WATER PRESSURE SYSTEMS

TECHNICAL HANDBOOK

PRESSURE SYSTEMS
WATER PRESSURE SYSTEMS
CONTENTS
Page
Product Data 2 Introduction 3

Range 7 Range 8

Design 13 Hydraulic Design 14

Thrust Restraint 18
Surge and Fatigue 20
External Compressive Loads/
Temperature De-rating 21
Chemical Resistance 22

Sitework Instructions 26 Handling and Storage 27

Jointing 28
End Load Joint Installation 30
Deflection and Curvature 31
Water Services Connections 32
Flange Jointing 33
Inspection and Testing/
Installation Above Ground 34
Bedding Requirements 35
Compaction Fraction Testing 36

Jacking Pipe 37 Jacking Range 38

General Information 39 Conversion Chart 40

PRESSURE SYSTEMS
1
PRODUCT DATA

PRESSURE SYSTEMS
 Introduction
The Water Pressure System offers
a range of PVC-A (PVC Alloy) pressure
pipes and fittings purpose-designed to meet
the specific requirements of the distribution
and trunk Sectors of the water industry.
The * Water Pressure System
comprises pipe and fittings in the diameters
90mm to 710mm and includes the
End Load Joint.The system is
available in blue and black for potable water
and sewerage applications respectively.
The system offers Engineers, Contractors
and Water Companies a new level of
performance and confidence, combining the
benefits of traditional materials with the
latest understanding in plastics technology.
The development of this plastics alloy
combined with the fittings range has given
specifiers a new option in the design of
pipelines carrying potable water and
sewage.
From the initial success of the launch of
pipe Hepworth have concentrated
further developments in the sewage sector
to optimise the benefits of the
system for the end user. The addition of
black pipe to the range enables water
companies to specify for both
clean and dirty water thereby optimising
new pipelines for all mains applications.
Development
The development of pressure pipe systems
has been rapidly progressing in recent
times. Every new development in the
materials or jointing designs of these
systems has claimed to eliminate or
minimise at least one of the drawbacks
of previous products and offer further
benefits to the end users.This ongoing
search for the perfect pipeline has now
exhausted most of the commercially
available materials and technologies.
Hepworth undertook a five year research
and development programme to identify
a new pipe material and enhanced jointing
technology that would meet the
requirements of Water Companies and
Engineers.
The result was , a unique blend
of materials forming a plastics alloy to give
significant improvements over traditional
materials.
Description
The Water Pressure System has
been specifically designed for the transport
of potable water and sewage.The system
comprises pipe and fittings in diameters
from 90mm to 710mm and is available in 8,
10, 12.5 and 16 bar pressure ratings, in blue
for potable water and black for sewage
ensuring its suitability all applications from
distribution to main trunk lines.
The system significantly improves
performance in three key areas:
1) Water Leakage
Minimising the long term risk of water
leakage either by long term pipe failure,
corrosion or joint failure.
2) Water Quality
Maintaining water quality by control of
contamination and pH values, and the
avoidance of cement linings combined
with a smooth bore to reduce the risk
of tuberculation and encrustation.
3) Whole Life Cost
Extended design life coupled with
optimum installation costs and low
maintenance costs give the system the
lowest overall life cycle cost of any
water pressure system.
The system has been designed for
use in new lay open cut situations and is
compatible with all modern methods of
laying including ‘Narrow Trenching
Techniques’.The range offers
simple, quick and correct installation which
is of paramount importance in the pursuit
of efficient utilisation of resources.
Specification
The Water Pressure System meets
the requirements of BS PAS 27,
‘Unplasticized poly(vinyl chloride) alloy
(PVC-A) pipes and bends for water under
pressure.’
This specification gives the requirements
for a new generation of unplasticized
poly(vinyl chloride) based plastics alloy
PVC-A pipes exhibiting a combination of
high strength and ductility. Pipes
conforming to this specification will provide
systems with a high level of integrity and
predictable performance.
The specification details the properties
required of pipes, integral joints
incorporating elastomeric sealing rings and
bends formed from pipes made from
for use for the conveyance of cold
drinking water and other fluids for below
and above ground use.The requirements
include material properties, dimensions,
quality control and type tests, effects on
water quality, and marking.
Elastomeric sealing rings are manufactured
from EPDM and conform to Type WA of
BS EN 681-1 1996.
Quality Assurance
Hepworth have an unparalleled
commitment to quality through the
innovation of new products.
The range is certified to
BSI PAS 27 under the Kitemark Licence
Certificate KM 45187.
The system is manufactured at our
Padiham site in Lancashire which is listed in
the BSI Register of Firms of Assessed
Capability certificate of registration
FM 01415 to ISO 9002.
BSI PAS 27
KM 45187
Water Quality
pipes have been tested in
accordance with the DWI requirements
of Regulation 25, contained in the
document ‘Guidance notes on the approval
of substances and products used in the
provision of public water supplies
December 1993 revision’. A copy of the
DWI certificate is available upon request.
This also includes the requirements laid
down in BS 6920.
Resistance to Biological
Attack/Growth
water pressure systems will not
deteriorate under attack from bacteria or
other micro-organisms and will not provide
a food source to micro-organisms, macro-
organisms or fungi.
Recent research has shown that certain
elastomeric sealing rubbers can be
susceptible to the support of
microbiological growth.The water industry
has specified that elastomers for use as
sealing rings in potable water pipes should
not be capable of supporting
microbiological growth
The Seal is manufactured from
EPDM (Ethylene Propylene Diene
Monomer) which has been listed by the
United Kingdom Water Fittings Bylaws
Scheme for use with potable water.
Hepworth jointing lubricant has been
similarly tested and approved for use with
potable water.
* Note references in this hanbook for
refer to pipe extrusions.
3

Material Description
pipes are manufactured from a
unique plastics alloy of three principal
materials:
● Chlorinated Polyethylene (CPE)
● Polyvinyl Chloride (PVC-U)
● Specially selected Acrylic Derivatives
Each material has been carefully selected
and blended together to give an alloy of
exceptional toughness and durability.
The alloying of these materials has
produced an ‘engineering plastic’ uniquely
designed to meet the exacting demands
of the water industry.
By combining the tough ductile
characteristics of PE with the high strength
characteristics of PVC-U, a new level of
material performance has been achieved.
The material properties are such that high
levels of fracture toughness are combined
with a high yield stress (ductility) thus
giving certain material performances in
excess of the traditional plastics materials
such as MDPE, HPPE and PVC-U, as shown
on the following pages.
Some of the fittings used in the
range may be manufactured from other
materials, such as PVC-U and aluminium.
Material Testing
An extensive testing programme has been
undertaken to prove the performance
characteristics of . loading tests where loads have been
These tests were conducted in the
laboratories of Pipeline Developments Ltd,
material consultants to North West
Water plc.
● Tensometer Test:
Samples of material with a dead sharp
notch are loaded until the sample
breaks. A large white plastic zone is
generated and causes the initial crack
to become blunt which prevents
embrittlement. only fails in a
tough ductile manner.
4
● C-Ring Test:
To evaluate performance under long
term loading, rings are cut from
pipe and notches are machined on to
the surface.These rings are then loaded
for many hours in bending. has
never failed in a brittle manner.
● Impact Test:
Impact damage is a common problem
during pipe installation.Testing was
carried out by dropping 25kg weights
with a 2cm striker onto pipe sections.
The striker always bounced off leaving
only minor indents.
● Fatigue Test:
Because pumps and valves
open/close/start/stop intermittently
surges can occur on a regular basis
creating a fatigue condition. Cyclic
applied to notched samples in a diurnal
cycle show that there is no reduction
in performance and the material
remains ductile.
● Point Load Test:
Although granular bedding is always
specified, pipes can often be laid on top
of boulders, bricks or rocks.This causes
point loading and is responsible for
many failures in pipelines.
yields and deforms, greatly reducing the
risk of failure.
● Pressure Test:
is designed with a factor of
safety of 1.4. Pressure testing both in
the laboratory and in field conditions
has been carried out to validate the
design theory and to confirm the factor
of safety used.
● Joint Test:
Extensive tests in the labs and over
thirty years experience in the field have
shown this simple push-fit joint to be
highly successful. Experience has shown
that push-fit joints are easy to assemble
and perform satisfactorily provided
that:
i Full lubrication of the spigot. Bedding
material and contamination of the
sealing area are prevented from fouling
the joint.
ii Joints are not deflected to a point
which can deform the sealing surfaces.
All tests were successful in proving the
material performance for the transport
of liquids under pressure.The
material has the most predictable long
term performance characteristics of any
polymer tested to date.
Testing has also been carried out on a
variety of field sites since 1990.
Water Pressure Systems have been
successful and are now used by Water
Utilities throughout the UK and overseas.
Case studies detailing sites are
available from the Hepworth literature
service on request.
 Figure 1 Fracture Toughness Data for Various Polymers
Material Performance
Kic (MN/m3/2)
The system utilises the concept of 10.0
purpose-designed materials aimed at
producing the optimum performance
characteristics for the specific application Hep O
of transporting potable water and other
liquids under pressure.The result of this
approach is a cost effective solution giving Tough HPPE
confidence to the designer and installer
through: 1.0

● High Toughness PVC-U

● Predictable Regression Characteristics

Poor HPPE
● Ductile Behaviour Under Load
The toughness of the material is
clearly demonstrated by the results shown
in Figure 1. Not only are the initial values 0.1
0 0 0 1 10 100 1000 10000 100000
high, but regression through time is far less
Failure Time (h)
pronounced than for other materials.
Throughout the test programme the
material has been characterised by Figure 2 Effect of Point Loading on Notched Pipes
predictable behaviour patterns resulting in Stress (MPa)
very close correlation with mathematical 100
projections of performance. Figure 2 shows
a comparison of the effect of point loads, Hep O + Notches : Pressure Resistance Unaffected
and clearly demonstrates the predictable
behaviour of the material. Standard Pipe

In all of the tests currently used to evaluate Notched Pipe + Point Load
both toughness and crack resistance, the
behaviour of the material has
PVC-U
always been ductile, with failure only
through ductile tearing.
Point Loading
Regression data for material 1.0
containing 25% deep notches is consistent
Defect in
with results from unnotched samples as wall
3 kN Point Load Applied Above Notch in Bore
shown in Figure 3. Notching the pipe does
therefore not effect the material 0 1 10 100 1000 10000 100000 1000000
properties. In practical terms this is
Failure Time (h)
important in terms of site abuse/poor
installation and subsequent long term
performance.
Figure 3 Effect of Notches on Pressure Regression
It is also an important characteristic in
Hoop Stress (MPa)
determining the design of the End Load
100
Joint.This style of joint, utilising the grab Unnotched Hep O
Crack Size : a=2.5 mm
ring technology, is only possible with a Notched Hep O
material that is not susceptible to notching Notched PVC-U
50 Years
and brittle failure. is therefore
ideally suited to this system.
The slow crack growth resistance indicated Hep O
in Figure 4 is exceptionally good.The
material is as resistant to cracking as HPPE
and considerably better than ABS.This 28 MPa
ensures that small discontinuities or stress PVC-U
concentrations, such as sharp objects in the
pipe bedding do not slowly develop into
cracks over long periods of time. NWW 17.5 MPa Design Stress

WIS 4.31.06 Design Stress for PVC-U

10
10-1 100 101 102 103 104 105 106

Failure Time (h)

5
The data established through extensive Figure 4 Resistance to Slow Crack Growth
laboratory and site trial work has developed
Crack Resistance (kJ/m2)
a confidence in the design of
60
material.This has been reflected in a factor
of safety of 1.4. Hep O & HPPE have same crack growth resistance
50
exhibits very predictable long-term
performance characteristics which allow a R
relatively high design stress of 17.5 MPa to 40
be adopted.The pipes have a combination of Hep O
high strength and high ductility.
30

Chemical Resistance
HPPE
pipe and fittings give excellent 20

resistance to aggressive environments

ABS
whether naturally occurring or as a result of
10
industrial activity.
Further details on the chemical agents likely
0
to be encountered either from ground 0.0 0.2 0.4 0.6 0.8 1.0 1.2 1.4 1.6
contaminants or within the water being Crack Growth (mm)
transported and the resistance of
can be found in the Design Section of this successful life history.The simple push-fit The design utilises enhanced ‘grab ring’
guide. system is easy to use on site in all technology locking the pipe into place by
conditions for all sizes of pipe.There are no simply tightening the three restraining bolts
Material Properties requirements for complicated welding (see installation details in Sitework Section).
has the following properties: equipment or lengthy preparation work to The use of grab rings is made possible due
slow down installation. to the notch resistance capability and
Specific Gravity 1390 kg/m3 inherent stiffness (avoidance of creep) of the
Young’s Modulus 2500 MPa The joint incorporates a triple compression
material, currently not available
seal, manufactured from EPDM rubber,
Coefficient of Thermal 7 x 10-5/K with traditional plastics materials.
which is resistant to both positive and
Expansion
negative pressure.As a safeguard against
Poisson’s Ratio 0.38 misuse the rubber sealing ring is locked into
Colebrook-White Surface 0.003 mm position during manufacture.The long seal
Roughness depth ensures that the pipe will not ‘flip’ out
Hazen-Williams C-Factor 150 during installation whilst allowing a degree
of flexibility within the system.
Jointing Technology
Introduction
Recognising the need for fast and efficient
installation, Hepworth have developed the
End Load Joint that can be used in
conjunction with the standard Loc-Ring
sealing joint when thrust restraint is
required.The overall aim is to produce a
pressure system that can be installed
correctly in all conditions without the need
for complicated welding systems or for
laying concrete to produce thrust blocks.
The reduction in installation time required
and its simplicity are key to the optimisation
of installed cost.
Loc-Ring Joint
currently utilises two types of joint End Load Joint
in the system.The Loc-Ring joint which has A pipeline operating under internal
been used in Hepworth Push-Fit pressure pressure will generate thrust forces at any
systems for some years.We are also change of direction, reduction in diameter,
introducing the Forsheda Power-lock system blank end or closed valve.This could
in certain sizes which simplifies potentially cause the joint to separate thus
manufacturing. Its performance is equal or causing serious operating problems.
better than the Loc-Ring system.
The End Load Joint is the solution to thrust
The Hepworth Loc-Ring Integral Joint has restraint, combining easy installation with a
achieved world-wide recognition because of new high technology design.
its innovative design and extremely

6
RANGE

PRESSURE SYSTEMS
 Range
Pressure Pipes - Single Socket

A
T
Pipe - 6m Effective Length
NOMINAL DIAMETER 90 110 160 200 250 315 400 450 500 630 710

A Outside Min 90.0 110.0 160.0 200.0 250.0 315.0 400.0 450.0 500.0 630.0 710.0
Diameter Max 90.3 110.4 160.5 200.6 250.8 316.0 401.0 451.0 501.0 631.0 711.0
T Wall 8 Bar Min – – 3.7 4.6 5.7 7.2 9.1 10.2 11.4 14.3 15.9
Thickness Max – – 4.2 5.3 6.6 8.1 10.2 11.4 12.8 15.7 18.0
10 Bar Min – 3.1 4.4 5.6 6.9 8.8 11.1 12.5 13.9 17.5 19.8
Max – 3.6 5.1 6.5 7.9 9.9 12.4 14.0 15.5 19.5 22.1
12.5 Bar Min 3.1 3.9 5.7 7.0 8.8 11.0 13.9 15.7 17.5 22.0 24.5
Max 3.6 4.4 6.6 7.9 9.8 12.3 15.5 17.3 19.5 24.4 27.2
16 Bar Min 4.0 4.8 7.0 8.7 10.9 14.0 17.5 19.7 21.9 27.5 30.1
Max 4.6 5.6 8.0 9.8 12.2 15.4 19.5 21.9 24.3 30.4 33.5
Weight (kg/m) 8 Bar – – 2.9 4.8 7.4 11.6 19.1 24.3 30.1 48.0 57.3
10 Bar – 1.7 3.6 5.7 8.8 14.0 22.8 29.2 35.9 58.0 70.8
12.5 Bar 1.4 2.1 4.5 7.0 10.8 17.1 28.0 35.7 44.3 71.3 86.9
16 Bar 1.7 2.6 5.4 8.5 13.2 21.2 34.5 44.1 54.3 87.2 105.9
Colour Blue ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Black ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓

Loc-Ring Joint Detail

D

S
A

NOMINAL DIAMETER 90 110 160 200 250 315 400 450 500 630 710

D Insertion Depth Min 140 160 190 210 235 265 290 300 315 360 420
S Seal Depth Min 60 75 86 100 115 125 138 150 170 189 200
A Outside Diameter Max 135 150 215 260 315 395 500 560 610 770 830

Note: All dimensions are in mm unless otherwise stated.

8
 End Load Joint
Note: This fitting should only be used on
pipe and fittings.

NOMINAL DIAMETER 90 110 160

Max Test Pressure (bar) 30 30 30

Long Radius Bend 90° - Single Socket

Note: Long Radius Bends are available in L1
both blue and black.
Double Socket Bends are also available
L2

NOMINAL DIAMETER 90 110 160 200 250 315 400 450 500 630

R Radius 300 350 665 1005 1110 1410 1795 1820 2325 –
L1 Length 600 675 970 1310 1520 1840 2230 2225 2830 –
L2 Effective Length 747 839 1164 1522 1759 2100 2525 2563 3152 –
Weight (kg/m) 10 Bar 2.1 2.9 7.8 15.9 27.8 51.4 98.8 127.7 189.5 –
16 Bar 2.5 4.2 11.5 23.0 41.2 77.2 148.4 191.0 285.8 –

Long Radius Bend 45° - Single Socket

Note: Long Radius Bends are available in
both blue and black.
Double Socket Bends are also available
L1
L2

NOMINAL DIAMETER 90 110 160 200 250 315 400 450 500 630

R Radius 300 350 665 1005 1110 1410 1795 1820 2325 2390
L1 Length 417 460 566 700 845 983 1140 1160 1418 1450
L2 Effective Length 564 624 760 912 1084 1243 1435 1458 1740 1818
Weight (kg/m) 10 Bar 1.8 2.4 5.9 11.4 20.2 36.1 67.8 87.8 126.6 207.6
16 Bar 2.1 3.4 8.6 16.3 29.6 53.6 100.4 129.3 188.7 306.9

Note: All dimensions are in mm unless otherwise stated.

9
 Long Radius Bend 22.5° - Single Socket
Note: Long Radius Bends are available in
both blue and black.
Double Socket Bends are also available

1
L
L2
NOMINAL DIAMETER 90 110 160 200 250 315 400 450 500 630

R Radius 300 350 665 1005 1110 1410 1795 1820 2325 2390
L1 Length 360 393 432 502 627 706 788 792 961 980
L2 Effective Length 507 557 626 714 866 966 1083 1100 1283 1348
Weight (kg/m) 10 Bar 1.6 2.2 5.0 9.2 17.3 28.5 52.2 67.9 95.2 156.3
16 Bar 1.9 3.1 7.2 12.9 25.2 41.8 76.3 98.7 140.1 228.1

Long Radius Bend 11.25° - Single Socket

Note: Long Radius Bends are available in
both blue and black.
Double Socket Bends are also available
L1
L2

NOMINAL DIAMETER 90 110 160 200 250 315 400 450 500 630

R Radius 300 350 665 1005 1110 1410 1795 1820 2325 2390
L1 Length 360 360 370 404 520 568 610 612 734 745
L2 Effective Length 476 524 564 616 759 828 905 920 1056 1113
Weight (kg/m) 10 Bar 1.6 2.1 4.5 8.1 15.0 24.6 44.5 58.1 79.4 130.7
16 Bar 1.8 2.9 6.5 11.2 21.6 35.9 64.3 83.6 115.8 188.7

Short Radius Bend 90° - Single Socket

Note: Double Socketed and Flanged Bends
L1
are also available
L2

NOMINAL DIAMETER 90 110 160 200

L1 Length 333 373 468 554

L2 Spigot Length 207 224 254 292

Note: All dimensions are in mm unless otherwise stated.

10
 Short Radius Bend 45° - Single Socket
Note: Double Socketed and Flanged Bends
are also available

L
1
L2
NOMINAL DIAMETER 90 110 160

L1 Length 306 340 421

L2 Spigot Length 207 224 254

Equal Tees
Note: Tees with any Spigot, Socket or Flanged
combinations are available
L2

L1

NOMINAL DIAMETER 90 110 160 200

L1 Length 666 746 936 1108

L2 Branch Length 333 373 468 554

Unequal Tees
Note: Tees with any Spigot, Socket or Flanged
combinations are available
L2

L1

NOMINAL DIAMETER 110 160 160 200 200 200

BRANCH DIAMETER 90 90 110 90 110 160

L1 Length 746 936 936 1108 1108 1108

L2 Branch Length 358 403 423 443 463 508

Note: All dimensions are in mm unless otherwise stated.

11
 Socket Flange
Note: Backing ring drilled to BS 4504 NP16

NOMINAL DIAMETER 90 110 160 200

L1 Overall Length 291 321 391 459

L2 Flange Thickness 19 20 26 26

Spigot Flange
Note: Backing ring drilled to BS 4504 NP16

NOMINAL DIAMETER 90 110 160 200

L1 Overall Length 263 290 345 405

L2 Flange Thickness 19 20 26 26

Reducers

L1

NOMINAL DIAMETER 110 160 200

REDUCING DIAMETER 90 110 160

L1 Effective Length 584 696 812

Double Sockets
A

S D

NOMINAL DIAMETER 90 110 160 200 250 315

D Insertion Depth Min 140 160 190 210 235 265

S Seal Depth Min 60 75 86 100 115 125
A Outside Diameter Max 135 150 215 260 315 395
Note: All dimensions are in mm unless otherwise stated.

12
DESIGN

PRESSURE SYSTEMS
 Hydraulic Design

The flow chart has been calculated

Figure 5 8 bar Hydraulic Flow Chart
on the mean bore of pipes of all working
pressure ratings.The exceptionally smooth
0.1 0.25 0.5
bore of pipes enables the system 0.1
to be hydraulically efficient when used for
the transportation of potable water.
The charts have been prepared using the 1.0
Colebrook-White flow equation to
determine the required pipe dimension and
subsequent loss of head. In this equation
the velocity of flow is related to the pipe
bore, the kinematic viscosity of water,
acceleration due to gravity and the
hydraulic roughness of the pipeline.
The Colebrook-White equation:
V = -2√2gDi Log
( Ks + 2.51v
3.7D D√2gDi
) 1

where:
V = velocity in metres per second
g = gravitational acceleration
Rate of Flow : Litres Per Second

(9.81 m/s2)
2.0
i = hydraulic gradient
v = kinematic viscosity of fluid

Velocity : Metres Per Second

(a value of 1.141 x 10-6 m2/s has been
assumed for water at 15°C)
Ks = linear measure of effective roughness
(0.003 mm)
D = Mean internal diameter of pipe in 10 16
0m
metres m 3.0
The frictional losses caused by fittings can 20
also be determined and are approximately
0m
m
proportional to the square of the liquid 3.4
velocity. Loss of head can be calculated
25
0m
using the following formula: m
H = Kv2 31
5m
2g m

where: 40
0m
m 4.5
H = loss of head (m) 45
0m
v = liquid velocity (m/s) 100 50 m
0m
g = gravitational acceleration m
(9.81 m/s2) 63
0
K = coefficient (dependent on type of 71 mm 5.7
0m
fitting) m
Various values for K are:
11.25° Bend = 0.025
22.5° Bend = 0.05
45° Bend = 0.1
90° Bend = 0.2 7.6

1000
0.0001 0.001 0.01 0.1

Hydraulic Gradient

14
Hydraulic Design continued

Figure 6 10 bar Hydraulic Flow Chart

0.1 0.25 0.5

0.1

1.0

1
Rate of Flow : Litres Per Second

2.0

Velocity : Metres Per Second

11
0m
m

10
16
0m
m 3.0

20
0m
m
3.4
25
0m
m
31
5m
m
40
0m
m 4.5
45
0m
100 50 m
0m
m
63
0m
71 m 5.4
0m
m

7.6

1000
0.0001 0.001 0.01 0.1

Hydraulic Gradient

15
Hydraulic Design continued

Figure 7 12.5 bar Hydraulic Flow Chart

0.075 0.1 0.25 0.5

0.1

1.0

1
Rate of Flow : Litres Per Second

2.0
90
mm

Velocity : Metres Per Second

11
0m
m

10
16
0m
m 3.0

20
0m
m
3.4
25
0m
m
31
5m
m
40
0m
m 4.5
45
0m
100 50 m
0m
m
63
0m
71 m 5.7
0m
m

7.6

1000
0.0001 0.001 0.01 0.1

Hydraulic Gradient

16
Hydraulic Design continued

Figure 8 16 bar Hydraulic Flow Chart

0.075 0.1 0.25 0.5

0.1

1.0

1
Rate of Flow : Litres Per Second

2.0
90
mm

11

Velocity : Metres Per Second

0m
m

16
10 0m
m
3.0
20
0m
m
25 3.4
0m
m
31
5m
m
40
0m
45 m
4.5
0m
50 m
100 0m
m
63
0m
71 m
0m 5.7
m

7.6

1000
0.0001 0.001 0.01 0.1

Hydraulic Gradient

17
 Thrust Restraint
All pressure pipelines with push-fit jointing
systems will be subject to separation forces. Where
Allowance should be made to Ai - is the cross sectional area of pipe
accommodate the thrust forces developed internal diameter (m2)
which would otherwise cause joint Ae - is the cross sectional area of pipe
deflection, extension or joint separation. external diameter (m2)
The development of plastics alloy P - is the internal pressure (bar)
has enabled significant improvements to be
made in the design of self anchoring or W - is the density of the fluid
thrust joints which has culminated in the (kg/m3)(1000 kg/m3 for water)
design of the End Load Joint. V - is the velocity of flow (m/s)
The new joint eliminates the need for the α - is the bend angle (degree)
construction of concrete thrust blocks at
all locations where thrust forces are Static thrust forces per 1 bar internal
encountered: pressure can be read from Table 1. By
● Changes of direction (bends) multiplying (P + 0.01V2) by the appropriate
● Blank ends and Junctions: thrust per bar of internal pressure, the
● Junctions = 102 Ae P (kN) combined forces can readily be deduced.
● Reductions in diameter ● Bends: End Load Joints are available in sizes 90mm
● Blank ends or closed valves = 102 Ae P 2Sin α2 (kN) to 160mm.These should be used where
● Adjacent pipes Dynamic thrusts are the result of water possible to avoid the use of concrete thrust
flowing in the pipe in the same direction as blocks.This will significantly speed up
● Limited space installation time and reduce the overall
the static thrusts. Dynamic thrusts are
● Steep inclines generally of small magnitude at low costs of the project.
● Soft ground or subsidence areas velocities of flow and only become Table 1 Thrust Forces
significant if the velocity of flow exceeds 1.5
Thrust forces acting on a pressure pipeline m/sec. Nominal End Radial Thrust on Bends
system are made up of static thrusts and External Thrust
Dynamic thrusts can be calculated: Diameter 90° 45° 22.5° 11.25°
dynamic thrusts both of which need to be (mm) kN kN kN kN kN
calculated to determine the overall force ● Bends: 90 0.64 0.91 0.49 0.25 0.13
acting upon a joint. = 2 x10-3 W A V2 Sin α2 (kN) 110 0.95 1.36 0.73 0.37 0.19
i
160 2.01 2.87 1.55 0.79 0.40
Static thrusts are the result of internal For design purposes the combined static 200 3.14 4.49 2.43 1.24 0.62
pressure and should be based upon the and dynamic forces at changes of direction 250 4.91 7.01 3.80 1.93 0.97
maximum internal pressure. In this instance should be calculated: 315 7.79 11.13 6.03 3.07 1.54
the End Load Joints have been designed to 400 12.57 17.95 9.72 4.95 2.49
● Bends:
= (P+0.01V2) 102 Ae 2Sin α2 (kN)
meet 1.5 times the maximum working 450 15.91 22.72 12.30 6.27 3.15
pressure plus 25% (i.e. 30 bar). 500 19.64 28.05 15.18 7.74 3.89
630 31.18 44.54 24.10 12.29 6.17
Static thrusts can be calculated: 710 39.60 56.56 30.61 15.61 7.84

18
 Thrust Restraint continued
Note: Where End Load Joints are used to
resist thrust forces the pipeline itself must
develop significant resistance to these
forces without allowing the joints to be
pulled apart.The resistance is built up at the
interface between the pipe and its
surrounding material.The designer must
calculate the distance over which this will
take place by comparing the shear
resistance between the pipe and surround
with the overall thrust force and calculate movements to occur to reduce the risk of
sufficient surface area to generate the stress concentrations.
necessary resistance.
The nature of the ground will determine
Concrete thrust blocks will be required for the dimensions and ultimate design of the
pipe sizes 200mm and above. At these concrete block.
points it is important to note that direct
The load bearing capabilities of the ground
contact between pipe and the
must be determined at the design stage.
concrete should be avoided. It is
recommended that a polythene sheet is
used to protect the pipe and allow minor

Figure 9 End Load Joint layout Example

Key This layout example shows the position

: End Load Joint where End Load Joints for diameters
90-160mm should be used. For diameters
:Pipe 4 above 160mm concrete anchor blocks will 8

: Thrust Force need to be designed and used.

1 : Gate valve
2 : Equal tee
3 : Reducer
4 : Blank end 3

5 :45°Bend
6 :45°Bend
7 :90°Bend 7
8 : Blank end 6

1 2 5

Figure 10 End Load Joint Usage Example

It is important to note that the End Load
Direction of Joint is used at both ends of the bend and
water flow on all three sockets on equal and unequal
tees.This is a minimum requirement and
should the interface resistance between the
soil and pipe not be sufficient the extra End
End Load Load Joints must be used on pipe joints
Joint before and after the thrust area.

Separation force
Direction of
water flow

Thrust force

End Load
Joint

19
 Surge and Fatigue

Table 2 Recommended Fatigue Re-rating Factors for

Daily Hourly Total Cycles 5ºC 10ºC 15ºC 20ºC 25ºC 30ºC
Frequency Frequency in 50 years Rating Factor Rating Factor Rating Factor Rating Factor Rating Factor Rating Factor

4 0.2 73,000 0.67 0.72 0.85 1.0 1.14 1.30

24 1.0 438,000 1.14 1.22 1.45 1.7 1.94 2.21
48 2.0 876,000 1.41 1.51 1.79 2.1 2.39 2.73
120 5.0 2,190,000 1.88 2.02 2.38 2.8 3.19 3.64
240 10.0 4,380,000 2.35 2.52 2.98 3.5 3.99 4.55
1200 50.0 22,000,000 3.75 4.03 4.76 5.6 6.38 7.28

Where detailed surge analysis is to be
carried out the modulus (E) for
may be calculated from the following
formula:
E (GPa) = 1.75 x (time in hours)-0.053.
Typical values being:
E = 3.05 GPa for t = 0.1 seconds
E = 2.70 GPa for t = 1.0 seconds
E = 2.39 GPa for t = 10 seconds
Fatigue
Fatigue usually occurs as a result of
repeated pressure cycles generally below
the rated pressure of the pipe.
It is recommended that the designer takes
into account cyclic loading conditions in
pipeline design. It is commonly accepted
that it is the total pressure range (the
difference between max and min) which
determines the decrease in lifetime with
fatigue.
When designing for fatigue a
pipeline should be re-rated to allow for the
decrease in strength as a function of
repeated cyclic loading. Re-rating factors
are illustrated in Table 2.
Example of use of Fatigue Re-rating
Factors
If for example, it was computed that there
would be 2 cycles/hr of pressures varying
over a range of 8 bar, with water
bedding recommendations can withstand
the negative pressures associated with a full
vacuum.
Surge and Fatigue
As with other plastics materials it is
important to consider the effects of surge
and fatigue on at the design stage.
The terms surge and fatigue are often used
collectively. However, whilst both
phenomena arise from the same events
(rapid valve closure, pump shut down, etc)
they should be considered separately since
they describe different effects on the pipe
material.
Surge
Surge is generally regarded as a ‘one off’
event. An isolated occurrence where
pressures may surge to high levels in
excess of the static rating in a very short
timescale, without causing fatigue problems,
(e.g. emergency pump shutdowns).
To establish if a pipeline will resist a surge
event, the peak surge must be identified.
This should be the worst anticipated event
(e.g. emergency trip of all pumps).
Figure 11 Surge Factors for
3.5
3.0
Surge Factor
Surge factors are used to calculate the
maximum allowable surge.These surge
factors are dependent upon the pressure
rise rate, and can be read from the graph in
Figure 11. If the designer is unsure of the
pressure rise rate, a worse case scenario
can be assumed and a surge factor of 2
applied.
Example of use of Surge Factors
● A pipeline has been
determined to have an operating
pressure of 6 bar.
● The pressure rise rate was calculated
to be 2 bar/sec and the peak pressure
predicted to be 12 bar.
● From Figure 1 the surge factor for
at 2 bar/sec would be 2.25.
Therefore a pipe rated at 8 bar (PN8)
static pressure would be capable of
resisting a peak surge pressure of
18 bar (8 x 2.25).
● This would be acceptable as the pipe
can resist a surge event of 18 bar when
the surge event in question is 12 bar.
Thermoplastics Pressure Pipes at 20ºC

temperature of 10ºC.Then the pressure

rating should be: 2.5
● At least bar 12.08 (1.51 x 8) for
. 2.0
● Therefore a 12.5 bar pipe can
be selected. 1.5
Further advice on surge and fatigue can be
found in Design Against Surge and Fatigue 1.0
Conditions for Thermoplastic Materials. UK 0.1 1.0 10.0 100.0
Water Industry Information and Guidance Pressure Rise Rate (bar/sec)
Note IGN 04-37-02.WRc, 1999.
Negative Pressures
It may be possible for a pipeline to be
subjected to a vacuum condition.
pipes when correctly installed in
accordance with sitework and

20
 External Compressive Loads/Temperature De-rating

Table 3 installation depths

NOMINAL DIAMETER 90 110 160 200 250 315 400 450 500 630 710

Narrow Trench Width 0.40 0.45 0.50 0.50 0.55 0.65 0.70 0.75 0.80 0.95 1.05
Depth 8 bar Min – – 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
(metres) Max – – 7.30 7.30 7.30 7.30 7.30 7.30 7.30 7.30 7.30
10 bar Min – 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
Max – 7.60 7.60 7.60 7.60 7.60 7.60 7.60 7.60 7.60 7.60
12.5 bar Min 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
Max 7.90 7.90 7.90 7.90 7.90 7.90 7.90 7.90 7.90 7.90 7.90
16 bar Min 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75 0.75
Max 8.50 8.50 8.50 8.50 8.50 8.50 8.50 8.50 8.50 8.50 8.50

External Compressive Loads Figure 12 Temperature De-rating

Under normal operating conditions it is not 18
necessary to confirm the performance of a
water pressure pipe for resistance
16 bar
to soil and traffic loadings. 16
In these conditions the stress resulting from
the internal pressure greatly outweighs the
soil and traffic load stresses. 14

However, in certain circumstances where

mains are expected to stand empty for long 12.5bar
periods of time, engineers may wish to 12
confirm the structural capabilities of the
pipe system under soil and traffic load
e (bar)

10 bar
conditions. 10
Table 3 acts as a guide to the minimum and
Pressur

maximum depth that can be

8 bar
installed. 8

The design procedure used as a basis for

the calculation of this table is based upon
the well recognised theory of M G Spangler. 6

The table is based on a main road traffic

loading condition and calculated using a
maximum allowable deflection of 6%, for 4
pipes installed in a granular
cohesive soil with moderate compaction.
Temperature De-rating 2

, as with other plastics materials,

should be de-rated when temperatures
exceed 20ºC.Where fluid or ambient 0
0 5 10 15 20 25 30 35 40 45 50 55 60
temperatures rise above 20ºC, the pressure Internal
or Ambient Temperature (ºC)
rating of the pipe should be reduced
proportionally or the service life of the
pipe is reduced. A conservative guide used
in the UK Water Industry for many years
employs a 2% reduction in pressure rating
for every 1ºC increase in temperature and
should be used up to a maximum
acceptable temperature of 60ºC as shown
in Figure 12.

21
 Chemical Resistance

Resistance to Corrosion Chemical Resistance

is resistant to almost all types of
corrosion, whether chemical or electro-
chemical in nature. Since is a non
conductor, galvanitic and electro-chemical
effects do not occur.
Because is non-metallic, the
material is completely resistant to all forms
of metallic corrosion. Aggressive waters
resulting from both high sulphate soils and
low hardness waters will not attack
in any way.
The resistance of to the chemical
agents listed below has been drawn from
CP312: Part 1: 1973 ‘General Principles
and Choice of Materials’.
Applications
For suitability and correct design in specific
applications, reference should be made to
national codes of practice. Details may be
found in the WRc Materials Selection
Manual and PVC-U Manual.

pipes and fittings are also resistant

to a wide range of industrial waters and
chemicals and will offer advantages in long
term system life and maintenance costs
thus giving real benefits in terms of whole
life cost.

Chemical Concentration Rating at 20°C Chemical Concentration Rating at 20°C

EPDM EPDM
Acetaldehyde 40% (w /v) soln. + + Anthràquinone + –
100% (w /v) soln. O O Anthraquinone sulphonic acid + +
Acetic acid 10% (w /v) soln. + + Antimony trichloride 90% aqueous + +
60% (w /v) soln. + O Aqua regia Dilute + C
glacial O + Arsenic acid 80% aqueous + +
Acetic anhydride Technically pure – + Aryl sulphonic acids + –
Acetone Technically pure – +
Up to 10% aqueous – O Barium carbonate + +
Adipic acid Saturated aqueous + + Barium chloride + +
Alcoholic spirits Barium hydroxide Aqueous saturated + +
Aliphatic hydrocarbons + + Barium sulphate + +
Aluminium chloride 10% aqueous + + Barium sulphide + +
Saturated + + Beer Usual commercial + +
Aluminium fluoride + + Benzaldehyde 100% saturated
Aluminium hydroxide + + aqueous – +
Aluminium nitrate + + Benzene Technically pure – C
Aluminium oxalate + + Benzoic acid All aqueous + +
Aluminium oxychloride + + Benzyl alcohol Technically pure O O
Aluminium potassium sulphate (alum) + + Bismuth carbonate + +
Aluminium sulphate 10% aqueous + + Borax, see disodium tetraborate All aqueous + +
Cold saturated Boric acid All aqueous + +
aqueous + + Boron trifluoride
Ammonia Gaseous technically Brine + +
pure + + Bromine Liquid – C
Bromomethane (methyl bromide) – –
Ammonia solution Aqueous cold Butadiene Technically pure + C
(ammonium hydroxide) saturated + + Butane Technically pure + C
Aqueous 10% + + Butanols Technically pure + +
Aqueous Saturated + + Butyl acetate Technically pure – O
Ammonium carbonate 50% aqueous + + Butylphenols Technically pure + C
Ammonium chloride Aqueous 10% + + Butyric acid 20% aq. soln. – –
Aqueous cold
saturated + + Calcium carbonate + +
Calcium chlorate + +
Ammonium ferrous citrate + + Calcium chloride Saturated
Ammonium fluoride 25% – + aqueous all + +
Ammonium hydrogen difluoride + + Calcium hydrogen sulphite + +
Ammonium metaphosphate + + Calcium hydroxide Aqueous saturated + +
Ammonium nitrate Aqueous 10% + + Calcium hypochlorite Cold saturated
Aqueous saturated + + aqueous + +
Ammonium orthophosphates + + Calcium nitrate 50% aqueous + +
Ammonium persulphate + + Calcium sulphate + +
Ammonium sulphate 10% aqueous + + Calcium sulphide – –
aqueous saturated + + Carbon dioxide Technically pure
Ammonium thiocyanate + + (carbonic acid) anhydrous + +
Ammonium zinc chloride + + Technically pure
Amyl acetate Technically pure – + moist + +
Amyl alcohol Technically pure – + Carbon disulphide Technically pure – C
Aniline Technically pure – O Carbon monoxide + +
Aniline hydrochloride Aqueous saturated + O Carbon tetrachloride Technically pure – –

Key + Recommended O Conditionally recommended

– Not recommended C Consult Hepworth Support Line

22
Chemical Concentration Rating at 20°C Chemical Concentration Rating at 20°C
EPDM EPDM

Casein Technically pure + + Fluorine Technically pure O C

Chloral hydrate Technically pure + + Fluorosilicic acid conc. + +
Chloric acid 10% aqueous + C Formaldehyde 40% (w /w ) aq. soln. + +
20% aqueous + C Formic acid 3% aq. soln. + +
Chlorine, gas 10% dry + + 10% aq. soln. + +
100% – – 25% aq. soln. + +
10% moist – + 50% aq. soln. – +
Chlorine water Saturated + + 100% aq. soln. – –
Chloroacetic acid mono Technically pure + + Fructose + +
50% aqueous + + Fruit juice Usual commercial + +
Chlorobenzene Technically pure – – Furfuraldehyde (furfural) Technically pure – –
Chloroethane (ethyl chloride) – –
Glucose + +
Chloroform Technically pure – – Glycerol + +
Chloromethane (methyl chloride) Technically pure – – Glycol + +
Chlorosulphonic acid Technically pure + C Glycollic acid 37% Aqueous + O
Chromic acid Up to 50% aqueous + C Grape sugar + +
All aqueous + C
Chromic potassium sulphate Heptane Technically pure + –
(chrome alum) + + Hexadecanol (cetyl alcohol) – –
Cider Usual commercial + + Hydrobromic acid 50% (w /v) aq. soln. + +
Citric acid 10% aqueous + + Hydrochloric acid 5% aqueous + +
Copper chloride + +
10% aqueous + +
Copper cyanide + + Up to 30% aqueous + +
Copper fluoride + +
36% aqueous + +
Copper nitrate + +
Hydrocyanic acid 10% (w /v) aq. soln. + +
Copper sulphate + +
Hydrofluoric acid 4% (w /v) aq. soln. + +
Cresols Up to 90% aqueous O C
40% (w /v) aq. soln. + C
Crotonaldehyde Technically pure – C
60% (w /v) aq. soln. + C
Cyclohexanol Technically pure – –
conc. C C
Cyclohexanone Technically pure + +
Hydrogen Technically pure + +
Hydrogen bromide anhydrous + +
Detergents (synthetic) Diluted for use + +
Hydrogen chloride anhydrous + C
Developers (photographic) Usual commercial + +
Hydrogen fluoride anhydrous + –
Dextrin Usual commercial + C
Hydrogen peroxide 3% (w /v) aq. soln. + C
Dextrose + +
10% (w /v) aq. soln. + C
Dibutyl phthalate Technically pure – +
30% (w /v) aq. soln. + C
Dichlorobenzene Technically pure – –
90% (w /v) aq. soln. + C
Dichlorodifluoromethane + +
Hydrogen sulphide + +
Dichloroethane (ethylene dichloride) – –
Hydroxylammonium sulphate + C
Dichloroethylene Technically pure – –
Hypochlorous acid + +
Dichloromethane
(methylene chloride) – –
Iodine soln. in potassium
Diesel oil – –
iodine – O
Digol (diethylene glycol) + +
Iron salts All aqueous + +
Dimethylamine Technically pure O –
Isopropyl alcohol Technically pure + +
Dioctyl phthalate Technically pure – O
Dioxane Technically pure – +
Lactic acid 10% (w /v) aq. soln + +
Dodecanoic acid (lauric acid) + +
100% (w /v) aq. soln. + +
Dodecanol (lauryl alcohol) + +
Lanolin Technically pure + C
Lauric acid Technically pure + +
Emulsifiers all + + Lauryl alcohol Technically pure + +
Emulsions (photographic) + + Lead acetate + +
Ethane + + Lead arsenate + +
Ethanediol (ethylene glycol) + + Lead nitrate + +
Ethanol (ethyl alcohol)† 95%-100% + – Lead tetraethyl + +
40% (v/v) aq. soln. + + Linoleic acid + +
Ethers Technically pure – – Linseed oil + C
Ethyl acetate Technically pure – +
Ethyl alcohol Technically pure + + Magnesium carbonate + +
96% Magnesium chloride + +
Ethyl butyrate – – Magnesium hydroxide + +
Ethyl chloride Technically pure – + Magnesium nitrate + +
Ethyl formate Technically pure – – Magnesium sulphate + +
Ethyl lacate Technically pure – –
Ethylene glycol Technically pure + + Maleic acid 25% (w /v) aq. soln. + C
Ethylene oxide (oxiran) Technically pure – C 50% (w /v) aq. soln. + C
liquid conc. + C
Malic acid 1% Aqueous + C
Fatty acids Technically pure + +
Manganese sulphate + +
Ferric chloride + +
Mercuric chloride + +
Ferric nitrate + +
Mercuric cyanide + +
Ferric sulphate + +
Mercurous nitrate + +
Ferrous chloride + +
Mercury + +
Ferrous sulphate + +
Metallic soaps (water soluble) + +
Fertilizer salts Aqueous + +
Methyl acetate Technically pure – C
Fixing soln. (photographic) + +
Methyl bromide Technically pure – C
Key + Recommended O Conditionally recommended
– Not recommended C Consult Hepworth Support Line

23
Chemical Concentration Rating at 20°C Chemical Concentration Rating at 20°C
EPDM EPDM

Methyl chloride Technically pure _ C Potassium bromide All aqueous + +

Methyl ethyl ketone, Technically pure – + Potassium carbonate + +
Methyl hydrogen sulphate 90% (w /v) aq. soln. + + Potassium chlorate + +
Methyl sulphate + + Potassium chloride All aqueous + +
Methylated spirits – – Potassium chromate Cold saturated + +
Methylcyclohexanone – – aqueous
Methylene chloride – C Potassium cuprocyanide + +
Milk Usual commercial + + Potassium cyanide Cold saturated + +
Mineral oils + + aqueous
Molasses Usual commercial + + Potassium dichromate + +
Monochlorobenzene – – Potassium ferricyanide + +
Potassium ferrocyanide + +
Naphtha + – Potassium fluoride + +
Naphthalene Technically pure – C Potassium hydrogen carbonate + +
Nickel chloride Cold saturated + + Potassium hydrogen sulphate + +
aqueous Potassium hydrogen sulphite + +
Nickel nitrate Technically pure + + Potassium hydroxide 1% (w /v) aq. soln. + +
aqueous 10% (w /v) aq. soln. + +
Nickel sulphate Technically pure + + conc. soln. + +
aqueous Potassium hypochlorite + +
Nicotonic acid + + Potassium nitrate 50% aqueous + +
Nitric acid 5% (w /v) aq. soln. + + Potassium orthophosphates + +
10% (w /v) aq. soln. + + Potassium perborate + +
25% (w /v) aq. soln. + + Potassium perchlorate 10% soln. + +
50% (w /v) aq. soln. – C Potassium permanganate 10% soln. + +
70% (w /v) aq. soln. – C conc. soln. + +
95% (w /v) aq. soln. – C Potassium sulphate All aqueous + +
Nitrobenzene Technically pure – C Potassium sulphide + +
Nitropropane Technically pure – C Potassium thiosulphate + +
Nitrous fumes Low, wet & dry + + Propane Technically pure + C
liquid
Octane + + Technically pure + C
Oleic acid Technically pure + O Gas
Orthophosphoric acid 20% aq. soln. + + Propylene oxide Technically pure
30% aq. soln. + +
50% aq. soln. + + Quinol + +
95% aq. soln. + –
Oxalic acid Cold saturated + + Ramasit Usual commercial + +
aqueous
Oxygen All + + Salicylic acid + +
Ozone Up to 2% air + + Sea water + +
Cold saturated + + Selenic acid +
aqueous Silver acetate + +
Silver cyanide + +
Palm oil + C Silver nitrate + +
Palmitic acid 10% + C Soap solutions (aqueous) + +
Paraffin oil + C Sodium acetate All aqueous + +
Pentane + + Sodium aluminate + +
Perchloric acid 10% + C Sodium antimonate + +
70% O C Sodium benzoate Cold saturated + +
Petroleum + C aqueous
Petroleum spirit + C Sodium bicarbonate Cold saturated + +
Phenol – – aqueous
Phenylcarbinol Technically pure – – Sodium bisulphate 10% aqueous + +
Phenylhydrazine Technically pure – – Sodium bisulphite All aqueous + +
Phenylhydrazine hydrochloride Aqueous + + Sodium borate
Phosgene gas + C Sodium bromide All aqueous + +
liquid – C Sodium carbonate Cold saturated + +
Phosphates + + aqueous
Phosphine + + Sodium chlorate All aqueous + +
Phosphoric acid Up to 30% aqueous + C Sodium chloride All aqueous + +
50% aqueous + C Sodium cyanide + +
85% aqueous + C Sodium ferricyanide + +
Phosphorus pentoxide Technically pure + + Sodium ferrocyanide + +
Phosphorus trichloride – – Sodium fluoride Cold saturated + +
Picric acid 1% (w /w )aq. soln. – – aqueous
Polyglycol ethers – – Sodium hydrogen carbonate + +
Potassium acid sulphate + + di Sodium hydrogen orthophosphate + +
Sodium hydrogen sulphate + +
Potassium antimonate + + Sodium hydrogen sulphite + +
Potassium bicarbonate + + Sodium hydroxide 1% aq. soln. + +
Potassium bichromate + + 10% aq. soln. + +
Potassium bisulphate + + 40% aq. soln. + +
Potassium borate + + Sodium hydroxide continued conc. + +
Sodium hypochlorite 15% available + +
Potassium bromate Cold saturated + + chlorine
aqueous Sodium hyposulphate + +
Key + Recommended O Conditionally recommended
– Not recommended C Consult Hepworth Support Line

24
Chemical Concentration Rating at 20°C Chemical Concentration Rating at 20°C
EPDM EPDM

Sodium metaphosphate – – Tartaric acid All aqueous + C

Tetraethyl lead Technically pure + +
Sodium nitrate Cold saturated + + Tetrahydrofuran Technically pure – –
aqueous Tetrahydronaphthalene (tetralin) Technically pure – –
Sodium nitrite Cold saturated Thionyl chloride Technically pure – C
aqueous Toluene Technically pure – C
t
r
iSodium orthophosphate – – Transformer oil Technically pure + +
Sodium perborate – – Tributyl phosphate Technically pure – –
Sodium peroxide – – Trichloroacetic acid Technically pure O O
Sodium silicate All aqueous + + 50% aqueous + O
Sodium sulphate Cold saturated + + Trichlorobenzene
aqueous – –
Sodium sulphide Cold saturated + + Trichloroethane – –
aqueous Trichloroethylene – –
Sodium thiosulphate Cold saturated + + Triethanolamine + –
aqueous Trigol + +
Soft soap + + Trimethylamine – –
Stannic chloride + + Trimethylol propane + +
Stannous chloride + – Trisodium phosphate, + +
Starch Usual commercial + C Tritolyl phosphate – –
Stearic acid + C Turpentine Technically pure – –
Sucrose + +
Sulphur colloidal + + Urea Up to 30% aqueous + +
Sulphur dioxide dry + +
moist – – Vegetable oils Usual commercial + –
liquid – – Vinegar + +
Sulphur trioxide + + Vinyl acetate monomer – –
Vinyl acetate polymer + +
Sulphuric acid 10% (w /w ) aq. soln. + +
20% (w /w ) aq. soln. + + Water Condensed + +
30% (w /w ) aq. soln. + + Water Distilled deionised + +
40% (w /v) aq. soln. + + Water Drinking + +
45% (w /v) aq. soln. + + Water Waste without + +
50% (w /v) aq. soln. + + organic solvent
55% (w /v) aq. soln. + + Wetting agents Up to 5% aqueous + +
60% (w /v) aq. soln. + + Wines and spirits Usual commercial + +
70% (w /v) aq. soln. + +
80% (w /v) aq. soln. – – Xylene Technology pure – C
90% (w /v) aq. soln. – – Xylenol – C
95% (w /v) aq. soln. – –
Sulphurous acid 10% aq. soln. + C Zinc Salts + +
30% aq. soln. + C
Surface active agents all + +
Tallow Technically pure + C
Tannic acid All aqueous + +
Tanning extracts Usual + +

Key + Recommended O Conditionally recommended

– Not recommended C Consult Hepworth Support Line

25
SITEWORK INSTRUCTIONS

PRESSURE SYSTEMS
 Handling and Storage

pipes are lightweight and easy to
handle.This plastics alloy has been
developed to overcome many of the
problems previously encountered by other
systems. Although this very tough material
is highly resistant to impact and abuse on
site, good site practice should be followed
where possible.
Care should be taken to prevent damage to
the pipe body, especially on the jointing
surfaces.The socket of the pipe protects
the captive sealing ring from damage in
most situations.
Lifting of pipes by mechanical means should
always be carried out so that there is no
direct contact between hooks and chains
*450 and 500 diameter pipes have differing
numbers of pipes per pack to achieve
maximum pipes per load.
Pipes up to 315mm can easily be carried by
hand although on difficult sites contractors
may wish to use mechanical means.
All pipes should be loaded on lorries
correctly to prevent damage and
subsequent performance problems.
on the mechanical performance of ,
however if there is any doubt please
contact the technical advisory service.
Pipe dust caps should not be removed until
jointing commences, this will reduce the
risk of contamination within the pipe.
Fittings and jointing materials should be
stored separately and preferably under
cover.
Attention should be paid at all times to
avoid theft, vandalism and contamination.
Adequate provision should always be made
to safeguard operatives and the public from
accidents.
0.7m 2.25m 2.25m 0.8m

✗
and the pipe or joint.
Transport Strapped
timber
battens
All pipes are delivered with end
caps to ensure that they arrive in the best 2m
max
possible condition. Pack details are listed in
Table 4.
Additional
support
battens
Table 4 Pack Quantities
Nominal Pipes per Packs per Pipes per
Diameter Pack Load Load
Storage
(mm)

90 96 12 1152 Pipe bundles should be stored no more

than 2m high stacked timber to timber.
110 50 16 800
Individual pipes should not exceed 7 layers
160 24 16 384 in height with the width of the bottom
200 20 12 240 layer no more than 3m wide. Generally
250 12 12 144 stacking heights should be kept to a
315 9 8 72 minimum with adequate surround space for
lifting machinery. It is advisable to store
400 9 8 72
different classes and sizes separately.
450 * * 50
500 * * 50 Exposure to ultra-violet light can discolour
the pipes and for prolonged storage
630 4 8 24
outdoors a protective opaque cover should
710 4 8 24 be used. Discoloration has a minimal effect

27
 Jointing
a) The spigot and socket to be joined
should be carefully examined for any
damage which would impair the jointing
procedure. Particular attention should be
paid to the spigot chamfer and the sealing
ring.The pipe should be chamfered to a
depth of half the wall thickness and at an
inclination angle of 15° to the pipe axis. If
pipes are cut on site they should be cut
square to the pipe axis with a fine toothed
saw and chamfered to half the pipe wall
thickness with a coarse file or Surform
tool.The chamfered spigot should be clean
and free from swarf and burrs.The sealing
ring should be correctly seated in the
socket groove, complete with the insert
ring.The sealing portion of the ring must
be free from damage of any sort. Joints
containing damaged or incorrectly fitted
rings must not be used.
b) The spigot insertion depth should be
measured as the depth from the mouth to
the shoulder of the socket.
Pipes are supplied with the spigot insertion
depth marked on the spigot end.The
spigots of cut pipes should be marked
similarly using an indelible crayon. If an
allowance for expansion is required, (e.g.
where changes in operating temperatures
are anticipated), this should be deducted
from the spigot insertion depth.
28
c) The mating areas of the spigot and
socket should be thoroughly cleaned. All
grease, dirt, swarf and other foreign matter
should be removed from the sealing areas.
d) The spigot end and the sealing ring
should be thoroughly lubricated with the
Hepworth lubricant supplied free of charge
with the pipe.The spigot should be
lubricated to the full insertion depth and
around its complete circumference, paying
particular attention to the chamfer area.
The seal should be lubricated around its
complete circumference.The guiding
principle should be to apply a liberal
quantity of lubricant and avoid ‘dry’ areas
on the mating surfaces.
e) Immediately after lubrication, the spigot
should be brought into contact with the
socket.The spigot pipe and parent joint
should be accurately aligned so that the
axes of the pipes are precisely in line.The
spigot should be hand fed into the socket
until resistance from the inner sealing
section is felt. Correct alignment at this
stage is essential to ensure that the rubber
sealing ring is not pinched or torn.
f) Leverage Method: sizes up to nominal
diameter 250mm can normally be jointed
by applying leverage with a crow bar at the
following socket end. A stout timber should
be inserted between the crow bar and the
pipe socket to prevent damage to the pipe.
The leverage should be applied in a steady,
continuous manner until the spigot
insertion depth mark coincides with the
mouth of the socket being jointed. No
further leverage should be applied. If any
undue resistance is felt or the spigot
cannot be levered home, the joint should
be disassembled and examined to
determine possible causes (e.g. lack of
lubrication and pinched or trapped sealing
ring).The procedure should then be
repeated as described previously.
 Jointing continued
Adapting to Other Materials
Jointing on to pipes of different materials
or to Imperial PVC-U sizes can easily be
achieved with the use of the Viking Johnson
adaptor couplings or the Stanseal range of
couplings and adaptors.
Jointing to metric PVC-U is simply achieved
by using the normal push-fit jointing
procedure.The OD of is identical
to the OD of Metric PVC-U and therefore
the two systems are compatible.

g) Jointing Clamps: are available for sizes

above nominal size 200mm and are
specially designed for use with
Water Pressure Pipes.These are
particularly useful where bends and tees
are to be installed in the pipeline system.
Instructions for using clamps to joint pipes
are enclosed with the product.

29
 End Load Joint Installation

A pipeline operating under internal

pressure will generate thrust forces at any
change of direction, reduction in diameter,
blank end or closed valve.
Utilising the End Load Joint, time
consuming and costly methods such as
laying concrete are now avoidable.The End
Load Joint is a simple method of restraining
movement at potential thrust areas
allowing work to continue quickly without
extra site equipment and personnel.
End Load Joint Installation
4) Slide grab ring housing and the grab 8) Insert pipe spigot into socket as
The following procedure ensures that the ring onto the pipe spigot. Largest normal using leverage method jointing
End Load Joint can be installed correctly, diameter facing socket. clamps. Ensure that the pipe is pushed
quickly and easily in all sizes and all up to the insertion depth mark.
conditions.

5) Slide grab ring up to the pipe insertion

mark. 9) Push grab ring up to socket face. Push
1) Undo bolts and disassemble joint housing up to and over the grab ring.
ready for installation Locate the bolts through the bolt
holes. Fit nuts and washers.

6) Clean and lubricate the pipe spigot up

2) Place ‘C’ clamp around the shoulder of
the pipe socket.
7) Clean and lubricate the pipe socket
3) Bolt together ‘C’ clamp to finger
tightness.
to the grab ring.
10) Fully tighten ‘C’ clamp bolt and the
three restraining bolts. Due to the
design of the fitting the bolts cannot
be overtightened.
Note: End Load Joints are designed only
for use with water pressure
systems. Hepworth cannot accept liability if
used with any other system components.
An End Load Joint installation instruction
leaflet is provided in the packaging for easy
reference on site. For further information
concerning the design and location of
thrust restraints refer to the Design
and the seal around its complete
Section in this leaflet.
circumference.

30
 Deflection and Curvature
Joint Deflection
Delection of the Joint is achievable
due to the compressibility of the
elastomeric sealing ring, and deflections
within the recommended limits will not
affect the performance of the seal.
The maximum deflection of the joint
should be limited to one degree (1º).
Any greater deflection than this may cause
‘binding’ of the socket and spigot which
could result in high stresses being imposed
within the joint.
A one degree deflection on a 6 metre pipe
represents approximately 100mm change in
direction (A) as shown in Figure 13.
Both the joint deflection and pipe
curvature methods of achieving longitudinal
bending should be strictly limited to the
recommendations given in this guide, and
preference given to the use of pre-
formed bends.
Pipe CurvatureGeneral
One of the practical features of is
its ability to bend when cold.The benefits
of this cold bending property can be
utilised during installation and when the
pipe is in service.
Figure 13 Angular deflection of a single
Ø (mm)
Figure 14 Maximum curvature permissible on a 6m
During installation pipes can be cold bent
as a means of overcoming certain
topographical and man-made obstructions
without recourse to the use of purpose-
made bends.The minimum radius for the
cold bending of is 150 times the
maximum mean outside diameter of the
pipe.The results of which are illustrated in
Table 5.
During service the pipe has an inbuilt
ability to take up ground movements
caused by subsidence or differential
settlement without undue stresses being
incurred on the pipe wall.
Practical Considerations
It can be shown that as the pipe diameter
increases the force required to affect the
bending radius quoted increases.
The force required can place practical
limitations on the maximum pipe diameter
considered suitable for bending during
installation. It is recommended that the
cold bending of be limited to a
nominal diameter of 200mm.To achieve
deviation in-line on larger diameters
pre-formed bends should be used.
Figure 14 illustrates the maximum
curvature permissible on a 6 metre
pipe.
1°
A
6m
pipe joint
6m
A 160
pipe
The following points must be
considered when cold bending:
● Cold bending should not be attempted
at ambient temperatures less than 5ºC.
● The trailing socket must be securely
fixed in position before the pipe is
bent.
● On no account must the trailing socket
be subject to angular deflection and
hence additional stresses.
● Bending should be carried out manually
wherever possible.
● If mechanical pulling devices are used
the pipe must be adequately protected
from damage. Metal chains, slings, hooks
or straps must not come into direct
contact with the pipe.
● The pipe must be securely fixed in its
radiused position before laying
proceeds. pipe has a ‘memory’
and will re-straighten itself if not
secured.
● Every precaution shall be taken during
the drawing operation to ensure the
safety of site personnel.
Table 5 Pipe Curvature
Nominal Dia, Ø A
(m)
90 1.30
110 1.10
0.75
200 0.60
31
 Deflection and Curvature continued
pipes, Sardinia
Water Services Connections to
has been extensively tested
successfully with various tapping tees under
both laboratory and site conditions,
however, as with all tappings care must be
taken since blunt cutters and/or badly
aligned tappings have been a significant cause
of pipe failures in the past, particularly when
carried out under pressure.
The recommended method of effecting a
service connection is by the use of a
purpose-made tapping saddle tee, of plastic
32
or metal construction, strapped around the acceptable, in a special case, on a large
pipe.The saddle tee incorporates a self- diameter main.
tapping ferrule, which ensures that the
Varying amounts of swarf are generated
cutter is sharp and geometrically correct,
when cutting depending upon the
and used only once. On withdrawal, the
diameter of the cutter and the wall
coupon of pipe is held within the cutting
thickness of the pipe, this swarf must be
head, which may prove useful as a
contained within the body of the cutter.
temporary closing device should such an
Larger diameters and thicker walled pipes
action be required.
therefore require longer cutters.
The design of the cutter is important the
The grooves of the flutes need to be fairly
cutter must be fluted, solid cutters are
short, again to retain the swarf.
not suitable for cutting .
The separation distance between two
On clamping the saddle tee to the pipe, care
adjacent tappings should be not less than
should be taken that sufficient compression
than 500mm or five times the main pipe
of the sealing gland is achieved to ensure a
diameter, whichever is the greater.
watertight seal, but without over-tightening.
At all service connections, extra care with
The outlet to the tapping tee should be
soil compaction is necessary to prevent
specified as to direction in relation to the
excessive bending and shear stresses being
main pipe, although swivel ferrules are
created by subsequent ground or pipe
available.The outlet union required will
movement.
depend upon the service pipe material to be
used. Manufacturers that have been tested on
include:-
The size of any one tapping should not
exceed one quarter of the outside diameter Barber, Booth, Plasson,Talbot and Waterfit.
of the pipe up to a maximum of 37mm.
Tapping machines are available for larger
diameters, but this would only be
 Flange Jointing

The system can be jointed to Adapting to Other Materials

pipes, fittings and valves of different
materials through the use of flanged fittings
in the range.
Most of the standard fittings within the
range are available with flanges or
a combination of flange, socket or spigots.
Jointing on to pipes of different materials or 8 1
to Imperial PVC-U sizes can easily be
achieved with the use of the Viking Johnson 4 5
adaptor couplings or the Stanseal range of
couplings and adaptors.
Jointing to metric PVC-U is simply achieved 6 3
by using the normal push-fit jointing
procedure.The OD of is identical 2 7
to the OD of Metric PVC-U and therefore
the two systems are compatible.

Flange Bolting Recommendations

● Mating surfaces must be clean and
undamaged.
● Use a single rubber gasket to BS 2494
of the correct size.
● No jointing compound is needed to
make the joint.
● Flange joints should be assembled
before other joints on the pipeline.
● The mating surfaces must be aligned to
within 5mm before bolting.
● Use undamaged nuts, bolts and flat
washers of the correctsize.
● The gasket must be correctly aligned
before bolting.
● The nuts and bolts are to be tightened
using a torque wrench to the
recommended torque in a diagonally
opposite sequence as illustrated,
progressively from finger tight to final
torque; e.g.
5% 20% 50%
of final torque of final torque of final torque
75% 100%
of final torque of final torque

● On 200mm and above it is

recommended two operators should
work simultaneously on diametrically
opposite bolts.
● Check the final torque of bolts after
one hour when they have been allowed
to relax.

Table 6 Bolt Torques

Size (mm) Torque (Nm)
90 40
110 45
160 60
200 75

33
 Inspection and Testing/Installation Above Ground
Inspection and Testing
When the system has been fully installed
all pipework and fittings should be visually
inspected and hydraulically tested.
Where practical, joints should be left
exposed until hydraulic testing has been
successfully completed.
Visual Inspection
The system should be visually inspected to
ensure that the correct installation
procedures have been followed and that
pipes and fittings are adequately supported
and restrained in the prescribed manner.
Hydraulic Testing
The PE Type 2 test method is used.
pipelines should be tested in
reasonable lengths, appropriate to the
diameter and site conditions. Pipelines
longer than 1 km may require testing in
sections.
a) Thrust Forces
During installation the pipeline should have
been suitably anchored to resist thrust at
changes of direction and at fixed points such
as branches and hydrant connections.Testing
should not take place until any
in-situ concrete has attained its required
strength (normally a minimum of 7 days
after pouring).
b) Charging the Main
The test section should be isolated, where
necessary, from the rest of the system.
A blank end connection, drilled and tapped
for test equipment, should be installed on a
suitable face flange or incorporated by
means of a VJ flange-adapter or similar.
All blank ends on the system should be
adequately strutted to resist the thrust
developed as a result of the internal
pressure. Testing should not be carried
out against closed valves.
The system should be filled from its lowest
point to encourage expulsion of air as the
pipeline fills.Adequate air release
mechanisms should be sited at high points.
c) Pressurising
After charging, the system should be left to
stabilise for at least 2 – 3 hours.
The recommended test pressure is 1.5
times the working pressure of the system,
up to a maximum of 1.5 times the rating of
the lowest rated component in the system.
The test pressure should be applied slowly
and steadily.The pressure rise should be
monitored and recorded. Upon reaching the
desired test pressure, the pipeline should be
isolated and the pressure allowed to decay.
d) Pressure Test Analysis
The use of a data logger is strongly
recommended.
The time taken to reach pressure is tL.Take
a pressure reading P1 at t1, where t1 = tL.
Take a second reading P2 at t2, where
t2 = 7tL.
34
To allow for the stress relaxation behaviour becomes less resistant to impact at
of the material, a correction factor sub-zero temperatures.The pipe should be
must be applied to the times, as follows: protected accordingly in exposed
t1c = t1 + 0.4tL, t2c = t2 + 0.4tL conditions.Waterproof lagging should be
employed to protect the pipe. Freezing
The slope of the pressure decay curve conditions are possibly the most serious
between t1 and t2 is calculated as the ratio: problem and provision to drain down the
log P1 – log P2 system at a low point should be employed.
n1 =
log t2c – log t1c Thermal Movement
For a sound main, the ratio n1 should be In common with a number of engineering
0.01 – 0.085 for pipes without constraintand materials will expand and/or
0.01 – 0.05 for pipes with compacted contract under the influence of variations in
backfill. pipe and ambient temperatures.The
coefficient of thermal expansion/contraction
If the values are significantly lower than this,
of is 7.0 x 10-5 per ºC. Due account
then there may be too much air trapped in
should be taken of possible expansion or
the pipeline.
contraction when installing pipes
Take a further reading P3 at t3 where t3 is at which will be subject to variations in
least 15tL.Again calculate the corrected time temperature either immediately following
t3c = t3 + 0.4tL. installation or in their service lifetime.
The slope of the pressure decay curve Thermal expansion and contraction should
between t2 and t3 is calculated as the ratio: be allowed for and sufficient freedom of
log P2 – log P3 movement allowed for at brackets.
n2 =
log t3c – log t2c Change in length can be calculated from the
formula:
A value of n2 in excess of 0.1 for a pipe ∆L = α L ∆T
without constraint, or 0.06 for a pipe with
constraint, indicates the presence of a leak. ∆L = Change in length (mm)
α = Coefficient of linear expansion
The sensitivity of the test can be increased
(0.07mm/m/ºC)
by extending the length of t3.
L = Original length of pipe (m)
If, at any stage the presence of an
∆T = Change in temperature (ºC)
unacceptable leak is indicated, it is advisable
to check all mechanical fittings, before Expansion can normally be accommodated
visually inspecting the pipe joints.Any within the Integral Socket without
defects revealed should be rectified and the recourse to special fittings or pipe
test repeated, once sufficient time has arrangements.
elapsed to allow the pipeline to recover Pipe Support Brackets
from the previously imposed conditions, These should be as wide as practical,
typically 5 times the previous test period. without sharp edges, but a minimum of
On completion of testing, the remaining 75mm. Plastic coating is ideal, otherwise,
pressure should be slowly released. rubber or another suitable membrane is
A more detailed copy of this test method is better than bare metal.
available on request. Support Centres
Commissioning
In many non-buried situations the need
Following a successful pressure test the arises to provide pipe supports to ensure
main should be cleaned, sterilised and that the weight of the pipe and its contents
brought into service as soon as possible.The are adequately supported.
following procedures should be completed:
The recommended maximum support
● Cleaning by flushing or swabbing the spacings are given in Table 7. For vertical
main pipe runs the values below should be
● Filling and disinfecting increased by 30%.
● Emptying with neutralisation Table 7 maximum support
spacings
● Refilling the main
Nominal PN PN
● Bacteriological sampling Size 8 & 10 12.5 & 16
(mm)
● Acceptance certification
90 1.4 1.5
● Introduction of the main into service 110 1.5 1.7
For further information please refer to the 160 1.8 2.1
WRc manual for PVC Pressure Pipe Systems 200 2.1 2.5
July 1994. 250 2.4 2.9
315 2.6 3.1
Installation Above Ground 400 3.1 3.7
Protection is required against exposure to 450 3.4 3.7
500 3.7 3.7
ultra-violet light, cold temperatures and
630 3.7 3.7
impact damage.
710 3.7 3.7
 Bedding Requirements
Trench Work
The line and level of the pipe and buried
depth of the pipeline, will have been
predetermined at the design stage.
The trench should not be excavated too
far in advance of pipe laying and should be
backfilled as soon as possible, however,
joints should be left exposed until testing
has been successfully completed.
The width of the trench at ground level will
depend on the type of subsoil and buried
depth of the pipeline.The minimum width
of the trench at the pipe springing line
should be as narrow as practicable but not
less than the pipe diameter plus 300mm.
The maximum width of the trench at the
crown of the pipe must not exceed the
pipe diameter plus 600mm.
Trench Information
a) Direct Laying
If the pipe is to be laid directly onto the
trench bottom make sure that the trench
formation is composed of stable, uniform,
fine-grained soil, with no boulders, bricks
or rocks which might cause point-loading
on the pipe.
When laying the pipe directly, the trench
formation should be trimmed to an even
finish which will provide continuous
support to the pipe.
Figure 15 Recommended trench detail
Not less than
750mm cover
Selected backfill to a
minimum of 100mm
above pipe crown
100mm min
Additional excavation will be required at The bedding material should be placed
the position of the pipe sockets to ensure carefully in the trench and properly
proper joint assembly and pipe support. compacted by hand to ensure a sound
continuous bed for the pipes. Particular
b) Pipe Laying on Bedding
attention should be paid to the socket
If the formation is unsuitable for direct
holes to ensure the correct placement and
laying the trench will need to be excavated
compaction of bedding material in this
to a further depth of a minimum of 100mm
area. Bricks or other forms of temporary
below the underside of the pipe.
pipe support should never be left in the
This should be made up with a suitable trench.
bedding material. In extreme conditions
To test the suitability of selected as-dug
such as waterlogged or unstable ground it
granular bedding and sidefill material
may be necessary to increase the thickness
representative samples should be evaluated
of the bedding material.
using the Compaction Fraction Test,
Pipelines laid through rock should always detailed over:
be laid on a minimum of 100mm bed of
suitable bedding materials.
Bedding Material
The bedding material selected may be
available from excavated trench material or
may need to be imported from another
source.The material should be granular in
nature, free from large stones or debris
and preferably fine grained. Materials such
as clay or hard chalk, which will break up
when wetted, should not be used. Suitable
materials are free draining coarse sand and
nominal single size gravel with rounded or
angular particles. Gravels should be nominal
single size 10mm or 5 to 10mm graded,
which have good self compacting
properties.
Place 200mm of
excavated material
on top of 100mm
No wider than pipe diameter of selected backfill
plus 600mm at pipe crown before using
mechanical
compactors
Top soil/road surface
Normal backfill
Selected backfill
Not less than pipe diameter Suitable bedding
plus 300mm material
35
 Compaction Fraction Testing
Apparatus
1. Open-ended cylinder
Approximately 250mm long and 150mm
(+10mm-5mm) internal diameter (160mm
diameter pipe is suitable).
2. Metal rammer
Metal rammer with striking face
approximately 40mm diameter and
weighing 0.8kg to 1.3kg.
3. Rule
Method
Obtain a representative sample more than
sufficient to fill the cylinder (about 10kg).
To obtain this sample, heap about 50kg of
the proposed material on to a clean
surface and divide it with a spade down the
middle into two halves. Divide one of these
and repeat this procedure until the
required mass of sample is left. It is
important that the moisture content of the
sample should not differ from the bulk of
the material at the time of its use in the
trench.
36
Place the cylinder on a firm flat surface and Suitability of Compaction Fraction
gently pour the sample material onto it,
Suitability of Compaction Fraction for use
loosely and without tamping. Strike off the
are:
top surface level with top of cylinder and
remove all surplus spilled material. Lift the Compaction Fraction Suitability for use
cylinder up clear of its contents and place 0.15 or less . . . . . . . . .Material suitable
on a fresh area of flat surface. Place about
0.15 - 0.3 . . . . . . . . . . .Material suitable
one quarter of the material back in the
but requires extra
cylinder and tamp vigorously until no
care in compaction.
further compaction can be obtained.
Not suitable if the
Repeat with the second quarter, tamping as
pipe is subject to
before, and so on for the third and fourth
waterlogged
quarters, tamping the final surface as level
conditions after
as possible.
laying.
Determination of Compaction
Over 0.3 . . . . . . . . . . .Material unsuitable
Fraction
Further information on bedding and sidefill
The Compaction Fraction is determined as
materials can be found in:
follows:
IGN 4-08-01 Issue 4: Imported Granular
Measure from the top of the cylinder to
and Selected As-Dug Bedding and Sidefill
the surface of the compacted material.This
Materials for Buried piplines.
distance in millimetres divided by the
height of the cylinder gives the compaction WIS 4-08-02 Issue 1: Specification for
of the material under test. Bedding and Sidefill Materials for Buried
Pipelines.
Jacking Pipe

PRESSURE SYSTEMS
 Figure 16
Jacking Pressure Pipe

JACKING OD
A
ID

t O D1

T a Pressure
Pipe
Key: Concrete
A = Plastic socket outside diameter ID1 = Inside diameter Chipboard
a = Minimum concrete thickness t = Plastic wall thickness Ring
O D1 = Pressure pipe outside diameter T = Overall wall thickness
O D = Overall outside diameter

This is a unique combination of materials transported through the completed

Jacking Pressure Pipe
As part of the company’s unparalleled
commitment to the innovation of new
products, Hepworth offer a range of pipes
for use in applications using trenchless
technology.This new range enables high
performance pressure pipes to be installed
in congested or inaccessible sites in a single
operation.
and technology.The pipe consists of a pipeline.
composite wall structure comprising
Jacking Pipes are designed to
pressure pipe on the internal face
provide a finished pressure pipeline of 10
and a concrete wall on the outside face.
or 16 bar rating in a single drive installation
The concrete part of the wall is designed
process.The pipes are available in lengths
to accommodate the jacking stresses and
from 1 m upwards.Typical lengths are
the the hoop stress created by
1.2 m, 1.5 m and 2.0 m.
internal pressure from the liquid being

Product Data
Jacking Pressure Pipe - 10 Bar Single Socket
NOMINAL INTERNAL DIAMETER MM 100 150 200 250 300 400 450 500 600
Working Pressure Bar P 10 10 10 10 10 10 10 10 10
Outside Diameter Min mm OD 230.0 330.0 380.0 430.0 530.0 630.0 780.0 880.0 980.0
Max mm OD 250.0 350.0 400.0 450.0 550.0 650.0 800.0 900.0 1000.0
Inside Diameter Min mm ID1 106.4 154.9 193.5 242.1 305.1 387.6 436.0 484.5 610.5
Max mm ID1 107.3 156.1 195.0 243.9 307.2 389.9 438.5 487.1 613.5
Plastic Outside Diameter Min mm O D1 110.0 160.0 200.0 250.0 315.0 400.0 450.0 500.0 630.0
Max mm O D1 110.4 160.5 200.6 250.8 316.0 401.0 451.0 501.0 631.0
Plastic Wall Thickness Min mm t 3.1 4.4 5.6 6.9 8.8 11.1 12.5 13.9 17.5
Max mm t 3.6 5.1 6.5 7.9 9.9 12.4 14.0 15.5 19.5
Plastic Socket Outside Diameter mm A 150.0 215.0 260.0 315.0 395.0 500.0 560.0 610.0 770.0
Minimum Concrete Thickness mm a 40.0 57.5 60.0 57.5 67.5 65.0 110.0 135.0 105.0
Overall Wall Thickness Min mm T 122.7 173.9 185.0 186.1 222.8 240.1 341.5 392.9 366.5
Max mm T 143.6 195.1 206.5 207.9 244.9 262.4 364.0 415.5 389.5
Weight kg/m – 96.7 186.2 231.8 272.6 397.9 517.4 853.5 1090.9 1194.2
Allowable Jacking Load No deflection Tonne – 65 174 216 222 348 390 1004 1466 1160
0.5 deflection Tonne – 65 130 134 112 154 153 319 433 339

Jacking Pressure Pipe - 16 Bar Single Socket

NOMINAL INTERNAL DIAMETER MM 100 150 200 250 300 400 450 500 600
Working Pressure Bar P 16 16 16 16 16 16 16 16 16
Outside Diameter Min mm OD 230.0 330.0 380.0 430.0 530.0 630.0 780.0 880.0 980.0
Max mm OD 250.0 350.0 400.0 450.0 550.0 650.0 800.0 900.0 1000.0
Inside Diameter Min mm ID1 104.4 152.0 190.2 237.8 299.6 380.5 428.1 475.7 599.6
Max mm ID1 105.6 153.5 191.9 239.9 302.0 383.5 431.3 479.1 603.5
Plastic Outside Diameter Min mm O D1 110.0 160.0 200.0 250.0 315.0 400.0 450.0 500.0 630.0
Max mm O D1 110.4 160.5 200.6 250.8 316.0 401.0 451.0 501.0 631.0
Plastic Wall Thickness Min mm A 4.8 7.0 8.7 10.9 14.0 17.5 19.2 21.9 27.5
Max mm a 5.6 8.0 9.8 12.2 15.4 19.5 21.9 24.3 30.4
Plastic Socket Outside Diameter mm t 150.0 215.0 260.0 315.0 395.0 500.0 560.0 610.0 770.0
Minimum Concrete Thickness mm t 40.0 57.5 60.0 57.5 67.5 65.0 110.0 135.0 105.0
Overall Wall Thickness Min mm T 124.4 176.5 188.1 190.1 228.0 246.5 348.7 400.9 376.5
Max mm T 145.6 198.0 209.8 212.2 250.4 269.5 371.9 424.3 400.4
Weight kg/m – 97.6 188.0 234.6 277.1 404.2 529.1 868.4 1109.3 1223.4
Allowable Jacking Load No deflection Tonne – 65 174 216 222 348 390 1004 1466 1160
0.5 deflection Tonne – 65 130 134 112 154 153 319 433 339
Note: All dimensions are in mm unless otherwise stated.

38
WATER PRESSURE SYSTEMS
GENERAL INFORMATION

PRESSURE SYSTEMS
 Conversion Chart

To convert into SI units multiply by the given factor.To convert SI to English/Metric divide by the factor.

LENGTH metre m VELOCITY m/s PRESSURE Pascal (P) kg/m-s2 N/m2

in 2.54 x 10-2 in/s 2.54 x 10-2 in-H2O 2.49089 x 102
ft 3.048 x 10-1 ft/s 3.048 x 10-1 ft-H2O 2.98907 x 103
yd 9.144 x 10-1 ft/min 5.08 x 10-3 in-Hg 3.38639 x 103
mile 1.60934 x 103 mph 4.4704 x 10-1 psi (lbf/in2) 6.89476 x 103
mm 10-3 cm/s 10-2 lbf/ft2 4.78803 x 101
cm 10-2 km/h 2.77778 x 10-1 tonf/in2 1.54443 x 107
tonf/ft2 1.07252 x 105
AREA metre2 m2 ACCELERATION m/s2 poundal/in2 2.14296 x 102
in2 6.4516 x 10-4 ft/s2 3.048 x 10-1 poundal/ft2 1.48816
ft2 9.29030 x 10-2 cm/s2 10-2 mm H2O (kgf/m2) 9.80665
yd2 8.36127 x 10-1 cm H2O 9.80665 x 101
acre 4.04686 x 103 FLOW volume m3/s mm Hg (torr) 1.33322 x 102
mile2 2.58999 x 106 ft3/s 2.83168 x 10-2 cm Hg 1.33322 x 103
mm2 10-6 cfm 4.71947 x 10-4 dyne/cm 10-1
cm2 10-4 gal/s 4.54609 x 10-3 atmosphere 1.01325 x 105
dm2 10-2 gal/h 1.26280 x 10-6 millibar 102
km2 106 litre/s 1.00003 x 10-3 bar 105
litre/h 2.77786 x 10-7 Newton/mm2 106
VOLUME metre3 m3 m3/min 1.66667 x 10-2 Newton/cm2 104
in3 1.63871 x 10-5 m3/h 2.77778 x 10-4
ft3 2.83168 x 10-2 VISCOSITY dynamic kg/ms
yd3 7.64555 x 10-1 FLOW mass kg/s lb/ft s 1.48816
gal (UK) 4.54609 x 10-3 lb/s 4.53592 x 10-1 lb/ft h 4.13378 x 10-4
gal (US) 3.78543 x 10-3 lb/h 1.25998 x 10-4 centipoise 10-3
barrel (US) 1.58988 x 10-1 ton/h 2.82236 x 10-1 poise 10-1
mm3 10-9 kg/h 2.77778 x 10-4
cm3 10-6 VISCOSITY kinematic m2/s
dm3 10-3 DENSITY kg/m3 ft2/s 9.29030 x 10-2
litre 1.00003 x 10-3 lb/in3 2.76799 x 104 ft2/h 2.58064 x 10-5
lb/ft3 1.60185 x 101 cm2/s 10-4
MASS kilogram kg lb/gal 9.97763 x 101 centistokes 10-6
grain 6.47989 x 10-5 slug/ft3 5.15379 x 102 Stoke 10-4
oz 2.83495 x 10-2 ton/yd3 1.32894 x 103 m2/h 277778 x 10-4
lb 4.53592 x 10-1 g/cm3 103
cwt 5.08023 x 101 g/litre 9.99972 x 10-1
ton (UK Long) 1.01605 x 103 g/m3 10-3
ton (US Short) 9.07185 x 102
µg 10-9 FORCE Newton (N) kg-m/s2
mg 10-6 lb-force 4.44822
g 10-3 poundal 1.38255 x 10-1
tonne (metric) 103 dyne 10-5
gm-force 9.80665 x 10-3
kg-force 9.80665
joule/cm 102

40
WATER PRESSURE SYSTEMS
INDEX

PRESSURE SYSTEMS
WATER PRESSURE SYSTEMS
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PRESSURE SYSTEMS