PVC Pipe for Trenchless Installation

PVC Pipe for Trenchless Installation

INSTALLATION GUIDELINES

Ver. 2

INSTALLATION METHODS

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1

Conventional Horizontal Directional Drilling (HDD)

2

Pipe in-line removal and replacement / Pipe eating / Pipe reaming with HDD Rig

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2

3

5

Un-cased auger boring / Pilot bore micro tunnelling / Guided boring

4

Pipe insertion into pre-drilled hole by push-in

3

Static pipe bursting

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6

Micro tunneling

6

CONTENTS

PAGE NUMBER

Installation Methods 1

General Installation Information 2

Horizontal Directional Drilling / Micro Tunneling / Pipe Reaming / Pipe Bursting / Slip Lining 3

Pipe Joint Assembly Instructions 4

RESTRAIN™ Pipeline Threaded End Protection 5

Service Lateral Connections 5

‘IPLEX’ The Company 5

GENERAL INSTALLATION INFORMATION

1

Changing a drill rod at one end

2

...whilst simultaneously screw-joining on another pipe length at the other end

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2

1 Direction of pipeline insertion 2 Direction of spigot insertion

3 Socket mouth facing on the opposite direction

RESTRAIN™ PIPE JOINT

ASSEMBLY & ORIENTATION

Be sure the threads and seal ring are completely clean and free of any dirt or grit, before beginning lubrication and assembly.

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2

3

Use only “Gensil 601” spray-on silicone lubricant or Iplex - approved equivalent, for

lubrication. Do not use conventional pipe jointing lubricant, such as Medlude or Novalube. Other than the recommended lubricant, joints should be kept dry to prevent fluid build-up in the thread and seal ring area.

Use strap wrenches with woven nylon webbing straps, for pipe turning during joint assembly. (“Rigid”, “Hit” or “Super Ego” brand or Iplex approved equivalent).

GENERAL COMMENTS

Lubrication

Trenchless applications with RESTRAIN™, including all methods except pipe bursting, require excellent “in-hole” lubrication within the host hole with either water or an appropriate water / bentonite suspension lubricant mixture, at all times.

Overcut

The amount of overcut of the host hole depends on factors including the type of soil, lubrication, pipe size and line length, and is normally at least 20mm larger than the maximum pipe OD, or may be 30 to 50mm larger, in rock or swelling clay.

SITE PRESSURE TESTING

RESTRAIN Pipe systems are tested on site in accordance with the relevant parts of AS / NZS 2566 Part 2, Appendix N “Leakage testing for Non Pressure Pipelines, or AS / NZS 2032 Section 7.3 Testing of Non pressure pipelines

1 Direction of pipeline insertion 2 Direction of spigot insertion

3 Socket mouth facing away from direction of installation

Ensure that joint assembly is spigot-into-socket, (not socket-over-spigot) and that the socket mouths always face in the opposite direction to the pipeline insertion direction .

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HORIzONTAL DIRECTIONAL DRILLING / MICRO TUNNELLING /

PIPE REAMING / PIPE BURSTING / SLIP LINING

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3

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2

1

Access pit excavation with support shields / sheet piles (and de-watering if necessary)

2

RESTRAIN™ pipe on site, the seal rings are only applied to the correct groove in the pipe spigot immediately before actual joint assembly

3

Pipe placed into the access pit

4

Typical pipe towing eye connection

5

In-line replacement - pipe reaming head with pressurized, continuous water lubrication

6

Horizontal directional drilling - pipe pulling head setup, with pressurized, continuous water lubrication in clay

PIPE JOINT ASSEMBLY INSTRUCTIONS

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1

Clean the seal ring and groove to remove any dirt or dust. Place the RESTRAIN™ seal ring into the seal ring groove with the “crown” of the seal ring facing outwards.

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2

Lubricate the seal ring outer surface with recommended aerosol lubricant. A single spraying rotation around pipe is normally sufficient.

Do not saturate the joint.

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3

Now lubricate the mouth of the socket where the seal ring will contact.

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4

Align and present the spigot to the socket mouth. Use temporary alignment support blocks.

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6

Engage and hand screw the spigot into the socket mouth, turning the spigot in the clockwise direction.

Continue to hand screw the spigot into the socket mouth as far as it will easily go, or up to near the seal ring

8

Continue to screw up until the seal ring completely disappears into the socket mouth, and the joint firmly resists further tightening. (The spigot end machining mark* on the spigot threaded section is the approximate “witness” mark.

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5

Hand-start and initially hand-turn the clean, lubricated, threaded joint. The initial thread engagement and first

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7

Final rotational tightening with hand

strap wrenches. Apply strap wrenches to both the spigot and the socket; screw up further.

7

ENSURE THE PIPE THREADS

REMAIN COMPLETELY FREE

OF ANY DIRT OR GRIT, AND

ARE UNDAMAGED, BEFORE

BEGINNING SCREw IN ASSEMBLY.

few turns should be smooth and free

of “binding”. Be sure to align the spigot with the socket, before beginning joint assembly, using temporary support blocks, to ensure smooth initial engagement of the threads. Do not cross thread.

*SPIGOT END MACHINING MARK

Spigot end machining mark Seal ring groove

Spigot thread

SERVICE LATERAL CONNECTIONS

1 DN 100 and DN 150 RESTRAIN™ pipes are compatible with standard injection moulded gravity PVC-U fittings, or with widely available fabricated PVC-U gravity sewer fittings.

2 DN 225 and larger size RESTRAIN™ pipes are compatible with widely available fabricated PVC-U gravity sewer fittings. 3 DN 100, quick fit, rubber ring clamp-on

saddle, for 90 Deg angle, vertical service entry to DN 150, 225 and 300 RESTRAIN™ pipe. If leaving the installed pipes ends exposed, protect the threaded spigot or socket ends with temporary caps. Re-file threads if lightly impacted or marked.

RESTRAIN™ PIPELINE THREADED

END PROTECTION

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2

2 Spigot cap 3 End cap in place

Iplex Pipelines is a major Australasian manufacturer and distributor of a wide range of plastics-based pipeline systems for the civil, mining, plumbing, irrigation, gas, telecommunications, and electrical cable conduit markets.

Iplex Pipelines is wholly owned by Crane Group Ltd, the leading Australian manufacturer of non-ferrous metal products and a major supplier to the New Zealand plumbing industry.

Iplex Pipelines is well placed for accessing the latest overseas products, technologies and service initiatives and has become a recognised leader in plastics pipes and associated fittings, together with related water engineering expertise.

Manufacturing and Standards

Iplex Pipelines operates modern manufacturing facilities in New Zealand and every mainland Australian state.

All factories operate under stringent requirements of local equivalents to International Standard ISO 9001. Where applicable Iplex products also have Standards Mark third party quality assurance accreditation.

Sales and marketing teams are strongly supported by advanced technical, communication and distribution systems to ensure prompt and effective service.

Products and Brands

Iplex products and brand names in New Zealand include APOLLO PVC-O pressure pipes, RHINO PVC-M pressure pipes, NOVAKEY PVC-U pressure pipes and fittings, BLUE BRUTE PVC-U pressure pipes, NOVADRAIN DWV pipes and fittings, POLIplex polyethylene pressure pipes, RESTRAIN drillable PVC-U gravity sewer pipe, NEXUS subsoil drainage pipe and fittings and FARMTUFF culvert pipe.

Markets and applications for the Iplex product range in New Zealand include water reticulation and transmission mains, sewerage reticulation and carrier mains, stormwater drainage, trenchless pipe systems, chemical and process water circuits, slurry and tailings pipe systems, drain, waste and vent plumbing, domestic hot and cold water plumbing, subsoil drainage systems, turf watering, stock watering, horticultural irrigation systems and broad acre irrigation systems.

3. IPLEX - The Company

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2

1

1 Socket cap

IPLEX PIPELINES (Nz) LTD RETAIN THE INTELLECTUAL PROPERTY RIGHTS FOR RESTRAIN PIPE. PATENT PENDING.

IMPORTANT DISCLAIMER: THE INFORMATION, OPINIONS, ADVICE AND RECOMMENDATIONS CONTAINED IN THIS PUBLICATION ARE PUT FORwARD wITH THE MAIN OBJECT OF PROVIDING A BETTER UNDERSTANDING OF TECHNICAL MATTERS ASSOCIATED wITH PIPELINE INSTALLATION USING IPLEX PIPELINES. wHILST ALL REASONABLE CARE HAS BEEN MADE IN ENSURING THAT THE INFORMATION CONTAINED IN THIS PUBLICATION IS ACCURATE, THIS PUBLICATION SHOULD NOT BE USED AS THE ONLY SOURCE OF INFORMATION BY THE READER. REFERENCE SHOULD ALSO BE MADE TO ESTABLISHED TEXTBOOKS AND OTHER PUBLISHED MATERIAL, AND READERS SHOULD NOT RELY ON THE INFORMATION CONTAINED IN THIS PUBLICATION wITHOUT TAKING APPROPRIATE PROFESSIONAL ADVICE FOR THEIR PARTICULAR CIRCUMSTANCES. PIPES AND FITTINGS HAVE BEEN SHOwN AS TYPICAL CONFIGURATIONS, HOwEVER, IN SOME CASES PRODUCT DIMENSIONS MAY VARY OR BE CHANGED wITHOUT NOTICE. IN ALL INSTANCES, THE READER SHOULD CONTACT IPLEX PIPELINES FOR CLARIFICATION THAT THE SPECIFIC PRODUCT IS APPROPRIATE FOR THEIR CIRCUMSTANCES. - IPLEX PIPELINES Nz LIMITED.

MAXIMUM TENSILE & COMPRESSIVE LOADS

SEwER / STORMwATER

PIPE SIZE PIPE OD/

mm Pipe Specification Maximum Tensile Load During Installation Load During InstallationMaximum Compressive

DN100 110 AS/NZS 1260 SN16 1,800kg 1,800kg

DN150 160 AS/NZS 1260 SN16 3,500kg 3,000kg

DN225 250 AS/NZS 1260 SN16 9,500kg 9,500kg

DN300 315 AS/NZS 1260 SN16 TBA TBA

CABLE DUCT

PIPE SIZE PIPE OD/

mm Pipe Specification Maximum Tensile Load During Installation Load During InstallationMaximum Compressive

DN100 160 AS 2053 Light Duty 1,800kg 1,800kg

DN150 160 AS 2053 Light Duty 3,500kg 3,000kg

DN225 250 AS 2053 Light Duty 9,500kg 9,500kg

The RESTRAIN™ pipe must be directly axially aligned with the host hole at the point of entry to the host hole. However some curvature back from the host hole entry point is permitted, such as in HDD applications. The minimum radai of curvature (based on 300x the pipe OD) are:

PIPE SIZE MINIMUM RADIUS OF CURVATURE FOR

INSTALLATION

SOCKET OD PIPE OD KG / 6M LENGTH

DN100 33 meters 115mm 110mm 13kg

DN150 48 meters 167mm 160mm 28kg

DN225 75 meters 260mm 250mm 67kg

DO NOT ATTEMPT TO BEND THE RESTRAIN™ PIPE AT THE POINT OF HOST ENTRY

RESTRAIN Pipe systems are tested on site in accordance with the relevant parts of AS / NZS 2566 Part 2, Appendix N “Leakage testing for Non Pressure Pipelines, or AS / NZS 2032 Section 7.3 Testing of Non pressure pipelines

SPECIFICATIONS

Pipe is manufactured in accordance with AS/NZS 1260. PVC pipes and fittings for drain, waste and vent applications.

Elastomeric seal ring complies with Section 3.4 of AS./NZS 1260 • Cl. 3.4.2 - Hydrostatic pressure test in accordance with AS/NZS 1462.10 • Cl. 3.4.3 – Liquid infiltration test in accordance with AS/NZS 1462.8

• Cl. 3.4.4 – Contact width and interface pressure test in accordance with AS/NZS 1462.13

Pipe is OD compatible with either DN 100 (NZ),150 or 225 PVC pipes to manufactured in accordance with AS 2053; 1984. Non-metallic conduits and fittings.

SPECIFICATIONS

BLUELINE & POLIPLEX

POLYETHYLENE PRESSURE PIPE

ALKATHENE™

LOW DENSITY POLYETHYLENE PIPE

NOVATUBE

HORTICULTURAL LATERAL TUBE

GREENLINE, REDLINE™, RURAL BLACK & BLACKLINE

POLYETHYLENE PRESSURE PIPE

PLASSON

METRIC COMPRESSION FITTINGS

NEXUS™FLO, NEXUS™COIL, NOVAFLO™ & NOVACOIL

LAND DRAINGE SYSTEMS

IPLEX EFFLUENT PIPE

MEDIUM DENSITY POLYETHYLENE PIPE

FARMTUFF™ & NEXUS™ CULVERT CULVERT PIPE

POLIGAS™

POLYETHYLENE GAS SYSTEMS

NOVADRAIN & NOVACOR

PVC DRAIN WASTE & VENT SYSTEMS

POLIDRAIN™

POLYETHYLENE DRAINAGE SYSTEM

SUPERSTORM™ & STORMFIT

PVC STORMWATER DUCT SYSTEM

NEXUS™ HI-WAY

ROAD DRAINAGE SYSTEM

TEGRA™

INSPECTION CHAMBER SYSTEMS

NOVAKEY™ & BLUE BRUTE

PVC-U PRESSURE SYSTEMS

WHITE & BLUE RHINO™

HIGH IMPACT PVC-M PRESSURE PIPE

APOLLO™ & APOLLOBLUE™

PVC-O PRESSURE PIPE

Offices At:

Auckland: PO Box 13772, Onehunga, 2 Rockridge Avenue, Penrose. Palmerston North: Private Bag 11019, 67 Malden Street.

Christchurch: PO Box 16225, 22 Braeburn Drive, Sockburn. Iplex Pipelines Nz Limited.

Call Centre -

Phone: 0800 800 262 Fax: 0800 800 804 Web: www.iplex.co.nz

© 2008 IPLEX PIPELINES (NZ) LIMITED. NEXUS™, IPLEX™, RESTRAIN™, APOLLO™, TEGRA™, NOVAFLO™, FARMTUFF™, NOVAKEY™, POLIGAS™, RHINO™, REDLINE™, POLYDRAIN™, SUPERSTORM™ are registered trademarks of IPLEX PIPELINES (NZ) LIMITED.