12/05
3 OpenTrenchInstallationWithSandBed
TableofContents
3.1 ProcedureDescription....................................................................................... 1
3.2 ProductDescription.......................................................................................... 2
3.3 QualityAssuranceforegeplastegelen®Pipes.................................................... 3
3.4 TechnicalInformation........................................................................................ 5
3.4.1 ProductDataSheetforegelen®DrinkingWaterPipes..........................................................................5
3.4.2 ProductDataSheetforegelen®GasPipes..........................................................................................6
3.4.3 ProductDataSheetforegelen®SewagePressurePipes........................................................................7
3.5 InstallationGuidelinesforegeplastegelen®PressurePipes.................................. 8
3.5.1 GeneralInformation.........................................................................................................................8
3.5.2 Installation.......................................................................................................................................8
3.5.3 JoiningTechniques............................................................................................................................8
3.5.4 Accessories......................................................................................................................................8
3.6 RFPForms........................................................................................................ 9
3.6.1 RFPFormforegelen®DrinkingWaterPipe..........................................................................................9
3.6.2 RFPFormforegelen®GasPipe........................................................................................................ 10
3.6.3 RFPFormforegelen®SewagePressurePipe...................................................................................... 11
3.7 RecyclingandEnvironmentalProtection............................................................12
egelen®
12/05
112/05
3 OpenTrenchInstallationWithSandBed
3.1 ProcedureDescription
SurfacenotchingPointloads
Fig3-1
Definedpipelinezonerequired
When installing a pipeline by theopen-trench method, the pipelinezone is precisely defined. The con-structionofthepipelinetrenchissub-ject to a number of regulations, in-cluding DIN 4124 „Excavations andTrenches“, which precisely stipulatesthespecificationsforworkspacewidthandinstallation.Theseensurethatthesoilsurroundingthepipeispreparedinsuchawaythatthepressurisedme-dium-bearing pipe is protected fromexternalinfluences.DINEN805andDVGW Directive W400-2 stipulateembedding the pipe in sand or finegravel.
DVGWWorksheetW400-2stipulatesfor this purpose amaximum particlesizeof22mmforroundmaterialsand11 mm for crushed stone sand andchipmixes.Onlyinthiswaycanpointorlinearloadsonthepipecausedbyunsuitablematerialsinthepipetrenchbeprevented.
212/05
3 OpenTrenchInstallationWithSandBed
3.2 ProductDescription
DrinkingWaterPipes·GasPipes·SewagePressurePipes·IndustrialPipes
Theegeplastegelen®pipeisastand-ardpressurepipemanufacturedfromhigh-densitypolyethylene(PE100,op-tionallyPE80).Inadditiontoitshighdimensionalaccuracy,greatflexibilityandlightweightarethequalitychar-acteristicsofthispipe.
egelen®
egeplastegelen®pipesareproducedin sizes ranging fromOD 16mm toOD1200mm.
egelen®pipesmadeofPE100(orPE80) offer the following technical ad-vantages:
•Longservicelife
•Highflexuralcreepmodulus
•Highnotchedimpactstrength
•Easyweldability
•Highresistancetorapidcrackpropagation
•RAL/DVGWcertifiedquality
In addition to the advantages men-tioned,egelen®pipesmadeofPE100allow:
•Areductioninwallthicknessforanunchanged inside pressure loadcomparedwithPE80,resultinginasavinginpipematerialandahigh-ermediumflowrate
•Alternatively,anincreaseintheop-eratingpressurewiththesamewallthickness
•Alternatively, an increase in thesafetymargin
egeplast egelen® pipes can also besupplied with an extremely resistantprotectivecoatingforusewithtrench-less installation techniques and ren-ovation procedures. Please refer toChapter5“TrenchlessInstallationandRenovation” and Chapter 6 “Detect-ing the installed PipelineandCheck-ing Integrity” for additional informa-tion.
312/05
3 OpenTrenchInstallationWithSandBed
3.3 QualityAssuranceforegeplastegelen®Pipes
Thequalityof thePEpipingproducedis criticallydependent notonlyon therawmaterialsused,butalsoonthetech-niquesutilisedinitsproduction:
MaterialPolyethylene has been continually de-velopedsinceitwasfirstusedasapipematerialin1957.Abalancedpropertyprofileisimportantforapplicationasapipematerial.Awiderangeofmaterialproperties ismonitored so thatapipe
canbemadefromthePErawmaterialthatcansatisfytherequirementsonthebuildingsiteforgasorwatersupplies,andforsewagedisposal.The European standards are differentaccording to application: EN 12201describes drinking water pipes; EN1555,gaspipes;andEN13244,sew-agepipes.Toallowabetterassessmentofthemate-rial,theDVGWhas,inWorksheetGW335,selectedtheparametersassociat-
edwiththequalityofthematerial(Table3-1(=Tab.6fromGW335))andpipes(seeTab.3-2(=Tab.7fromGW335)),andhencewiththeirapprovalforuseintheareasofgasandwatersupply.
WorksheetGW335describes the re-quirements for polyethylene pipingwhich isassumed tobe loaded solelyby internal pressure; i.e. the piping isbedded in sand inanopen trench in-stallation.
Tab3-1
TestingoftheMaterialsPE80andPE100
Property Requirement TestProcedure Frequency
Meltindex asperspecificationsENISO1133:1999ConditionT5kg,190°C10minutes
Min.1xperweekaswellasoneverychangeofmaterialandoneverydimensioncheck
Lossondrying ≤0.1% Infraredmethod percharge
Homogeneity ≤grade3 ISO18553 percharge
Density ≥930kg/m3DINENISO1183-2,DINENISO1872-1
percharge
Colour asperDVGWGW335PartA2 regularly
ResistancetoweatheringasperDVGWGW335PartA2DINEN12201-1DINEN1555-1
BlackasperISO6964,blueandyellowasperDINEN921andfol-lowingDINENISO6259-1
regularly
Thermalstability >20minutesat200C DINEN728 percharge
MicrobiologyasperKTWrecommendationaswellasDVGWGW335PartA2
DVGWW270 approvaltesting
FastcrackgrowthasperDVGWGW335PartA2DINEN12201-1,DINEN1555-1
ISO13477 1xannually
GasresistanceasperDVGWGW335PartA2DINEN12201-1,DINEN1555-1
DVGWGW335PartA2 approvaltesting
HygieneasperKTWrecommendationaswellasDVGWGW335PartA2
DINEN10204 approvaltesting
OdourandtasteasperKTWrecommendationaswellasDVGWGW335PartA2
DINEN10204 percharge
SlowcrackgrowthasperDVGWGW335PartA2DINEN12201-1,DINEN1555-1
NotchtestDINENISO13479 annually
Slowcrackgrowth -FNCTISO1677080C,4N/mm2,2%Arkopal
Notestingrequiredbytheregula-torycodes
egelen®
412/05
3 OpenTrenchInstallationWithSandBed
Productionegeplast is a member of the Quick-Switch partnership. TheQuickSwitchsystem,patentedbyegeplast,allowstheexternaldiameteroftheextrudedpiping to be varied accurately overmultiple dimensions during the run-ningextrusionprocess.Furthermore,itworkswith cooling sections of up to85mlength,whichleadstoextremely
gentlecoolingofthepipe.Onlyinthiswayisitpossibletoguaranteecompli-ancewiththenarrowtolerancesneed-edforelectrofusionweldingofmould-edfittings.Thishasasimilarlypositiveinfluenceontheinternaltensionscreat-edinthepipeduringthemanufactur-ingprocess,andhencealsoitsshrink-age.Amaximumof3%changeafter
warm storage is specified in Work-sheetGW335.Theshrinkageofege-plastpipesliesatca.1%.Adherence to dimensions and toler-ances,described in thecurrentbodyofregulations,isanabsolutemust.Forthis reason, egeplast operates withhundred percent ultrasound monitor-ingoftheproducedpipes.
Tab3-2
AdditionalTestingoftheFinishedPiping
Property Requirement TestProcedure Frequency
LabellingasperDVGWGW335PartA2DINEN12201-2DINEN1555-2
visualinspection regularlyevery2hours
Texture asperDVGWGW335PartA2 visualinspection regularlyevery2hours
Colour asperDVGWGW335PartA2 visualinspection regularlyevery2hours
Warmstorage asperDVGWGW335PartA2 1xperweek
Homogeneity asperDVGWGW335PartA2 visualinspection 1xperweek
Thermalstability >20minutesat200C DINEN728 1xperweek
InternalpressurecreeptestasperDVGWGW335PartA2DINEN12201-2DINEN1555-2
80C,165h;PE80s=4.6N/mm2PE100s=5.5N/mm2
oneverystartatleast1xperweek
Meltindexmax.20%variationfromtherawmaterial
ENISO1133:1999ConditionT5kg,190°C10minutes
oneverychangeandoneverydimensioncheckatleast1xperweek
HygieneasperKTWrecommendationaswellasDVGWGW335PartA2
DVGWW270 1xannually
Slowcrackgrowth -
FNCTISO1677080C,N/mm2,2%Arkopal
-
Pointloadingtest -
HESSELPAPLP2.2-22004-0580C,4N/mm2,2%Arkopal
-
egelen®
512/05
3 OpenTrenchInstallationWithSandBed
3.4 TechnicalInformation
3.4.1 ProductDataSheetforegelen®DrinkingWaterPipes
Dimension: OD16mm–OD1200mm
Pipeconstruction:
PE100:RoyalblueforSDR17andSDR11orblackwithbluestripes
Alt.PE80:BlackwithbluestripesforSDR11andSDR7.4
Material: PE100,alternativelyPE80
Approval: DVGW,KIWA,DS,SVGW,ÖVGW,SIS,DIN-Gost,Belgaqua,WIS,DWI,KIWA-Gas,IGNG,VUSAPL-NITRA,SFS
Standards: DINEN12201,DIN8074/75
Weldinggroup: 003–010
Finish: Withsmoothends
Labelling: Withcolouredmetremarking
Deliveryform: •6,12or20mstraightlengths(uptomax.30m)•Bundledcoilsof100m(uptoOD160/180mm)•Customlengthsonrequest•Largerlengthsondrums
Regulatorycode/installationmethods: DVGWW400-1/2;DINEN805;DIN4124
egelen®
612/05
3 OpenTrenchInstallationWithSandBed
3.4.2 ProductDataSheetforegelen®GasPipes
Dimension: OD16mm–OD1200mm
Pipeconstruction:
PE100:Orange-yellowforSDR17,SDR17.6andSDR11orblackwithorangestripes
Alt.PE80:BlackwithyellowstripesoryellowforSDR17,SDR17.6andSDR11
Material: PE100,alternativelyPE80
Approval: DVGW,KIWA,DS,SVGW,ÖVGW,SIS,DIN-Gost,Belgaqua,WIS,DWI,KIWA-Gas,IGNG,VUSAPL-NITRA,SFS
Standards: DINEN1555;DIN8074/75
Weldinggroup: 003–010
Finish: Withsmoothends
Labelling: Withcolouredmetremarking
Deliveryform: •6,12or20mstraightlengths(uptomax.30m)•Bundledcoilsof100m(uptoOD160/180mm)•Customlengthsonrequest•Largerlengthsondrums
Regulatorycode/installationmethods: DVGWG472;DINEN805;DIN4124
egelen®
712/05
3 OpenTrenchInstallationWithSandBed
3.4.3 ProductDataSheetforegelen®SewagePressurePipes
Dimension: OD16mm–OD1200mm
Pipeconstruction:
PE100:BlackwithbrownstripesforSDR33toSDR7.4
Alt.PE80:BlackwithbrownstripesforSDR33toSDR7.4
Material: PE100,alternativelyPE80
Approval: Theegelen®sewagepressurepipesbeartheDINCertcoDINplusmarkofconformityinaccordancewithZP14.3.1.
Standards: DINEN13244;DIN8074/75
Weldinggroup: 003–010
Finish: Withsmoothends
Labelling: Withcolouredmetremarking
Deliveryform: •6,12or20mstraightlengths(uptomax.30m)•Bundledcoilsof100m(uptoOD160/180mm)•Customlengthsonrequest•Largerlengthsondrums
Regulatorycode/installationmethods: Recommended:byanalogytoDVGWW400-1/2;DINEN805;DIN4124
egelen®
812/05
3 OpenTrenchInstallationWithSandBed
3.5 InstallationGuidelinesforegeplastegelen®PressurePipes
SupplementtotheinstallationinstructionsforPEpressurepipesA135andA435fromtheKunststoffrohrverbande.V.inBonn
3.5.1 GeneralInformation
egeplastegelen®pipesaremanufac-turedaccordingtoENstandardsandDVGWdirectivesandcarry,depend-ing on their application, the DVGWregistrationnumberortheDINCertcomarkofconformity.
ScopeofapplicationThe installation instructions apply tosoil covered egeplast egelen® pipesmade of HDPE in accordance withDIN8074andDIN8075foruseasdrinkingwater and sewage pressurepipelines, and as gas pipelines. Thepipe joints and pipeline componentsmustberatedforusewiththeirrespec-tiveoperatingpressures.
Pipes are to be checked forsound condition and full la-bellinginaccordancewiththe
DVGW regulations before laying inthe pipe trench. Grooves, scratches,andlaminarabrasionsonthepipesofupto10%oftheminimumwallthick-nessarepermissible.Pipeswithdam-ageexceedingthisextentmaynotbeinstalled.
ThestandardsforassessmentofthefillbasearesetbyZTVA-StB97fromtheGermanRoadandTransportationRe-searchAssociationinCologneaswellasbyDIN4022andDIN18196.
Thepipetrenchistobedugoutinac-cordancewithDIN4124(trenchpro-fileandsheeting)andDIN1998(lay-outofpipelines inpublicareas).Theminimum covering for gas pipelinesis 0.6 to 1.0m, although the cover-ingcanbereducedto0.5mforsec-tionsup toca.2.0m longwhichdonotcarryaheavyload(frontgardens,pavements).Drinkingwaterandsew-agepressurepipelinesaretobelaidatadepthof1.0to1.8m(accordingtoclimateandgroundconditions)safefromfrost.Applicabletotheconstruc-tionofwaterconduitsis,furthermore,DVGWWorksheetW400-2.
3.5.2 Installation,OpenTrenchMethodWithaSandBed
3.5.3 JoiningTechniques
Weldability of PE 80/PE 100 pipeswithmouldedfittingsWeldingtogetherofegeplastPE80/PE100pipes,andwithstandardisedmouldedfittings,ispossibleforHDPEusingthe
•Buttfusionweldingmethod•Electrofusionweldingmethod
accordingtotheparametersgivenbytheDVSGuideline2207,Part1,Edi-tion 09/2005. Proof of suitability asrequiredbytheDVSguidelines(weldcreepfactorinaccordancewithDVS2203-4)hasbeenprovided.
FordetailedinformationonjoiningtechniquesseeChapter1.5“TechnicalFundamentals–JoiningTechniques”
3.5.4 Accessories
The market offers a complete rangeof accessories for pipelinesmade ofpolyethylene. Adapters from PE tothevariousmaterialsusedinpipelinenetworks are available frommultiplemanufacturers. In principle, the alter-nativeofcreatingaconnectionusingaflangedjointisalwaysavailable.
Fordetailed informationonmouldedfittingsandadaptersseeChapter1.7„Technical Fundamentals – Connect-ingtotheNetwork“
OpenwithSandBed
egelen®
912/05
3 OpenTrenchInstallationWithSandBed
Preliminarynote:DrinkingwaterpipeinaccordancewithDIN8074/8075,DINEN12201madeofPE100,pipecolourroyalblueorblackwithbluestripes,verifiedinaccord-ancewithDVGWGW335PartA2.Allnecessarypipeline jointscreatedbymeansofeitherelectrofusionweldingorbuttfusionweldingaretobemadeac-cordingtotherequirementsoftheapplicableDVStechnicalguidelines.Thepip-ingistobestoredandtransportedonthebuildingsiteincompliancewiththeKRVguidelines.
Product: egeplastegelen®drinkingwaterpipe PE100orequivalent
Manufacturer: egeplastWernerStrumannGmbH&Co.KG Robert-Bosch-Str.7 D-48268Greven Tel.:+49.2575.9710-0 Fax:+49.2575.9710-110 e-mail:[email protected] http://www.egeplast.de
Specificationofservices: egeplastegelen®drinkingwaterpipewithdimensions:
mm,SDR
Odeliveredasstraightlengthsof6/12m
Odeliveredasbundledcoilsinlengthsofm
DeliverrunningmetresandinstallprofessionallyaccordingtoDINandappropriateinstallationguidelinesas
drinkingwaterpipe:€/runningmetre
3.6.1 RFPFormforegelen®DrinkingWaterPipe
3.6 RFPForms
egelen®
1012/05
3 OpenTrenchInstallationWithSandBed
Preliminarynote:GaspipeinaccordancewithDIN8074/8075,DINEN1555PE100,pipecol-ouryellow-orangeorblackwithyellowstripes,verifiedinaccordancewithDVGWGW335PartA2.Allnecessarypipelinejointscreatedbymeansofeitherelec-trofusionweldingorbuttfusionweldingaretobemadeaccordingtotherequire-mentsoftheapplicableDVStechnicalguidelines.ThepipingistobestoredandtransportedonthebuildingsiteincompliancewiththeKRVguidelines.
3.6.2 RFPFormforegelen®GasPipe
Product: egeplastegelen®gaspipe PE100orequivalent
Manufacturer: egeplastWernerStrumannGmbH&Co.KG Robert-Bosch-Str.7 D-48268Greven Tel.:+49.2575.9710-0 Fax:+49.2575.9710-110 e-mail:[email protected] http://www.egeplast.de
Specificationofservices: egeplastegelen®gaspipewithdimensions:
mm,SDR
Odeliveredasstraightlengthsof6/12m
Odeliveredasbundledcoilsinlengthsofm
Deliverrunningmetresandinstallprofessionally
accordingtoDINandappropriateinstallationguidelinesasgas
pipe:€/runningmetre
egelen®
1112/05
3 OpenTrenchInstallationWithSandBed
Preliminarynote:Sewagepressurepipe inaccordancewithDIN8074/8075,DINEN13244madeofPE100,pipecolourblackwithdarkbrownstripes,verifiedinaccord-ancewithDINCertcoZP14.3.1andlabelledwiththeDINCertcoDINplusmarkofconformity.Allnecessarypipelinejointscreatedbymeansofeitherelectrofu-sionweldingorbuttfusionweldingaretobemadeaccordingtotherequirementsoftheapplicableDVStechnicalguidelines.Thepipingistobestoredandtrans-portedonthebuildingsiteincompliancewiththeKRVguidelines.
3.6.3 RFPFormforegelen®SewagePressurePipe
Product: egeplastegelen®sewagepressurepipe PE100orequivalent
Manufacturer: egeplastWernerStrumannGmbH&Co.KG Robert-Bosch-Str.7 D-48268Greven Tel.:+49.2575.9710-0 Fax:+49.2575.9710-110 e-mail:[email protected] http://www.egeplast.de
Specificationofservices: egeplastegelen®sewagepressurepipewithdimensions:
mm,SDR
Odeliveredasstraightlengthsof6/12m
Odeliveredasbundledcoilsinlengthsofm
Deliverrunningmetresandinstallprofessionally
accordingtoDINandappropriateinstallationguidelinesassew-
agepressurepipe:€/runningmetre
egelen®
1212/05
3 OpenTrenchInstallationWithSandBed
3.7 RecyclingandEnvironmentalProtection
Polyethylene is an organic materialand consists only of carbon and hy-drogen.Ithasawhollyneutralimpactontheenvironment.PE,beingather-moplastic,canberemeltedanalmostunlimited number of times and proc-essedintonewproducts.Pipeoff-cutsand discarded plastic pipe material,which, for example, accumulate dur-ingtheinstallationofplasticpipesys-tems, should thereforebe recycled ifatallpossible.
At thestartof1994, theKunststoffro-hrverband (KRV), together with theGütegemeinschaft Kunststoffrohre(GKR),hadalreadyintroducedana-tionalcollectionandrecyclingsystemforplasticmaterials,which is freeofcharge for the trade and its custom-ersandincorporatesanobligationtotake back these materials. This envi-ronmentally conscious system elimi-natesdumpingorincinerationtogeth-erwiththehighcostswhicharisefromdisposalbythesemethods.
Recycling boxes are provided on aloanbasis to the customeras collec-tioncontainers.Theplasticpipemate-rial,atleastpartiallycleaned,isthenthrown into these boxes. Once theboxes have been filled, their collec-tionandexchangeforemptyboxesisarranged.Onlyboxeswhicharefilledexclusivelywith plastic pipematerialare taken. The recycling boxes arethen brought, via regional collectionpoints, to a recycling plant in whichthecollectedpipematerial is sorted,cleaned,andcut intosmallpiecestobe employed subsequently for otheruses.
Fig3-2 Fig3-3:Recyclingbox
egelen®