire (see Section 16), which can also be used
as a specification, and send it to the client, contractor and pipe
manufacturer.
After the pipes have been installed, short-term deflection of 4%
max. is permissible in accordance with ATV A 127. Any
deflection over and above this limit in the first 24 hours
following installation cannot however be tolerated and would
result in the long-term deflection being exceeded.

In addition, ropes can be attached to the bolts in the shaft wall

for unloading.
As for pipe transport, bending and impact loads should also be
avoided when loading custom-built assemblies.
Check every delivery immediately for defects. Discard damaged
parts to prevent them from being used, mark and store them
separately. Furthermore, check the pipe branding for
manufacturers trademark, number of the general type approval
or DIN No., and RAL marking from the Plastic Pipe Quality
Association. Only then can you reliably determine that the parts
delivered to the site conform to the product standards,
engineering specifications and clients requirements.

Transport and unloading

Protect all pipe system parts against damage. Use wide plastic
slings or synthetic rope for loading, unloading and securing
parts during transit. Do not use hooks, metal cable, chains or
other sharp edged hoisting tackle. Avoid concentrated and
impact loads.
Pipes of different diameters can be transported more
economically by nesting smaller ones inside larger ones. The
nested pipes should however rest on the others and not hang
from steel straps.
The nested pipes should be extracted by fork-lift truck with the
metal forks protected and extended to suit the pipe length, thus
preventing the inner pipe surface from being damaged.
For transporting manholes and other custom-built assemblies,
similar instructions apply. Manholes can either be transported
horizontally or vertically, depending on their height. Loose
accessories (e.g. covers) are installed on site. It is easiest to
unload them with commercially available self-tensioning tackle
designed to prevent the pipe shaft from being damaged.

Storage

The original packaging, usually a pipe pallet, is suitable for both

transport and storage. Pipes should be stored on a level
surface and kept away from intensive heat, open flames,
solvents etc. They should also be protected against mechanical
damage, soiling of the seals and concentrated loads.
If stacked at a later date (see Fig. 1), the height depends on the
soil conditions, local handling equipment and safety features.

Wooden chocks should be inserted under the first layer to

prevent the pipes from becoming covered in mud during rainfall
or freezing to the ground. On site pipes should not be stacked
higher than 2 meters to prevent accidents. Place wedges and
chocks between the layers to keep them stable.

Fig. 2: Storage with staggered couplings

45 or to suit pipe haunch

Installing pipes and pipelines

4.1 Laying operation

Diameter
DN

No. of
pipe lengths

200
250
300
400
500
600
700
800
900
1000
1100
1200
1400

8
7
6
5
4
3
3
2
2
2
2
2
1

Check all the pipe system parts for damage before lowering
them into the trench.
Depending on the weight and local conditions, most parts, especially pipes up to around DN 400 can be installed manually. If
used, suspension and hoisting tackle should not pose a threat
to the pipe wall. Hooks, chains, metal cable and any other
sharp-edged aids that could slip or cause impact and shock
should be avoided at all costs. It is therefore advisable to use
textile slings.
Every pipe and fitting should be installed to the specified line
and grade. Because the pipes are relatively long, check the level several times, ensuring that a continuous straight route of
the specified gradient is adhered to throughout.

Fig. 1: Storing in stacks

If they are stored without intermediate blocks, the pipes have to
face alternate directions to prevent the couplings from resting
on the pipe barrels (see Fig. 2).

10

4.2 Pipe joints

4.2.1

4.2.2

Joining the pipes

4.2.2.1

Push-on couplings

Types of couplings
Type

FWC

FWC
Asymmetric

Diameters
DN
300 - 2600

150 - 1200

Permissible bending
DN
a max
500
3
600-900
2
1000-1400
1
1400
0,5

500
> 500

3
2

Before joining the pipes, check that all the parts are there and
correctly positioned in the trench. The pipes have to rest on the
bedding over their entire length, except at the bell holes under
the couplings. Point and line loads must be avoided. Clean the
mating surfaces thoroughly immediately prior to jointing,
especially the grooves in the rubber seal.
Now coat the spigots and the inner coupling surface with a
lubricant as recommended by the manufacturer to reduce the
required jointing force to a minimum. Ensure that no sand or
similar comes into contact with the coated surface.
The pipes have to be joined centrically in the direction of the
pipe axis. This can be done manually up to a diameter of
around DN 400 and above that with levers, grabs, winches,
jacks or bulldozer blades. It is extremely important for the force
to be applied under controlled conditions and the pipe parts to
be protected against damage during the entire jointing
operation.

DC

150 - 600

500
> 500

3
2

No equipment may be used that does not ensure controlled

jointing of the pipes or could damage them. Point or local loads
must not be applied to the spigots. We therefore recommend
using suitable bolsters to distribute the load (e.g. wood).
When using special couplings, the mounting depth should be
checked beforehand and, if necessary, marked on the pipe to
ensure a reliable seal.

Fig. 3: Types of couplings

11

12

In the course of pipe laying, fittings can be attached in the

same way as pipes. They have to be aligned with the pipes
however and prevented from slipping as a result of the inner
pressure if they are not resistant to tensile stress. Every pipe
and fitting has to be calibrated by suitable means (locating
device, leveling instrument, laser system etc.). Do not attempt
to correct the position by pressing, pushing or striking them
with heavy-duty machinery.

Maximum
deflection
Pipe length

4.2.2.1.1 Angular deflection between adjacent pipes

The permissible deflection at the joint and the resultant radii of
curvature are shown in Table 1.

Fig. 4: Permissible deflection

Table 1:

4.2.2.2

Minimum possible radius of curvature as a result of

maximum permissible deflection

DN

Max. perm.
deflection

[]

Deflection [mm]
per
pipe length

Resultant minimum
radius of curvature [m]
for pipe length

3m

6m

3m

6m

DN 500

157

314

57

115

500 DN 900

105

209

86

172

52

105

172

344

0,5

26

52

344

688

900 DN 1800
1800 DN

Flanged joints

GRP pipes can be joined both with GRP flanges and with other
industry standard flanges. The applicable standard for flange
dimensions is DIN 2501-1.
Joining pipes with flanges requires:
a.) Cleaning the flange surfaces and the housing for the sealing
ring, if necessary.
b.) Checking that the sealing ring is clean and is not damaged
in any way.
c.) Positioning the sealing ring on the sealing surface or in the
ring housing.
d.) Pressing the flanges together.
e.) Positioning the bolts and nuts. The jointing and sealing
materials have to be clean and intact. If GRP flanges are
used, washers have to be inserted.

13

14

f.) Tightening the opposite nuts (with a torque wrench)

alternately (in the case of GRP flanges to DIN 16966 with a
torque of 35 Nm).
g.) Repeating step f), several times if necessary, and tightening
the bolts with the permissible torque for the relevant bolt
size and strength class. The maximum permissible torque
for GRP flanges is 70 Nm.
h.) Checking the bolts after around an hour and tightening them
again with a torque wrench. Again, the maximum
permissible torque for GRP flanges is 70 Nm.
To fit lapped flanges, follow the procedure described above.

4.2.2.3

4.2.3

Making adapters

First cut the adapters to length with a stone saw. Then bevel
both the pipe spigots to be joined and the adapter as detailed
in Table 2 and Fig. 5..
Table 2: Bevel dimensions
Diameter
DN

Dimension
A [mm]

Dimension
B [mm]

150
200 - 350
400 - 700
800 - 1500
1500 - 2600

20
30
30
40
50

3
5
6
10
12

Steel couplings

These couplings can be used both to join and repair pipes.

They consist of a split steel casing with a rubber seal inside.
Three types of steel casing are available:
- Epoxy or PVC coated
- Stainless steel
- Hot-galvanized
Checking the bolt tightening forces is very important when this
type of coupling is used. After putting the coupling in place,
tighten the bolts slightly and, before finally tightening, check
that the coupling and above all the seals are fitted properly.
Then tighten the bolts slowly and evenly. For the permissible
tightening torque, see the coupling manufacturers
instructions.

15

Fig. 5: Bevel at the spigot

16

They are made 10 20 mm shorter than the gap that actually

has to be closed. The adapters are fitted to the pipe with the
help of the couplings defined in Sections 4.2.1 and 4.2.2.3.

4.2.4

GRP-PVC (DIN V 19534/DIN EN 1401)

Connecting to other pipe systems

GRP-cast iron

GRP-concrete

GRP-stoneware

GRP-PE-HD (DIN 8074)

Fig. 6: Joints

17

18

4.3 Laying double pipes

Double pipe systems that are primarily used in potable water
reservations (Protection Zone II to ATV A 142) are normally
pre-assembled before being delivered to the site.

After checking the connecting height, lay the subbase (e.g. 8/16
gravel/chips). Then, before finally installing the manhole, check
that it is located centrally between the connector and the pipe,
adjusting the subbase if necessary (see Fig. 8). The manhole
can be connected in the same way as the pipes, using
additional tools if required e.g. a winch.

Fix the media pipe in place with skids. To comply with the
stress rating, at least 2 skid rings per 6 m pipe are required. Due
to the varying rating for the individual skid models, more rings
may be used if necessary or under more difficult installation
conditions. Proof of suitability for the application should be
provided by the skid manufacturer. When joining, mount and
check the media pipe first and then the casing pipe.

DE
Winch
Chock

4.4 Installing manholes

Do not embed the connecting pipe or bend. Allow for a bell
hole for the manhole (see Fig. 7).

Fig. 8: Aligning a manhole

After the manhole has been connected, check the following:
1. Ensure that the coupling and seal are in the correct location
and fit properly
2. Check the gradient

Connecting height
+ approx. 50 mm

Fig. 7: Bell hole for manhole

Prepare and compact both the bell hole and the pipe bed,
ensuring that varying degrees of settling between the manhole
and the pipe cannot occur later. The manhole is usually lowered
onto the compacted bed consisting of stable soil or gravel
(larger manholes on lean concrete). No further preparation is
required.

19

3. Ensure that the joint between the manhole and pipe is free of
stress (use a bend)
4. Check that it is stable
5. Ensure that the maximum angular deflection between the
pipe and connector meets the requirements detailed in
4.2.2.1.1.

20

When backfilling the trench, ensure that the manhole cannot

alter its position in any way. This is why one-sided backfilling
has to be avoided. The manhole and connecting pipes should
therefore be embedded and covered uniformly to prevent
different degrees of settling.
Table 3: Manhole installation dimensions
Manhole installation
dimensions

s connection length
DE outside diameter
DN connection
diameter
DNs manhole DN

DE

Pipe trench

5.1 Terms
The meaning of the terms pipe zone and backfill, and the
various parts of the pipe zone:
- Lower pipe bed
- Upper pipe bed
- Backfill
- Cover
are illustrated in Fig. 9 on the basis of DIN EN 1610 "Installation
of buried and sewers and pipelines.

DNS
DN

1000/1026
s

200

300

300

300

300

300

300

250

300

300

300

300

300

300

300

300

300

300

300

300

300

350

350

350

350

350

350

350

400

350

350

350

350

350

350

500

400

400

400

400

400

400

600

400

400

400

400

400

400

700

500

500

500

500

500

Upper pipe bed

800

500

500

500

500

500

Lower pipe bed

900

600

600

600

600

1000

600

600

600

600

1200

600

600

600

1400

600

600

1200/1229 1400/1439 1600/1638 1800/1842

s
s
s
s

2000/2047
s

Ground surface
Trench walls
Main backfill

Cover depth

Cover zone
c (at least 30 cm)

Trench depth

Pipe zone backfill

Pipe zone

OD
Pipe bed

Trench bottom

Fig. 9: Illustration of trench terminology

5.2 Trench geometry
Select the pipe route ensuring that the line is as straight as
possible because any changes in direction can have a
detrimental effect on the flow characteristics.

21

22

Avoid counter-gradients. If there are any, there have to be vents

at all the high points and drains at the low points in the pipeline.

DIN EN 1610, DIN 4124, DIN 18300, DIN 18303 and DIN 19630
apply to the design and digging of pipe trenches and pits, but
local conditions should also be taken into consideration. What
is important when calculating the trench width is that it is at
least wide enough to accommodate the machinery for
compaction.
Table 4:

Minimum trench width in relation to the outside pipe

diameter de

Lined trench

Unlined trench
60

[mm]

> 60

225

da + 0,40

> 225 - 350

da + 0,50

da + 0,50

da + 0,40

> 350 - 700

da + 0,70

da + 0,70

da + 0,40

> 700 - 1200

da + 0,85

da + 0,85

da + 0,40

> 1200

da + 1,00

da + 1,00

da + 0,40

1)

da + 0,40

In the table above (de + x) corresponds to x/2 of the minimum working

space between the pipe and trench wall or lining, where de is the outside diameter in mm and the slope angle

Table 5 shows the minimum trench width in relation to the

trench depth.

23

Trench depth
[m]

Minimum trench width

[m]

<1

No minimum trench width specified

> 1,0 < 1,75

0,8

1,75 < 4

0,9

Exceptions to minimum trench width

In the following situations, exceptions can be made to the
minimum trench width:

Minimum width (de + x)1)

[m]
Outside pipe
diameter de

Table 5: Minimum trench width in relation to the trench depth

- If personnel do not ever enter the trench

- If personnel do not ever enter the space between the pipe
and the trench wall
- If space is restricted or the trench is unavoidably narrow
Each of these cases requires special care in planning and
execution.
5.3 Types of soil
Both the native soil and the bedding material have to be of
sufficient load-bearing capacity. Frozen soil must not be used in
the pipe zone or be covered. In the case of unstable soil, it
should be removed completely or at least in part. The various
types of soil to ATV A 139 are listed in Table 6. In Austria
NORM B5012 applies.

24

In the case of soil that is unstable or in danger of settling, it may

be necessary to take action to prevent the pipeline from
sinking. There is a risk of settling in particular in soils with a high
peat content, mud etc. We then recommend replacing the soil
completely or using geo-textiles, a bed of broken stones,
wooden battens or pile foundations.

Table 6: Types of soil with modulus of compressibility

Modulus of compressibility E [N/mm_]
at relative compaction DPr [%]
DPr =
85
90
92
95
97 100

Soil types (to ATV)

Group 1
Dense
soils,
gravel

Group 2
Dense
soils,
sand

Group 3
Cohesive
mixed
soils

Group 4
Cohesive
soils,
gravel

GE: closely
graded
gravel
GW: clean
gravel with
sand

GI: alternately
graded gravel/
sand mixtures
GU: gravel/silt
GT:
gravel/clay
mixture (5-15*)

16

23

40

SE: closely
graded
sand
SW: widely
graded
sand/gravel
mixtures

SI: alternately
graded sand/
gravel mixtures
SU: sand/silt
mixture (5-15*)
ST: sand/clay
mixture (5-15*)

1.2

11

20

GU:
gravel/silt
mixture
(15-40*)
GT: gravel/
clay
mixture
(15-40*)

SU: sand/silt
mixture (15-40*)
ST: sand/clay
mixture (15-40*)

0.8

13

UL: slightly
plastic silts
UM:
medium
plastic silts
TL: slightly
plastic clays
TA: highly
plastic clays
OU: silts
with organic
material

OT: clay with

organic material
OH: coarse to
mixed grain
soils with
humus material
OK: coarse to
mixed grain
soils with limy
and gravelly
material

0.6

1.5

10

* = percentage by weight less than or equal to 0.06 mm grain size

25

26

5.4

Building materials in the pipe zone

5.4.3.2

5.4.1

General

These are:
- Stabilized soils
- Lightweight concrete
- Lean concrete
- Unreinforced concrete
- Reinforced concrete

Building materials in the pipe zone have to provide lasting

stability and sufficient bearing capacity for the installed pipeline.
They must also be compatible with the pipe material. In
addition, they have to meet the planning specifications and
correspond to the definitions in Section 5.4.2 and/or 5.4.3.

Hydraulic building materials

Table 7: Grades of uniform gravel nominal sizes

Building materials for the embedment zone must not have any
constituents larger than:
- 22 mm for DN 400
- 40 mm for DN >400

5.4.2

Native soil

The native soil can be reused, provided that

- it can be compacted, if required
- it is free of material that could damage the pipe
- it corresponds to Section 5.4.3.

5.4.3

Supplied building materials

Screen size
[mm]
Screen set
63
31.5
16.0
8.0
4.0
2.0
1.0
0.50
0.25

Screenings with the following nominal sizes

as quantities by weight in %
[mm]
32
100
85 - 100
0 - 15
0-5
0-3

16
100
85 - 100
0 - 25
0-5
0-3

The building materials listed below can be regarded as suitable.

5.4.3.1 Granular and non-cohesive building materials
These include:
- Uniform gravel
- Material of graded size
- Sand
- Crushed building materials

27

28

100
85 - 100
0 - 25
0-5
0-3

Table 8: Grades of graded gravel

Screen size
[mm]
Screen set
63
31.5
16.0
8.0
4.0
2.0
1.0
0.50
0.25

Table 10: Crushed building materials

Screenings with the following nominal sizes

as quantities by weight in %
[mm]
2/8
100
90 - 100
10 - 65
0 - 15
0-3

8/16
100
90 - 100
0 - 15
0-3

16/32
100
90 - 100
0 - 15
0-3

Table 9: Grades of sand

Screen size

Screenings with the following nominal size

ranges of grain as quantities by weight in %

[mm]

[mm]

0/4
8.0
4.0
2.0
1.0
0.25
0.063

0/2
100
90 - 100
55 - 85
*)
0-5

0/1
100
90 - 100
0 - 25
0-5

*) The manufacturer has to supply information on mean and

range on request

29

for DN

11
20

< 900
1000

5.4.4 Building materials for the backfill

Building materials that are suitable for the pipe zone can also
be used for the backfill.
The maximum grain size may however be limited in specific soil
conditions or due to groundwater etc. Check that the
excavated material is suitable for backfilling, especially if the
pipes are to run under traffic areas.
According to DIN EN 1610, soils can also be used if the stones
they contain are a maximum of 30 cm in grain size or a
maximum of the cover zone thickness or a maximum of half the
compaction layer.

6
100
85 - 100
*)
0-5

Maximum grain
[mm]

Pipe zone

6.1 General
The embedment zone is of decisive importance to the load
bearing capacity of the pipeline. It therefore has to be laid with
due care, taking the following recommendations into
consideration.
Ensure that the pipes are lying uniformly on the bed. If any
corrections have to be made to the level, fill up or remove part
of the pipe bed. Do not attempt to compact the soil locally.

30

6.2 Lower pipe bed

Avoid loosening the soil in the pipe bed area. If the soil has
become loosened, level it out again with suitable material
ensuring that it regains its original stiffness all over.
The minimum thickness for the lower pipe bed is:

Fill the bedding material on both sides of the pipeline up to a

height of 30 cm above the crown in layers of 30 cm maximum
and compact them. Compacting the backfill under the
haunches of the pipe is particularly important. If advisable,
compact the material less above the crown to avoid any
unnecessary pipe deformation. Compaction at the side of the
pipes inside the pipe zone should be at least DPr = 90% or the
figure determined by structural analysis.

Hmin = 100 mm + 1/10 DN

6.5 Embedding pipes in concrete
If the native soil corresponds to Group 3 or 4 (Table 6) and
consists of clay or silt, it may prove necessary to lay a drainage
layer and make the pipe bed thicker.
6.3 Upper pipe bed
Loosely fill material onto the lower pipe bed until the layer is approx. 30 50 mm thick, checking that it is level and not
rounded. To ensure that the pipe barrels lie evenly on the bed,
make bell holes in the area of the couplings (approx. 2-3 times
the coupling width). When making these hollows for the
couplings, there has to be room for joining the pipes, no axial
displacement of adjacent pipes in the area of the joint and no
bearing pressure peaks.

Under certain circumstances it may be necessary to encase the

pipe in concrete. In this case a concrete bed has to be laid on
top of the lower pipe zone. Ensure that the pipe does not lie on
the bed, but 5 10 cm higher (on concrete supports, not
wood). It is advisable to lay pre-stressed steel hoops in the bed
at the same time (e.g. crate straps) which can later be used to
prevent the pipes from floating during concreting. At least three
straps should be used per pipe (see Fig. 10).

6.4 Embedding the pipes

The embedment of the pipes fundamentally determines their
load bearing capacity. Incorrect embedment can lead to
excessive pipe deformation. The pipe bed therefore has to be
compacted using suitable machines (e.g. hand or small
pneumatic tamper). In addition, the trench width and the
thickness of the bed layers in the pipe zone have to be such
that the compaction machine can be operated properly.

31

32

Fig. 11: Installation in steep slopes

Fig. 10: Flotation prevention

In lined trenches, lumber wedged under the pipeline over its

entire length can serve the same purpose. Remove the wood
after the concrete has been placed and vibrated.

8.1 Scope of application

Water reservations

The requirements for sanitary sewers, pipelines and manholes

in water reservations are given in ATV Code A 142 in connection
with DIN 4033.

Laying in slopes
8.2 Design guidelines

Special precautions have to be taken in pipe trenches with

steeper gradients, e.g. on slopes or in the mountains, to
prevent the pipeline from slipping. This is achieved in most
cases with concrete bulkheads, which also prevent the bed
from being eroded and the pipeline from being undermined.

When planning sewers and pipelines in a watershed system,

the water authorities and operators have to be involved and the
licensing requirements under national legislation taken into
consideration.
For proof of stability, a 20% higher safety factor is required than
Class A in ATV Code A 127.

33

34

Piping sewage through Protection Zone I is strictly prohibited.

In Protection Zone II piping sewage is not permissible. If

however sewers and pipelines have to be installed in the
protection zone due to local circumstances, the necessary
precautions have to be taken.

To achieve the necessary degree of compaction, the pipe

trench has to be kept free of water. When compacting the soil,
ensure that the pipeline cannot move to the side or up. Light
pipes (up to around DN 350) should be secured at the required
level during the embedding process.

These requirements can be met with GRP sewage pipes as

follows:
a)

Laying sewers and pipelines in a leaktight protective

pipe (double pipe), or

b)

Laying single wall sewers and pipelines, but taking

additional precautions:
- annual inspection
- leak test every 5 years

Backfilling and compacting

If necessary, backfill and compact both sides at the same time

or weigh the pipeline down with bedding material in sections. In
the area of the embedment layer, compact by hand or use light
vibratory tampers (max. force 0.3 kN) or plates (max. force 1
kN) at a suitable compaction depth.

Laying and operating sewers and pipelines is however

permissible in Protection Zone III.
8.3 Installing sewers and pipelines
Pipes and joints have to meet the requirements of ATV A 142
and proof thereof has to be furnished. The pipes to be selected
and pressure test conditions have to be determined and
monitored by an independent institute (Plastic Pipe Quality
Association).
8.4 Leak testing in operation
If sewers and pipelines are laid in Water Protection Zone II, leak
tests have to be performed on them at certain intervals, but at
least every five years. In Water Protection Zone III leak tests
should be performed as required, as a rule every ten years.

35

36

220
272
324
376
427
530
616
718
820
924
1026
1099
1229
1439
1499
1638
1842
2047

200
250
300
350
400
500
600
700
800
900
1000
1100
1200
1400
1500
1600
1800
2000

37

620
672
724
776
1127
1230
1318
1418
1520
1624
1726
1799
1929
2139
2199
1338
2842
3047

bed width
approx. or to
bg
[mm]

0.359
0.410
0.463
0.518
0.834
0.985
1.118
1.280
1.448
1.626
1.808
1.946
2.188
2.607
2.741
3.032
4.219
4.774

Material
requirement
with bed
[m3/m]

For trench cross section, see Fig. 12

DN

Outside pipe
diameter
da
[mm]

Diameter

Material
requirement
with bed
[m3/m]

0.305
0.356
0.411
0.467
0.701
0.853
0.985
1.153
1.330
1.520
1.716
1.857
2.134
2.607
2.741
3.090
5.721
6.581

Material
displacement
with bed
[m3/m]

0.397
0.468
0.546
0.630
0.977
1.205
1.416
1.685
1.976
2.296
2.634
2.895
3.374
4.233
4.506
5.139
6.883
8.065

Material
requirement
for support
[m3/m]

0.074
0.084
0.094
0.105
0.158
0.185
0.211
0.241
0.273
0.308
0.345
0.378
0.424
0.513
0.550
0.608
0.796
0.914

U 1A cross section1

Table 11: Bedding requirement (gravel 0 32 mm)

0.067
0.079
0.088
0.099
0.151
0.177
0.202
0.231
0.263
0.296
0.332
0.363
0.408
0.494
0.529
0.585
0.770
0.884

Material
requirement
for support
[m3/m]

0.343
0.415
0.493
0.578
0.844
1.073
1.283
1.558
1.789
2.191
2.543
2.806
3.320
4.234
4.506
5.198
8.387
9.871

6
7
8
9
10
12
14
16
18
20
22
24
27
29
30
32
36
40

Material
Average time
displacement per pipe length
with bed
(approx.)
[m3/m]
[min]

V 1A3:1 cross section1

U 1A SECTION
V 1A 3:1 SECTION

Fig. 12: Trench cross section

Apart from under exceptional circumstances, only Group 1 and

2 compactible soils should be used for the embedment.

The required density in the pipe zone determined by structural

analysis has to be achieved by compacting the soil accordingly.
Ensure that the compaction in the embedment layer at least
reaches the value for the pipe cover.

If a lining is planned for the trench, it should be installed in

sections and the bedding material compacted in layers. This
prevents the pipe from being subjected to higher stress or
moving. The type of lining and removal method should meet the
structural specifications.

38

39

kg

Weight

Suitability

light

- 25
25 - 60

light

- 600

- 100
- 100
medium 100 - 300
light

light

medium

o
+
+

+
+

heavy

medium

heavy

medium

+
+
+
o
o

24
2-4
3-4
3-5
3-5
4-6

- 15
20 - 40
20 - 30
- 20
20 - 30
20 - 30

+
+
o
o
+
+

20 - 40
40 - 50
20 - 40
30 - 50
30 - 50
20 - 50

24
2-4
3-4
3-4
3-5
4-6

+
+
+
+
o
+

Suitability

15 - 30
20 - 40
25 - 35
30 - 50
20 - 40
20 - 40

15 - 25

15 - 25
- 15
15 - 25

- 15
15 - 30

Layer
cm

2-4
2-4
3-4
3-4
3-5
5-6

5-6

3-5
4-6
4-6

24
3-4

No. of
passes

Layer
cm

- 10
10 - 30
20 - 30
10 - 30
20 - 30
20 30
30 - 40
-

Suitability

+
+
+
+
+
+
+
-

2-4
2-4
3-5
3-5
-

3-5
-

24
2-4

No. of
passes

Cohesive, fine-grade soils

UL, UM, TL, TM

V3

The above figures are averages only. Under adverse conditions (e.g. relatively high water content, trench lining) the densities may have to be reduced,
while they can be exceeded under especially favorable conditions. Exact figures can only be determined by testing.

+ = recommended o = usually suitable

Vibratory
roller

60 - 200
100 - 500
> 500
300 - 750
600 - 8000

medium 25 - 60

Surface vibrator medium

Frog
rammer

Vibratory
tamper

V2
Soil classes
Cohesive, mixed grade soils
G*, GT*, SU*, ST*

No. of
passes

Layer
cm

2. Medium and heavy duty compaction machines (above the pipe zone)

Vibratory
roller

Surface
vibrator

Frog
rammer

Vibratory
tamper

VI

Non to slightly cohesive,

coarse grade and mixed soils
GW, GI, GE, SW, SI
SE, GU, GT, SU, ST

1. Light compaction machines (primarily for pipe zone)

Type of machine

Compactibility classes

Table 12: Guidelines for compaction options

10 Removing the trench lining

Removing the trench lining from the pipe zone after backfilling
has been completed can have serious consequences for the
load bearing capacity and lead to alterations in the position and
level of the pipeline. The lining should therefore be removed
progressively as the pipe zone is backfilled. If this is not
possible, the following action should be taken:

- Carry out structural analysis

- Leave parts of the lining in the ground

- Backfill any voids that occur

- Compact the side backfill again after removing the lining

- Select the building materials for the pipe zone with care

Note: removal of the trench lining must meet the installation

specifications as per structural analysis.

11 Leak tests

The leak tightness of the sewer or pipeline, including the fittings

and manholes, has to be checked. A preliminary test can also
be performed before backfilling the sides. Carry out acceptance
inspection after backfilling and removing the lining. Air or
hydrostatic tests may be carried out, and combinations or
partial tests are also possible. If changing from air to water, the
hydrostatic test is decisive. In the event of groundwater banking
above the pipe crown, an infiltration test with case-related
specifications can be carried out.

40

11.1

Hydrostatic test

Table 13: Test pressure, duration and pressure loss for air test

Carry out the test with pressure on the pipe crown of between
10 and 50 kPa. The pipeline should be prefilled with water for
1 hour before performing the actual test for 30 min. The pipe
passes the test if the water volume to be added during this time
is no greater than:
- 0.15 l/m2 1) for pipelines and sewers
- 0.20 l/m2 1) for pipelines and sewers with manholes
- 0.40 l/m2 1) for manholes
11.2

Air test

Test
po*)
p
procedure [kPa] [mbar]

DN
100

DN
200

DN
1000

10
(1)

2,5
(0.25)

10

14

19

24

LB

50
(5)

10
(1)

11

15

19

LC

100
(10)

15
(1.5)

11

14

LD

200
(20)

15
1.5

1.5

1.5

2.5

*) Pressure above atmospheric

For initial pressure, pressure drop and test duration, see

Table 13. The figures apply to pipelines without manholes.
When testing manholes, use test times that are half as long as
those for sewers or pipelines of the same inside diameter. After
slowly building up and then maintaining the pressure at around
10% above the test pressure for 5 minutes, set the pressure in
pipes up to DN 1000 to the figures in Table 13.
The test is deemed passed if the maximum permissible
pressure drop Dp in Table 13 is not exceeded within the given
time.
Device error limit for measuring the pressure drop: 10% Dp
Device error limit for measuring the test time:
5s

11.3

Leak test in double pipe systems

For the media pipe test, follow the procedure detailed in

Section 11: 11.1 to 11.2. When testing the annulus between the
media and protective pipes, check for bulges in the media pipe.
Recommendation: test the annulus and media pipe at the
same time with the same pressure.

Square meter here means the wetted inside surface

of the pipe

41

DN
800

LA

In the interests of safety the test with air has to be carried out
with due care, especially in the case of larger pipe diameters.

1)

Test duration [min]

DN
DN
DN
300
400
600

42

12 Connections to structures and masonry

150 1200

Shaft lining with sand

coating, variable wall
thickness

150 2600

Masonry support with

sand coating and
thrust ring, variable
wall thickness

150 2600

Pipe inlet in sandcoated protective pipe

(GRP), with seal,
variable wall thickness

Table 14: Connections to structures and masonry

Type

Diameter
DN

Application

150 2600

Masonry connector
with pipe ferrule and
sand coating, variable
wall thickness

150 2600

150 2600

43

Masonry connector
with pipe ferrule, sand
coating and thrust ring,
with greater resistance
to longitudinal displacement and groundwater
level, variable wall
thickness
Masonry connector
with pipe ferrule, sand
coating and wall collar
with greater resistance
to longitudinal displacement and pressurized
groundwater, variable
wall thickness

13 Retrofitting connections (saddle)

Tabelle 15: Montagehinweise fr Sattelstcke
1. Determine where the
connection is to be fitted,
create space to work, clean any dirt off the outside
surface of the pipe
2. Ensure that the surface
where the adhesive is to
be applied is dry

44

14 Fitting intermediate lengths

3. Select the exact location

for the cutout and adhesive, and mark with a
felt pen

See Section 4.2.3: Making adapters.

15 Repairs
4. Cut the pipe along the
marking with a saw
(carbide or stone disc,
not metal) or bore with a
core drill

5. Roughen and clean the

surfaces for the adhesive

15.1

Assessing damage

Slight scratches or evidence of abrasion on the pipe surface do

not generally affect its service life. If the pipe is subjected to
greater impact, however circular or star-shaped cracks may
occur in the area. Damage of this type to the inside surface of
the pipe has to be repaired.
15.2

single component
or

6. Mix the adhesive following the manufacturers

instructions (in the case of
two-component adhesive)

See Section 4.2.3: Making adapters.

To err on the safe side, ensure that the defective pipe section
plus 300 mm is cut out.

two-component
adhesive

15.3
7. Apply the adhesive evenly
to the appropriate surfaces.
Close the single-component container immediately after use (e.g. with
string) to ensure that it
can be used again.

Replacing a defective pipe section

Adhesive
Saddle

Repair couplings

If the defective section is only very small, a repair coupling can

be mounted. The type of coupling used depends on the actual
damage and the application for the pipeline.

Pipe

Before mounting the repair coupling, clean the defective area.

The coupling can then be opened up, placed round the
defective area and tightened.

8. Mount the saddle and fix

in place until the adhesive
has hardened (e.g. with a
strap)
45

46

15.4

Repair laminate

16 Project questionnaire

Due to the special processes involved, only the pipe

manufacturer should repair pipes with laminate.
15.5

Sender Company
Company
Contact
Contact
Address
Adress

Removing a pipe coupling

Tel.
Tel.

Newly installed pipelines can be dismantled with a mounting

device under normal conditions (see Fig. 13). After removing the
coupling, check that the sealing lips have not been damaged in
any way. Replace, if necessary. When applying force to
dismantle the joint, ensure that it is kept under control to
prevent the pipe material from being subjected to excessive
stress. If a coupling is too tight, it is advisable to cut the
laminate with a saw and replace it with a repair coupling (do not
damage the pipe surface).

Fax

Date
Project
Diameter DN
Cover h=

made of GRP
to

Traffic load No traffic load

Train, single-track

Air traffic

Heavy-goods vehicles

Train, multiple-track

Type of soil To ATV A 127, Table 1

G1 non-cohesive: sand, gravel

Native

Pipe zone

Cover

G2 slightly cohesive: sand, gravel

G3 cohesive mixed soils and silt

G4 clay, loam

Other soils

Building land As native soil

Threaded rod

Other

Very hard or rocky

Non load-bearing

Pipeline foundation on:

Depth of foundation under pipe bed:

Fig. 13: Dismantling tool

Groundwater None
Existent
Height above pipe bed h:

47

48

to

Support on native soil

Removal of In stages during backfilling

Gravel-sand
Custom design
Support angle for

trench lining After backfilling

In stages only in
the pipe zone

With effective re-compaction

60 (special case)

Stress analysis

90

Strain analysis

180

Deflection analysis

180

Conditions for
embedment
and backfill

To be completed by the manufacturer:

Embedment

Backfill

B1

A1

B2

A2

B3

A3

B4

A4

Pipes quoted
Key data Nominal diameter
Inside diameter
Outside diameter
Wall thickness

DN
mm
mm
mm

License no.
Trench shape Backfill or embankment

Single trench

Multiple trench

Stepped trench

Quality mark
Plastic Pipe Quality Association

* Only if trench walls are installed permanently

can a load-reducing effect be achieved:

yes

no

Width of
trench bed bbed = max
Slope angle 45

60

at 90

With the following lining:

Horizontal

Vertical planks

Vertical light sheeting

Vertical wooden boards

Lining boards, devices

Other

49

50

17 Standards and guidelines

DIN 19565-1

DIN 19565-5

Pipes and fittings made of glass fiber reinforced

polyester resin (GRP) for buried sewers and
pipelines; centrifugally cast, filled dimensions,
engineering specifications
Pipes, fittings and manholes made of glass fiber
reinforced polyester resin (GRP) for buried
sewers and pipelines; prefabricated manholes
dimensions, engineering specifications

DIN EN 1610 Installation and testing of sewers and pipelines

DIN 2501-1

Flanges, connection dimensions

DIN 4124

Trenches and pits; slopes, width of space for

working, lining

DIN 18300

Standard building contract terms; Part C;

earthwork

DIN 18303

Standard building contract terms; Part C;

lining work

ATV-A 139

Installation and testing of sewers and pipelines

addenda and notes on DIN EN 1610-1

ATV-A 241

Structures in drainage works

R 7.8.1/8

Centrifugally cast pipes and fittings made of

glass fiber reinforced polyester resin (GRP) for
buried sewers and pipelines with the quality
mark awarded by the Plastic Pipe Quality
Association
.

51

R 7.8.24

Wound pipes and fittings made of glass fiber

reinforced polyester resin (GRP) for buried
sewers and pipelines with the quality mark
awarded by the Plastic Pipe Quality
Association:
.

ZTVA-StB 97 Additional technical terms, conditions and

guidelines for digging trenches in traffic areas
ZTVE-StB 94 Additional technical terms, conditions and
guidelines for earth work in highway
construction
and the relevant safety regulations.

52

Published by:

Kunststoffrohrverband e.V.
Plastic Pipe Industry Association
Dyroffstrasse 2 D-53113 Bonn Tel: +49 228 91477-0
Fax: +49 228 211309 Website: www.krv.de
E-mail: kunststoffrohrverband@krv.de

53

54