AV K

I NT ERN ATION AL

A/S

AV K R e p a i r c l a m p s

Te c h n i c a l b r o c h u r e

Whenever a leakage in a water mains occurs due to a crack, it

is essential that the repair is done quickly and efficiently so that
the consumers and surroundings experience a minimum of
disturbance.
As most cracks occur without any prior notification it is of
greatest importance that the repair products are available
ex-stock either at the waterworks, the contractor or as minimum
at the wholesaler. To make this possible the repair products
must have multi functionality, flexibility and wide tolerances.
Furthermore the key demands when conducting repairs are
easy and fast installation and reliable functionality.
For all these specific purposes and demands AVK offers a
comprehensive range of products specially designed for all
sorts of cracks in the most common pipe materials.

Ty p i c a l p i p e c r ac ks

PVC pipes have for many years been used for potable water

repaired is cut out and replaced by a new piece of pipe, which

pipelines as well as for sewage.

is directly welded into the PE pipe system by using socket

fusion welding.

The material has proved to be very stable because of the low

weight and relatively high pressure class. If a crack appears it

With minor damages repair clamps of stainless steel can be

might be caused by earth settlements or increased traffic load.

used due to the fact that no stress relieve is required for PE

A typical crack will be unstructured and can move in both

pipes.

longitudinal and circumferential direction.

The application of ductile repair clamps is seldom seen but can
The best way to repair a cracked PVC pipe is to cut out and

however be used in line with stainless steel repair clamps.

replace by a new piece connected with couplings. In this way

Cast iron was widely used in water and gas systems in the past

the stress in the pipe will be neutralised and new cracks

and today forms 90 - 95 % of all ferrow pipe failures.

prevented. If for some reason there is no possibility to use

couplings, the AVK stainless steel repair clamps can be used.

The most common leakage is circumferential cracking

caused by:

Ductile iron has been in use for 30 - 35 years. It is more

resistant to impact and settlement forces.

A. Differing soil types causing earth settlement.

B. Increased road traffic resulting in settlements and cracking

The most common failure mode is longitudinal cracking caused

by cathodic attack i.e. a puncture in the pipe coating which will

Cast Iron pipes can be repared with ductile repair couplings

create a location for an electric cell from stray currents picked

since stress relief is essential.

up from overhead power cables, adjacent railways or from

alcaline soil.

Asbestos Cement is used mainly in water systems. Failure

mode is similar to cast iron pipes, a circumferential crack

The longitudinal cracking can be quite dramatic - the pipe can

caused by earth settlements or increased road traffic.

virtually unzip. Common corrective action is to drill a small hole

at both ends of the crack to prevent it from travelling further,

Pipe dimensions are only reliable at the pipe ends. It is therefore

and then mount a repair clamp on the pipe.

essential to use e.g. a sliding caliper to determine the suitability

of repair fitting as to tolerances. Also here AVK ductile repair

In the northern part of Europe PE is one of the most used

clamps are to be preferable.

materials for water networks. Normally there are very few leak
problems and very often the leaks are due to external damages
such as digging. When repairing PE pipe systems the part to be

Typical longitudinal crack in a pipe typicaly caused by earth settlement or

increased traffic load.

Easy and fast neutralization of the crack is essential in order to minimize

disturbance for consumer. Here AVK universal supacollar repair fitting is
mounted.

Ty p i c a l p i p e c r ac ks

XXDefective

AC

(asbestos

cement) coupling
Cast iron pipes:
1. Cracks typically appear circumferentially on the pipe
2. The cracks are most often caused by stress in the pipe

XXCracks in AC, steel, cast

3. The pipe should be stress relieved before repair

4. With minor earth settlements part of the pipe is cut out and
replaced by a new piece of pipe and couplings

iron or PVC

XXPipe ends angled

Ductile iron pipes:

1. Direct pipe cracks, where the pipe cracks in two, appear very
seldom

XXHoles in AC, steel or cast

2. Most often leaks appear in connection with wrong pipe fitting,

resulting in galvanic corrosion
3. Longitudinal cracks are stopped by drilling the pipe at both
ends of the crack

iron

XXDamage caused by service

crane or breaking-off of
branching section

PVC-pipes:
1. The pipe is typically deteriorated because of ozone and
UV-radiation

XXSeal of AC coupling is
damaged

2. Crack zone longitudinal and circumferential of the pipe

3. The pipe should be releived from stress before repair

XXBreaks in AC and cast iron

pipes

Asbestos cement pipes:

1. Pipe cracks typically appear circumferentially because of
stress in the pipe
2. Often the crack zone is in the middle of the pipe, where the
external diameter fluctuates the most

XXCorrosion leaks

3. The tolerance area of the repair clamp is important

4. Stress relief is required

XXPipes

do

not

join

up

Pipe ends do not lie in the

same plane

PE-pipes:
1. Cracks most often appear because of mechanical impact on
the pipe
2. Repair of big PE cracks is done by cutting out the damaged
piece and inserting a new piece by means of socket fusion
welding

S t a i n l e s s S t e e l Re p a i r C l a m p s
- S e r i e s 72 9 S/ D

The AVK Rewag series 729 is a widely used clamp when dealing
with leaky pipes or complete ruptures in the pipe system. The
clamp construction ensures a cost effective and reliable
solution for quick repairs of pipes in any pipe material. The
clamps can be used for permanent repair of punctures,
longitudinal and circumferential cracks.
The functional principle of the repair clamp rests on a stainless
steel, pre-rolled plate, which is clamped round the pipe and
fastened with lugs and nuts. The clamp has a rubber lining. The
tensile force applied by the clamp fastening is converted to a
radial pressure on the rubber lining.
AVK offers stainless steel clamps in following variants:
Single band, standard or with threaded outlet. To be used
exclusively as repair clamp and/or as tapping saddle due to
the outlet. This type is recommended for cost effective repair
on primarily pipes where small tolerances are required.
Diameter range from 48 mm to 360 mm.

Main areas of use are for water, gas and sewage covering a
temperature range from -30 C to +110 C.

Double band, standard or with threaded or flanged outlet. To

be used exclusively as repair clamp and/or tapping saddle.

The single and double band repair clamps can be supplied in

This type is recommended for cost effective repairs on pipes

lengths from 100-600 mm with an interval of 100 mm.

where bigger tolerances are required. Diameter range from 88

mm to 650 mm. An advantage of the double band repair

The repair clamp is made of stainless steel AISI 304 with teflon

clamp is a high degree of a tight equally distributed sealing

coated stainless steel A2 bolts, bolts and washers. Gasket is

pressure due to the double band.

made of NBR rubber as standard. Optional gaskets can be

supplied in EPDM or SBR rubber.

Making the repair

Mounting instructions for AVK repair clamps
1. Excavate pipe allowing sufficient clearance to fit The Repair Clamp.
2. Clean area of pipe where the fitting is to be installed.
3. Measure and check diameter of pipe against tolerance of fitting.

4. Ensure that proper tools are used, i.e. spanner.

5. Open the clamp and place it on the pipe next to the leak.
6. Hook the clamp together and slide it over the leak.
7. Tighten the bolts/nuts in a cross diagonal sequence.

L a r g e i n t e r n a l a n d ex t e r n a l r e p a i r c l a m p s
- S e r i e s 72 9

AVK external repair clamp

Repair of large pipes is costly in terms of excavation and traffic
diversion. Companies focus on minimizing repair time and
resources when repairs are needed. It is therefore essential to
have a product on the market that is easy to install and is
expected to last for many years.
We consider the AVK Series 729 the optimal solution for this
task.
The AVK Rewag external repair clamp series 729 primary area
of use is for repair of cracks, holes and open joints in large
dimension pipelines. The clamp is made of two shells that are
fastened with lugs and nuts. The sealing pressure is equally
distributed when tightening the lugs.
Covering angular deflection up to maximum 4 degrees the
clamp is a versatile and user friendly product that is made of
high quality materials to ensure long lifetime.
Major advantages of the AVK Rewag repair clamp series lie in
the fact that all possible parts are made of stainless steel.
Furthermore it is to be mentioned that all welds are chemically
passivated that ensures optimal resistance to corrosion.

Allround Repair

Installation of large pipes is costly

in terms of transportation,
excavation and installation.

The external repair clamp is easily

mounted by one or two workers in
spite of the large dimension
pipes.

Repairs can be done quickly. No

problem with non-round pipes.
The clamp absorbs the form of
the pipe.

AVK internal repair clamp

The internal repair clamp is made of several segments
(depending on size). Using a key spanner the couplings are able
to expand. The special rubber profile is placed at the edge of
the clamp and it seals off the leakage of the pipe when
expanding the clamp.
The advantages of using the internal clamp is primarily based
on the fact that no excavations or traffic diversion are needed
before installing the clamp. This is time and money saving and
furthermore the installation can be done by using a key spanner
only.
The AVK Rewag Internal Repair Clamp technical features are
identical with the external edition of the clamp.
The internal/external clamps are made of stainless steel AISI316
with teflon coated stainless steel A2 bolts, nuts and washers.
The clamps are also available in AISI314. A4 bolts are
recommended in especially aggressive soil. Gasket is made of
NBR rubber or EPDM rubber approved for drinking water.
The standard sealing range of the repair clamps is 400 mm to
3000 mm. Lengths can be supplied in 200 mm and 400 mm. On
request any diameter and length can be supplied.
The clamps are suitable for water, gas and sewage covering a
temperature range of -30 C to +110 C.
Allround Repair

Due to the large dimension of the

pipes a person can move around
inside the pipe without difficulty.
The clamp weight has been kept
very low for easy handling.

The internal repair clamp is

mounted using only a spanner.

The special rubber sealing

ensures that the repair clamp
shuts off the leakage permanently.
Time from detecting the leakage
to fulfilled installation is minimal
and with no external
disturbances.

AV K S u p a c o u p l i n g
- s e r i e s 6 01, 6 0 2 a n d 6 0 3

The AVK Universal couplings are used for mechanical assembly of pipes. Quick and easy assembly
of different pipe materials and different outside diameters is possible using only one coupling
suitable for all types of piping materials including cast iron, ductile iron, PVC and asbestos cement.
The system includes adaptors that can be connected to any flanged object, valves or pipes.
In renovation or repair situations the flexibility of the Supa Coupling System facilitates a fast
assembly of the needed AVK product and the operation can be commenced with short notice.
The system includes:
Series 601 universal Supa coupling DN 40-400 PN 16 and series 602 universal stepped Supa
coupling: accepts angular deflection of 8 degrees in total
Series 603 universal Supa adaptor: accepts angular deflection of 4 degrees in total
The unique gasket design of EPDM (DVGW/KTW approved) for water with moulded ribs ensures
that any minor imperfection in the pipe is absorbed by the gasket thus securing a safe mounting
on all pipe materials regardless of size and condition of the pipeline.
The coupling features a maximum tolerance of up to 26 mm on the pipe diameter. Sleeve and
brackets are in ductile iron GGG-40 with epoxy coating to DIN 30677. Bolts/nuts are of mild steel
with rilsan coating, alternatively stainless steel. The use of high quality materials ensures long life
time of the coupling.

Mounting instructions
1. Excavate pipe allowing
sufficient clearance to fit the
supa coupling

3. Measure and check diameter

of pipe against tolerance of
fitting

2. Clean area of pipe where the

fitting is to be installed

4. Lubricate area of pipe where

fitting is to be installed. Use
soap based lubricant or similar.

5. All couplings and adaptors are

pre-assembled to allow a quick
and efficient installation. Within
few minutes mounting is
completed by the use of a
torque wrench.

6. Tigthen bolts in a cross

diagonal way according to the
label on the product.
7. The coupling in place.Two
different types of pipes have
been bridged and are now
ready for use.

AV K U n i ve r s a l s u p ac o l l a r r e p a i r f i t t i n g s
-s e r i e s 5 2

The AVK universal supacollar repair Fitting series 52 consists of two identical halves fitted with
rubber seals. Only four bolts are used on all sizes to seal and tighten the fitting. This ensures an
easy and very convenient installation process.
The universal tapping tee/universal collar has a unique sealing system consisting of:
rubber coated triangular bars sealing along the pipe.
a rubber gasket encircling the pipe effectively.
The tapping tees are available with branch outlets from 80 mm and up to the
diameter of the main pipe itself max. 300 mm. On the tapping flange a shut-off valve can be
mounted directly in order to drill under pressure.
The universal collars with 1/2" - 2" threaded holes are suitable for use as tapping saddles. The
universal supacollar repair system is suitable for repairing all types of leaks under pressure. If the
pipe is completely broken, a maximum 4 angular deviation of the pipe ends can be covered. The
coupling is designed to meet the requirements of British Gas BG/PS 8, part 4.

Mounting instructions
1. E xcavate pipe allowing sufficient clearance
to fit the repair clamp.
2. Clean area of pipe where the fitting is to be
installed.
3. Measure and check diameter of pipe against
toleance of fitting.
4. Lubricate area of pipe where fitting is to be
installed. Use soap based lubricant or
similar.

5. All bolts are fitted with O-rings to prevent

the bolts dropping in the trench.
Furthermore the domed head square neck
bolts automatically stay in position during
installation/tightening.

6. Split fitting into two halves by removing

nuts.
DO NOT remove bolts
DO NOT remove seals
DO NOT remove seal assembly or flexibility
ties

7. Mount the fitting half complete with bolts on

downside of pipe and support manually.
Locate other half of the fitting over bolts.
Loosely tighten nuts and bolts.
If necessary, rotate fitting carefully on pipe
to required position.

8. Cross tighten to the recommended torque

indicated on the fitting.
Use torque wrench.
Ensure fitting is level along axis of pipe
during installation.

9. Pressure test fitting.

10

Us e r g u i d e fo r
AV K r e p a i r e q u i p m e n t

Recommended field of application

Each product group has its own colour indicating field of application. The statement
of dimensions is a guideline based on our experience and refers to the external pipe
diameter. The application table below is a recommendation but in reality all AVK
repair products can be used regardless of their ability to accept angular deflection.

AVK universal suparcollar repair fittings

- series 52
The AVK universal supacollar repair fitting is
available in a 1/2" to 2" BSP drilled and
tapped version or as a flanged branch
connection from DN 80 to DN 300.

DN

PVC

Steel

40

50

48,3

50

63

60,3

60

75

76,1

65

75

76,1

80

90

88,9

100

110

114,3

125

125

139,7

150

160

168,3

175

200

193,7

200

225

219,1

225

250

244,5

250

280

273,0

300

315

323,9

350

355

355,6

375

N/A

N/A

400

400

406,4

450

N/A

N/A

500

560

508

600

630

610

11

AVK Rewag large diameter repair

AVK Rewag repair fitting series 729 S/D

AVK Supa coupling series 601, 602 & 603

The series 729 internal/external repair clamp

program is available in standard sealing
range of 400 mm to 3000 mm. Lengths can
be supplied in 200 and 400 mm. On request
any diameter and lengths can be supplied.

The series 729 is available in diameter range

from 48 mm to 360 mm in the single band
version and diameter range from 88 mm to
650 mm in the double band verison. Both
version are available with female/male
threaded outlet from 1/2" to 4" BSP.

The Supa universal coupling series 601

covering total angular deflection of max. 8.
Diameter range from DN 40 - 400
The Supa step coupling series 602 covering
total angular deflection of max. 8. Diameter
range from DN 40 - 400
The Supa adaptor series 603 covering total
angular deflection of max. 4. Diameter
range from DN 40 - 400

Ductile

Cast Iron

56

55,9

66

69,1

86

77

77

86

82

82,3

106

98

95,5

126

118

121,9

153

144

149,9

178

170

177,3

A/C

204,7
234

222

259

332,2
259,1

288

274

286,0

344

326

333,8 / 345,4

404

378

386,6 / 399,3

N/A

N/A

413 / 426,2

456

429

439,4 / 453,1

510

480

480

564

532

532

678

635

635

T h e AV K R a n g e s of Re p a i r C l a m p s

The philosophy behind the existing product programme is

to cover the need of our customers in the most efficient
and comprehensive way without compromising quality and
price.
We steadily improve and develop our product programme in
order to offer state-of-the-art products and services. The AVK
repair programme for every possible repair and renovating
situation that demands for prompt and effective handling.

AVK Supa coupling series 601,

602 and 603
Use for quick assembly purposes
of pipes. Able to join different
piping materials in different sizes.
Absorbs a high degree of angular
deflection due to unique gasket
design.

AVK universal supacollar repair

fitting series 52

AVK Rewag internal/external

repair clamps series 729

Can be used as tapping saddle or

repair fitting. The patented rubber
seal function with ductile iron inserts allow up to 30mm tolerance
on the pipe diameter. Suitable for
A/C, cast iron, ductile iron and
steel pipes.

Easy to mount repair clamp for

large pipe systems. Made of high
quality materials and ensures
optimal corrosion resistance due
to passivated stainless steel.

AVK Rewag repair fittings

series 729 S/D
Single or double band repair fitting with or without flange. Light
weight and cost effective solution
for long lasting repair of pipe
systems.

AVK INTERNATIONAL A/S

Bizonvej 1, Skovby
DK-8464 Galten, Denmark
Tel.: +45 87 54 21 00
Fax: +45 87 54 21 20
E-mail: sales@avk.dk
www.avkvalves.com
41729XEB/2011-10-07
CopyrightAVK Group A/S 2011