TECHNICAL INFORMATION / LAYING INSTRUCTIONSFor pipe systems

Information / Scope 76

Backfilling materials 78

Applications / Type overview 80

Transport and storage 82

Information for laying 84

Pipe connections 85

Retrofitted lateral connections 90

Additional information for installation 94

Information for special laying situations 99

Suggested construction site record 106

Final inspection 107

Static load analysis 109

Hydraulic dimensioning 112

Chemical resistance 116

Other applicable standards 117

Suggested test record 118

Questionnaire for hydraulic dimensioning 120

Questionnaire for static load analysis 121

CONTENTS

75

INFORMATION / SCOPEPipe systems

he following information applies to planning, storing, transport, installation and application of REHAU sewer pipe systems made from unplasticised polyvinyl chloride (PVC-U) and polypropylene (PP). These sewer pipe systems are intended for underground wastewater sewers and lines in property drainage and sewer construction,

which are designed for the safe transport of wastewater, mixed water and stormwater and are normally operated as gravity pipelines (pressure-free).The pipes and parts of pipelines may only be processed and installed by trained specialists.

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Abbreviations, units and conversionsAbbreviations

A Cross-sectional area mm2; m2

B Trench width at soffit mDIN Deutsches Institut für Normung e.V.DN Nom. diameterDN/OD Nom. diameter. external calibration mmDN/ID Nom. diameter. external calibration mmDWV German Association for Water.

Wastewater and WasteDPr Degree of compaction acc. to Proctor % d Medium pipe diameter dn - en

dn Nominal outside diameter di Inside pipe diameter mmEB Deformation modulus of the ground N/mm2

EN European standard ENV European pre-standard EPDM Ethylene propylene diene rubber

(soft sealing material)en Nominal wall thickness mmf Deflection mmg Inherent weight N/mm3

g Gravity acceleration 9.81 m/s2

Hw Groundwater level mhT Partial filling height mm; mISO International Organisation for Standardisation Is Bottom slope %. ‰Ie Energy gradient ‰K Degree of heat Kelvin KK Concrete consistency factor -KGUS Connecting reducer from KG to STZ made of PP and PVC-U kN Kilonewton kNKs Hydraulic resistance coefficient m1/3/skb Roughness value mmMFR Melt flow rate g/10‘NBR Nitrile butadiene rubber. oil-. grease- and petrol-

sealing matNW Nominal width as an identifying feature

compatible pipe parts mm

OD Externally calibrated pipesPEHD High-density polyethylene PEX Crosslinked polyethylene PP PolypropylenePP-QD Polypropylene. containing silicates (Q) in powder form

(D)prEN Provisional European standardPVC Polyvinyl chloridePVC-U Polyvinyl chloride without plasticiserp Load kN/m2

Q Drainage m3/s; l/sQmax Permissible drainage load m3/sQT Drainage with partial filling m3/sQV Drainage with complete filling m3/sq Load as surface load kN/m2

S Series (pipe classification)SDR Standard Dimension Ratio. ratio of

outside diameter to wall thickness -

SN Stiffness nominal. pipe stiffness

STZ Vitrified clay pipe v Medium flow velocity m/svT Medium flow velocity with partial filling m/svv Flow velocity with complete filling m/s

Greek letters Unitα Coefficient of linear expansion mm/m Kβ Slope angle °γR Coefficient of resistance -ΔL Length change mmΔT Temperature difference °C; Kε Elongation (length change per length unit) -σ Tension N/mm2

ф Internal friction angle of natural ground °ψ Discharge coefficient -

UnitsConversion of pressure units

Pa N/mm2 bar m water head WS kN/m2

[N/m2] [MPa]1Pa = 1 10-6 10-5 10-4 0.0011 N/mm2 = 106 1 10 100 10001 bar = 105 0.1 1 10 1001 m WS = 10000 0.01 0.1 1 101 kN/m2 = 1000 0.001 0.01 0.1 1

ConversionsSurfaces and tensions

N/mm2 N/cm2 kN/mm2 kN/cm2 kN/m2 MN/cm2 MN/m2

1 N/mm2 = 1 102 10-3 10-1 103 10-4 11 N/cm2 = 10-2 1 10-3 10-3 10 10-5 10-2

1 kN/mm2 = 103 105 1 102 106 10-1 103

1 kN/cm2 = 10 103 10-2 1 104 10-3 101 kN/m2 = 10-3 10-1 10-6 10-4 1 10-7 10-3

1 MN/cm2 = 104 106 10 103 107 1 104

1 MN/m2 = 1 102 10-3 10-1 103 10-4 11 kp/mm2 = 10 103 10-2 1 104 103 101 kp/cm2 = 10-1 10 10-4 10-2 102 10-5 10-1

1 Mp/cm2 = 102 104 10-1 10 105 10-2 102

1 Mp/m2 = 10-2 1 10-5 10-3 10 10-6 10-2

77

BACKFILLING MATERIALSfor AWADUKT HPP SN16

Permissible backfilling materials for AWADUKT HPP SN16Load-bearing capacity up to SLW 60 (if not otherwise specified), static load analysis is recommended

Backfilling material* actual grain size [mm] AWADUKT HPP SN16(even distribution) DN 110 - DN 200 DN 250 - DN 630

Pipe surrounding 0 - 4Round sand 0 - 4

0 - 8Grit (crushed material) 2 - 4

4 - 88 - 1111 - 1616 - 32

Round gravel/Round gravel mixture 4 - 8 4 - 168 - 1616 - 320 - 160 - 320 - 630 - 75

Mixed gravel (crushed material) 4 - 8 4 - 168 - 1616 - 320 - 160 - 320 - 630 - 75

Levelling ravel (crushed material) 0 - 160 - 320 - 630 - 75

Recycling gravel (crushed material), e.g. recycled concrete and brick 0 - 160 - 320 - 630 - 75

Glass sand, glass sand grit and glass chippings from recycled glass 0 - 8Glass sand grit from recycled glass 0 - 8

4 - 8

* Backfilling materials other than those given in the standard can only be used following approval by REHAU.

Load up to SLW 60, Load up to SLW 60, coverage >/= 1m, Load up to SLW 30, coverage >/= 1m

78

BACKFILLING MATERIALS for AWADUKT PP SN10

Approved backfilling materials for AWADUKT PP SN10 (DIN EN 1610)Load-bearing capacity up to SLW 60 (if not otherwise specified), static load analysis is recommended

Backfilling material* actual grain size [mm] AWADUKT HPP SN10(even distribution) DN 110 - DN 200 DN 250 - DN 800

Pipe surrounding sand 0 - 4Rundsand 0 - 4

0 - 8Grit (crushed material) 2 - 4

4 - 88 - 1111 - 1616 - 32

Round gravel/Round gravel mixture 4 - 8 4 - 168 - 1616 - 320 - 160 - 320 - 40

Mixed gravel (crushed material) 4 - 8 4 - 168 - 1616 - 320 - 160 - 320 - 40

Levelling ravel (crushed material) 0 - 160 - 320 - 40

Recycling gravel (crushed material), e.g. recycled concrete and brick 0 - 160 - 320 - 40

Glass sand, glass sand grit and glass chippings made from recycled glass 0 - 8Glass sand grit from recycled glass 0 - 8

4 - 8

* Backfilling materials other than those given in the standard can only be used following approval by REHAU

suitable

79

APPLICATIONS / OVERVIEW OF TYPESPipe systems

Designation AWADUKT HPP SN16BLUE, OIL PROTECT

AWADUKT PP SN10BLUE, OIL PROTECT, FUSION

AWADUKT PP SN4 AWADUKT PVC SN8classic/blue

Standards/approvals

Relevant standards DIN EN 1852 DIN EN 1852 DIN EN 1852 DIN EN 1401

Data/properties

Load classification Heavy duty Heavy duty Normal load Heavy duty

Ring stiffness to DIN EN ISO 9969 [kN/m2] 16 10 4 8

Ring stiffness to DIN 16961 [kN/m2] - - - ≥ 63

Material PP PP PP PVC-U

Average density [g/cm3] ≥ 0.9 ≥ 0.9 ≈ 0.9 ≈ 1.4

Colour Orange/Blue Orange/Blue Green Red brown/Blue

Available dimensions [DN/OD] 110-630 110-800* 110-400 110-500

Installation length [mm] 1/3/6 1/3/6 1/2/6 1/3/5

Jointing technique Socket coupler Socket coupler Socket coupler Socket coupler

Welding if required Welding if required Welding if required Bonding if required

Range of fittings yes yes yes yes

Transition to otherpipe materials

AWADUKT HPP SN16 Direct Direct Direct Direct

AWADUKT PP SN10 Direct Direct Direct Direct

AWADUKT PP SN4 Direct Direct Direct Direct

AWADUKT PVC SN8 classic/blue Direct Direct Direct Direct

Vitrified clay Adapter Adapter Adapter Adapter

Cast iron pipes (SML) Adapter Adapter Adapter Adapter

Connection to chambers

Concrete chambers Chamber lining Chamber lining Chamber lining Chamber lining

AWASCHACHT DN 315/DN 400 Direct Direct Direct Direct

AWASCHACHT DN 600 Direct Direct Direct Direct

AWASCHACHT PP DN 1000 Direct Direct Direct Direct

* DN 800 only in orange Standard

80

Designation AWADUKT HPP SN16BLUE, OIL PROTECT

AWADUKT PP SN10BLUE, OIL PROTECT, FUSION

AWADUKT PP SN4 AWADUKT PVC SN8classic/blue

Properties

Short-term modulus of elasticity [N/mm2] 1700 1700 1700 3600

Coefficient of linear expansion [1/K] 14x10-5 14x10-5 14x10-5 8x10-5

Thermal conductivity in [W/Km] 0.2 0.2 0.2 0.15

Surface resistance in Ω > 1012 > 1012 > 1012 > 1012

Minimum permissible bending radius for welded joints (20 °C)

30 x d 30 x d 50 x d 300 x d

Hydraulic capacity ++ ++ ++ ++

Possible initial deformation caused by transport, storage and production within REHAU’s responsibility

≤ 2 % ≤ 2 % ≤ 2 % ≤ 2 %

Chemical resistance*** ph 1-13 ph 1-13 ph 1-13 ph 2-12

Impact strength ++ ++ ++ +

Recommended application

Use under traffic loads* up to SLW 60 up to SLW 60 up to SLW 30 up to SLW 60

Covering heights [m]* 0.5-8 0.5-8 1-5 0.5-6

Max. possible groundwater levels above 6 5 2 4

Soffit. without traffic load [m]*

Permitted bedding material to DIN EN 1610or table “Backfilling materials”

to DIN EN 1610up to 22 mm with DN ≤ 200up to 40 mm with DN > 200up to DN ≤ 630

to DIN EN 1610up to 22 mm with DN ≤ 200up to 40 mm with DN > 200up to DN ≤ 630

to DIN EN 1610up to 22 mm with DN ≤ 200up to 40 mm with DN > 200up to DN ≤ 630

Maximum wastewater temperatures [°C]

Permanent load 60 60 60 40

Short-term 90 90 90 60

Usual slope range [‰] 2-200 2-200 2-200 3-80

Recommended maximum flow velocity [m/s] 10 10 10 8

Suitability for high-pressure rinsing ++ ++ ++ +

Possible applications

Road construction ++ ++ + ++

Railway construction + + - +

Airport construction ++ ++ - ++

Tunnel construction ++ ++ O ++

Agricultural drainage ++ ++ + ++

Drainage below bottom plate ++ ++ ++ ++

Regions of mining subsidence + + + O

Swamp soil ++ ++ + O

Oil- and petrol-containing wastewater** ++ ++ + O

Commercial kitchens** ++ ++ + O

Steep gradient drainage ++ ++ O O

Water protection area II and III ++ ++ O O

++ + O - --

Very good Unsuitable

* The information is for guidance purposes only (standardised statics), individual static evidence is required in the case of diVerent conditions

** Use oil/petrol and grease resistant sealing ring

*** The pH values represent a guidance value, the chemical resistance, among other things, also depends on the temperature and type of medium

If you have any queries, please contact our REHAU specialist adviser.

81

TRANSPORT AND STORAGEPipe systems

TransportIn order to ensure that the AWADUKT sewer pipes, fittingsand sealing function properly, they have to be stored properly and transported correctly. Loose pipes should be in contact with the support surface down their entire length and are to be secured against shifting. Deflection and impact stresses are to be prevented.

Bundled AWADUKT sewer pipesSuitable moving equipment should be used for loading and unloading bundled sewer pipes (e.g. fork lifts with wide forks). The forks must not be inserted into the pipes during unloading and transport.

Loose AWADUKT sewer pipes and fittingsLoose sewer pipes and fittings have to be loaded and unloaded manually. Tipping transport equipment or throwing pipes is not permitted.Dragging the pipes over the ground should be avoided. Grooves and scratches can cause leaks in the push-fit joint in particularPipes, fittings and other accessories have to be checked upon delivery to ensure that they are adequately labelled and meet planning requirements. Components must be checked carefully when they are delivered and immediately before they are installed to ensure that they show no signs of damage.

StorageAll materials should be prevent them from contamination or damage. This particularly concerns elastomeric sealing agents, which are to be protected against mechanical and chemical attack (e.g. oil). Pipes are to be secured to to avoid damage by rolling away.

Excessively high stack heights should be avoided to avoid overloading the pipes in the lower section of the

stack. Pipe stacks are not permitted to be created close to open trenches! In cold weather, all pipes should be stored on bases to prevent the pipes becoming frozen to the ground.Pipes have to be stored on a level base.Longitudinal deflections should be avoided. All pipeline components should be stored so that contamination of the socket area is avoided. Unilateral eects of heat, e.g. the sun’s rays can lead to deformation due to the thermoplastic behavi-our of the plastic pipes, which may make it dicult for them to be laid properly where the planning slope is low.For this reason, the pipes should be protected against direct sunlight, e.g. by covering them with light tarpaulins.Heat accumulation must be avoided. Care should be taken to ensure that there is good ventilation. Fading or discolouration caused by storage in the sun has no adverse eect on the quality of PP pipes. Local whitening or brightening on the inside of PP pipes and fittings may indicate external short-term point loads or impact stress. However, these occurrences do not aect the pipes’ stability or service life. Pipes and fittings with inserted seals should however not be stored outdoors for longer than 2 years after the date of production (see lettering). If longer-term outdoor storage is required, the seals should however be checked for perfect condition before the installation. If necessary, the seals should be replaced with new seals.The timber frame crates (packaging for pipe) are to be stacked “wood” on „wood.”

After unloading, the individual lengths are to be stored on a level surface and protected against warpage. In this process, ensure that no sharp, pointed objects damage the lower pipe layer.

82

Securing the pipe stack

The sockets must lie free. Through an alternatingArrangement, it is possible to achieve virtually complete

support for the individual pipe layers arrangement. When stacking with individual wooden supports, these must be at least 80 mm wide. The intermediate and support timbers should be arranged in line with the diagram.

Storage with wooden spacers or with staggered sockets

The pipes stacked in layers without pallets are to be secured to ensure they do not roll apart. The height of this type of pipe stack should not exceed 1 m for all DN.

max. 1 m

Rohrstapel seitlich sichern, max. Höhe 1 m

Secure the pipe stack

ca 0,8 m ca 0,8 mmin. 10 cm 1 - 2 mapp. 0,8 m app. 10 cm 1 - 2 m app. 0,8 m

Secure the pipe stack at the side, max. height 1 m

83

INFORMATION FOR LAYINGPipe systems

General, terms

OD

cb

a

1

2

3

4

5

66

7

89

3

10 13

12

11

Presentation of the termsThese definitions also apply, where relevant, for trenches with sloping walls and for pipes under embankments.

SurfaceLower edge of the road or track construction, where presentTrench wallsMain backfillCoverSide backfillTop bedding layer Lower bedding layerTrench bottomCovering heightThickness of the beddingThickness of the pipe zoneTrench depth

a Thickness of the bottom intermediate bedding layer b Thickness of the top bedding layer c Thickness of the coverOD Outside diameter of the pipe in mm

Lowering pipes into the trenchesFor safety reasons, use suitable equipment and processes to lower the components into the pipe trenches.

Check pipes, pipe components and sealing materials for damage before lowering them into the trenches.

Due to the low weight of pipes having smaller diameters, they are generally lowered into the trenches manually. The pipes must not be thrown into the trench. When using lowering equipment, ensure that the pipes are not damaged. Lay the pipes starting with the lowest point of the pipeline. The pipes should usually be laid so that the sockets point towards the top end.The ends of the pipes should be temporarily sealed when work is interrupted for a long time. Only remove the protective caps just before you make the pipe connection. Pipes should be protected from the ingress of any building materials etc. All foreign objects must be removed from the pipes.

Direction and elevationThe pipes should be laid with precision in accordance with the direction and elevation within the limit values specified by planning. Any necessary adjustments to the elevation has to be made by filling up or removing the bedding, ensuring that the pipes are supported across their entire length. It is recommended to work with short installation lengths ≤ 3 m in very low laying slopes, as the position and elevation can be aligned more easily during every push-fit connection process.

84

PIPE CONNECTIONSPipe systems

Socket coupler connection, trimming pipes

GeneralOnly remove end closures with a protective function immediately prior to connection. The parts of the surface of the pipe that are exposed to the connecting elements should be undamaged and clean.Use suitable materials where the pipes cannot be connected manually. Protect the ends of the pipes, where necessary. The pipes should be connected with the constant application of axial forces, without applying too much stress to the components. Check the accuracy of direction and, if necessary, adjust after connection.The spigot end is to be inserted completely up to the socket base for underground pipes-Where a clearance is specified between the spigot end and the socket of the following pipe, the limit values specified must be complied with(see Uncovered installation Special construction types).

Recesses in the connection areaSocket recesses are to be provided for in the bedding when installing pipes, so that the connection can be made as intended, and the pipe can be protected prior to resting on the connection. The recess should not be larger than necessary to make a professional connection.

Following socket connection, the sockets are to be tamped properly.

Establishing the jointThe pipes should be joined accurately.

Kantholz

Only the factory-fitted sealing rings should be used to seal the pipe connection. Before each insertion process (pipes and fittings), the chamfered plug-in end (spigot end) should be cleaned with a cloth to remove any contamination. To check that the push-fit connection has achieved the maximum insertion depth, the depth of the socket (=insertion depth) should be marked using a suitable pen on the insertion end, where this has not already been done at the factory,

available ex works - to be marked on the socket end using a suitable pin. A sealing ring loosely inserted at the factory should generally be removed prior to the coupling operation. Then the socket, groove chamber and sealing ring should be cleaned of any dirt and potential contamination. The cleaned sealing ring must then be correctly inserted in the cleaned groove chamber again. A factory-fitted sealing inserted in the socket can remain in the socket, however must equally be cleaned of any dirt sticking to the sealing lips, and its correct location has to be ensured.The sealing rings should be checked for any possible damage. Damaged sealing rings must not be used.The chamfered spigot end is to be coated with REHAU lubricant (chamfer and spigot end). Organic or petrochemical or polluting substances must not be used. For underground pipes, the spigot end should then be pushed into the socket coupler up to the base of the socket (i.e. up to the stop). Use the insertion marks placed on the pipe beforehand to check that the maximum insertion depth has been achieved. The pipes should be pushed to together centrically in the direction of the pipe axis and this may be done by hand or over DN 250 pies using levers as shown in the illustration. When using levers, lay a square-shaped timber diagonally in front of the pipe to achieve a better force distribution when pushing the pipes together and prevent pipe damage.

Trimming pipesA fine-toothed saw or a pipe cutter is used to cut the pipes to length. Equipment for woodworking (circular saw, etc.) is also suitable. For cutting PP pipes, we recommend using the special disc cutter from the REHAU product range. The shortened pipe end must be chamfe-red with a file or chamfering tool (e.g. angle grinder with flap disc) according to the table.

Squared timber

85

DN/OD b appr. [mm] DN/OD b appr. [mm]110 7 315 17125 7 400 20160 9 500 23200 10 630 25250 14 710 28

800 32

Fittings must not be trimmed.

Precautions for later connectionsPipe ends or branches, on which subsequent connections will only be made after backfilling, must be fitted with permanently watertight closures and, where necessary, with suitable fixings.

Bending of pipes between push-fit jointsDirectional changes are typically carried out with appropriate fittings or inspection chambers. However, AWADUKT sewer pipes can be bent. Depending on the bending radius „r“, this results in the following max. dimensions „h“ for a pipe length „L“. No bends are permitted in the sockets.Please note that a relatively large force is needed to bend the pipes. The pipes should be protected against recovery until fully backfilled. Securing timbers or similar should be removed prior to complete filling of the trench.

h

L

AWADUKT PVC SN8

h [mm]d rmin L = L = L =

[m] 2 m 5 m 10 m110 33 15 95 380125 37.5 13 83 330160 48 10 65 260200 60 8 52 210

AWADUKT PP SN4

h [mm]d rmin L = L = L =

[m] 2 m 5 m 10 m110 11 46 290 1200125 12.5 40 250 1040160 16 31 200 800200 20 25 150 630250 25 20 125 505315 31 16 100 405400 40 12 78 313

AWADUKT PP SN10 / AWADUKT HPP SN16

h [mm]d rmin L = L = L =

[m] 3 m 6 m 10 m110 11 10 416 1200160 16 70 283 800200 20 56 226 630250 25 45 180 505315 31 36 145 405400 40 28 112 313500 50 22 90 250630 63 17 71 198800 80 14 56 156

86

Connection of AWADUKT PVC/PP pipes to vitrified clay pipes

Vitrified clay socket EN 295, socket coupler Lconnecting system F (DN 100-200)If the vitrified clay pipeline has a socket at the end, then the AWA-DUKT adapter serves as a connecting reducer between the vitrified clay socket and the plastic KGUSM. The seal between the KGUSM connecting piece and the vitrified clay socket is made with a rolling ring or the L seal in the vitrified clay socket. Lubricant is required when using the L seal but not with the rolling ring.

Vitrified clay spigot end (DN 100-300) to EN 295. TKL 160 (normal load)If the vitrified clay pipe ends with a spigot end, then an AWADUKT adapter should be used to connect the vitrified clay spigot end to the plastic KGUS.

KGUS PVC KGUS PP

Universal connection options using AWADUKT FLEX-CONNECTFor joining a wide range of pipe materials and diameters, our universal pipe coupling AWADUKT FLEX-CONNECT is available.. It can be infinitely adjusted within its clamping range to fit a wide range of pipe diameters.Detailed information can be found in chapter “AWADUKT FLEX-CONNECT“.

Welded jointsTo create a longitudinally stable inseparable welded joint of AWADUKT PP sewer pipes, there are essentially two processes:Butt fusion jointing Electrofusion jointing

Welds are to be made by qualified sta. The relevant guidelines, e.g. DVS 2207-11, as well as

the assembly instructions and operating instructions accompa-nying the welding fittings and welding equipment, are to be observed.The machines and equipment used for welding must comply with the specifications of DVS 2208-1.

Prerequisites for weldingThe welding area is to be protected against adverse weather condi-tions e.g. with a heated welding tent. It is recommended that trial welding seams are created and tested at the local conditions encountered on site.If the parts to be welded are heated unevenly because of the sunlight, the temperature is to be compensated by covering of the welding areas in good time. Cooling during the welding process caused by draughts is to be avoided.The connecting surfaces of the parts to be welded must not be damaged and must be free from contamination (e.g. grease, dirt, swarf).

Butt fusion jointing

GeneralDuring butt fusion jointing, the connecting surfacesof the parts to be welded are heated on a heated plate and butt-wel-ded by pushing them together.

Butt fusion jointing

During this process, a welding bead forms on both sides (on the inside and outside of the pipe). In order to avoid a

negative influence on the hydraulic performance, we recommend that the welding bead on the inside of the pipe is removed with suitable equipment.

87

Brief version of the processing instructions toDVS 2207-11 for butt fusion jointing

Note: The entire DVS 2207-11 guideline is to be observed to achieve a professional weld.

- Create the permitted working conditions, e.g. welding tent.- Connect the welding equipment to the network or the AC generator

and check the function.- The parts to be welded should be aligned and clamped, e.g. on

pulley blocks.- The pipe ends should be closed to prevent draughts.- Clean the jointing area beyond the welding with a cleaning agent as

per section 3.2.1 and 3.2.3 DVS 2207-11 with unused, absorbent, lint-free and uncoloured paper.

- The surfaces to be connected should be prepared, for pipes e.g. with a facing tool.

- Remove facing tool from the pipe welding machine.- Remove swarf from the welding area without touching the jointing

areas.- Check plane-parallelism by bringing together the jointing areas.- Check oset (max. 0.1 x wall thickness).- Clean heated plate with a cleaning agent as per section 3.2.1 and- 3.2.2 DVS 2207-11 with unused, absorbent, non-fibrous and

un-coloured paper and allow to evaporate.- Check heated plate temperature (210 ± 10 °C).- Establish movement pressure or movement force prior to every

welding process and document in the welding report.- Determine the settings for the contact, heating up and jointing

pressure.- Determine approximate values as per table 2 (DVS 2207-11).- Move the heated plate into the welding position.- Press the surfaces onto the heated plate until a bead has formed (in

line with table 2, column 2, DVS 2207-11).- Heating up with reduced pressure ≤ 0.01 N/mm2, heating up time

as per table 2, column 3 (DVS 2207-11).- After heating up the jointing areas to be welded, remove them from

the heated plate and move them into a welding position.- The areas to be welded are brought together rapidly just before they

are touching within the conversion time (table 2, column 4, DVS 2207-11). The actual jointing is then to be undertaken very slowly. Immediately following this, the jointing pressure undergoes a linear increase during the increase time (table 2, column 5, DVS 2207-11).

- After joining with pressure 0.10 N/mm2, a bead must have formed. As per fig.3 (DVS 2207-11), the welding bead height K must equal > 0 in every position.

- Cooling down under jointing pressure as in table 2, column 5 (DVS 2207-11).

- Take the welded parts out at the end of the cooling time.- Complete the welding record.

Electrofusion jointing

GeneralWith electrofusion jointing the pipes and fittings are heated and welded by means of resistance wire embedded in the electrofusion coupler.

Electrofusion jointing

The ovality of the pipe must not exceed 1.5 %, maximum 3 mm, of the outside diameter in the welding

area. Appropriate rounding equipment are to be used if necessary. We recommend the use of rotary peeling devices to remove the oxide layer in the welding area.

Brief version of the processing instructions according toDVS 2207-11 for electrofusion jointing

Note: The entire DVS 2207-11 guideline is to be observed to achieve a professional weld.- Create the permitted working conditions, e.g. welding tent.- Connect the welding equipment to the network or the AC generator

and check the function.- Deburr the ends of the pipe separated at right angles on the outside.

Cut the pipe if the end of the pipe dip is too pronounced. See picture 5 (DVS 2207-11).

- Ensure pipe roundness e.g. by means of rounding clamps, permis-sible ovality ≤ 1.5 %‚ max. 3 mm.

- Clean the jointing area beyond the welding with a cleaning agent as per section 3.2.1 and 3.2.3 DVS 2207-11 with unused, absorbent, lint-free and uncoloured paper.

- Process pipe surface in the welding area mechanically, possibly with a rotary peeling device and wall thickness reduction of approx. 0.2 mm.

- Remove swarf without touching the pipe surface.- Clean processed pipe surface - if subsequently contaminated- with

a cleaning agent, according to 3.2.1 and 3.2.3 (DVS 2207-11) with unused, absorbent, lint-free and uncoloured paper and allow to evaporate.

- Inserts the pipes into the fitting and check the insertion depth by marking or using a suitable device. Secure pipes to prevent them from moving.

- Connect the cable to the fitting with weight compensation.

88

- Enter the welding data, e.g. using a barcode reader, check the display on the device and start the welding process.

- Check the correct welding process on the welding equipment, e.g. by checking the display and, if available, the welding indicators. Note error messages.

- Remove the cable from the fitting.- Take the welded parts out of the clamp after the end of the cooling

time according to the manufacturer’s instruction. Remove the used locating devices.

- Complete the welding record, unless automatically recorded.

Articulated pipe jointsREHAU articulated pipe sockets and ball joints enable continuously adjustable bending by ± 7.5°. In this way, e.g. the chamber connec-tions can be flexibly adjusted to the local conditions on site. If a pipe is crossing, for example, the chamber can simply be moved by a few metres thanks to the movable connection. The bend is incorporated in the articulated socket or ball joint. Even changes in gradient can be overcome without any problems. In particular on long sewer pipe sections, which are installed with large radii, the fittingsallowing bending between 0 – 15° are innovative, self-contained connection elements. These are ideal not least for areas in danger of subsidence. If ground settlements occur, they are mainly absorbed by the articulated pipe sockets. The connection continues to be free from stresses and is therefore permanently root-resistant and watertight.Please note the sot and flow direction markings.When installing the articulated sockets, however, ensure that the bending in the socket is made as evenly on both sides as possible.

Equal bending in the articulated socket on both sides

Articulated socket DN 250 and DN 315 Ball joint DN 160 and DN 200

α

β φ

α

Correct

Incorrect

89

RETROFITTED LATERAL CONNECTIONSto plastic pipes and chambers

Connection through the branchThe branch should be installed at an appropriate angle to receive the incoming pipe. If a branch has to be inserted into an existing pipe, it may be necessary, depending on the material, length and the type of branch and bedding, to temporarily interrupt the operation of one or several pipes or remove them. To maintain the cohesion of the pipeline, only the necessary pipe lengths should be removed for inserting the branch in the pipeline. Implementation may also require the installation of a short pipe section in addition to the branch. Irrespective of whether or not push-fit connections or sleeve couplers are used, they must be suitable for the pipeline to ensure the exact location and position and enable a functioning seal. For the subse-quent installation of AWADUKT branches, a pipe section (installation length of the fitting plus around twice the outside pipe diameter) must be removed.The pipe ends are deburred and chamfered and the branch is pushed on. An AWADUKT sleeve coupler KGU is pushed onto the second end of the pipe and onto the infill section to be inserted and the pipeline is closed. Under construction site conditions, greater frictional forces can arise in dimensions > DN/OD 250 when the sleeve couplers are pushed on, which make installation dicult. The use of tools, e.g. levers and ropes is required for this. At the same time, take care that the sleeve couplers are pushed on evenly and centrally. Do not install the sleeve couplers using any impact.

AWADOCK POLYMER CONNECTThe AWADOCK POLYMER CONNECT is suitable for connecting plastic pipes DN/OD 160 or DN/OD 200 onto plain-ended polymer pipes made from PP, PE, PVC and GRP. The screw crown has an integrated ball joint that permits infinite bending of ± 7.5°. This reduces shear forces, such as those due to settlement, to a minimum. The large volume connection seal contains an additional, swellable elastomer seal just to be on the safe side.The connection saddle made of polypropylene is particularly impact-resistant and resistant to aggressive wastewater. The internal marking makes it possible to identify the connecti-on during inspection with a camera. The connection of a connecting pipe with the AWADOCK POLYMER.CONNECT is more ecient than conventional variants with a branch and sleeve couplers. The connection can be made during a new installation or also at a later stage with a drill bit. Please see the chapter “Connection systems” for details about the possible main pipes.

90

AWADOCK T-FlexAWADOCK T-Flex is used to connect dierent types of pipes to main pipes with a smooth outer surface.

- Suitable for main pipe DN/OD 200 to DN/OD 500- Connection DN/OD 110, 160, 200

The seal is made via the outer wall of the main pipe, by means of a stainless steel sleeve and an EPDM seal. With the AWADOCK T-Flex connection system, it is possible to cover large borehole distances, i.e. standard drill bits can be used. AWADOCK T-Flex can be used universally. It fits all smooth and thin-walled pipes (incl. PP, PVC, fibre cement, cast iron, GRP, etc.).

DN/OD Outside dia. Outside dia. Core hole[mm] [mm]Connecting pipe Main pipe [mm]

110 105-120 200-400 117-125160 150-170 250-500 167-175200 175-200 300-500 203-213

Connection with saddle piecesThe weld-on sewage saddle made of polypropylene connects sewer pipes DN/OD 160 to AWADUKT PP SN10 and AWADUKT HPP SN16 pipes DN/OD 200 up to DN 500.

The sewer saddle is firmly fastened on the pipe using a special clamping device.

All universal welding devices with reader pen for barcode recognition, temperature compensation, log memory and 4 mm connector can be used. Installation and welding of the sewer saddle have to be carried out by a skilled worker having passed the plastic welder‘s qualification test according to DVS2207-11.

After the end of the cooldown time, the connection should be opened using the special REHAU milling drill.

The connection between the connecting pipe and the saddle is established with a suitable electrofusion socket (connecting pipe AWADUKT PP SN10/HPP SN16) or a double socket coupler (connec-ting pipes made of smooth plastic pipes DN/OD 160).

Detailed information for the installation can be found in the assembly instructions for weld-on saddles on the REHAU homepage www.rehau.de

91

Connection of AWADUKT pipes to concrete chambers and concrete structures AWADUKT pipes are connected to concrete chambers using AWA-DUKT chamber liners KGF and AWADUKT combination chamber liner.

The chamber liners must be set in concrete in such a way that the bases of the connected pipe and drainage channel are level. During this process, the pipe wall thickness varies depending on the material, ring stiness and diameter.The position of the seals has to be ensured at the distance to the spigot end stipulated in the standards in direction of the pipe’s axis. This insertion depth can be reduced thanks to the special construction type for the AWADUKT combination chamber liner with DiBT certification. The insertion depth is defined with the stop in the chamber liner. The chamber liner is to be set in concrete in such a way that the connecting pipes can be inserted to the required depth without colliding with the drainage channel. The same shaft liners can be used for AWADUKT PVC and AWADUKT PP.However when connecting channels or in the subsequent fitting of chamber liners, it should be noted that the inside diameter of the various types of pipe diers. The height of the channel should therefore be adjusted to the particular type of pipe.

Amin

Schacht-

futter (KGF)

Gerinne

Abwinkelungs-

möglichkeit

AWADUKT-

Rohr

DN/OD Amin [mm]to DIN EN 1852-1

110 40125 43160 50200 58250 68315 81400 98500 118630 144

Dimensions of the chamber lining for AWADUKT PVC/PP

Install d Outside dia. Inside dia.[mm] [mm] [mm] [mm]

DN/OD L Dmax di

110 110 110 130.8 114.7110 240 110 138.8 121.8125 110 125 147.5 129.8125 240 125 153.5 136.7160 110 160 184.2 164.4160 240 160 190.0 171.5200 110 200 226.0 204.4200 240 200 231.5 211.4250* 150 250 345.0 235.0315* 150 315 410.0 296.0400* 150 400 495.0 378.0500** 150 500 595.0 466.0630** 150 630 710.0 586.0800 240 800 848.0 809.0

* Chamber lining of dimensions DN 250 to DN 400 are made from polypropylene

** Chamber lining of dimensions DN 500 to DN 630 are made from polyurethane

DN 110 – 200

DN 250 – 400

DN 500 – 630

pipe

Chamber lining (KGF)

Drainage channel

Bending option

92

di

Dmax

L

3°

Applicable to chamber lining of dimensions DN 110 to DN 200

Applicable to chamber lining of dimensions DN 250 to DN 6300

Supporting and anchoring If there is a risk of flooding and buoying upwards during the laying of, the pipes need to be secured through suitable extra loads or stabilised by anchoring.

These forces can reach a considerable magnitude. In the case of gravity drainage pipelines, it may be

necessary to secure fittings temporarily during the water-tight-ness test. Additional forces that can arise in pipes in steep gradients should be taken into account in the design, e.g. by forming a concrete casing or safety catch simultaneously acting as protection against washing out or the draining eect of the bedding (see chapter sloped trenches). Soil analyses should be carried out, where necessary.

93

ADDITIONAL INFORMATION FOR LAYINGPipe systems

Components and building materials

Standards/approvalsComponents and building materials should meet national/European standard or approvals. Where standards and approvals are not available, components and building materials must meet the require-ments of the planner.

B

a) im Graben b) in Dammschüttungen

*) Auflagewinkel 2α

**) Mindestdicke des Auflagers entsprechend Punkt 7

Einbettung

Leitungsz

one

Auflager

C C

d1 1,5 d1 d1 1,5 d1

**) **)

*) *)

Grabensohle

Construction materials for the pipe zone

GeneralMaterials in the pipe zone must comply with the relevant sub-sections “Components and building materials” to ensure permanent stability and the load-bearing capacity of the pipe in the ground. These materials should not restrict the pipe, the pipe material or the groundwater. Frozen material must not be used. Building materials for the pipe zone must meet the planning requirements. These materials should either be in-situ soil, whose suitability for use has been tested, or supplied building materials. Materials for the bedding should not contain any components larger than:- 22 mm for DN/OD ≤ 200- 40 mm for DN/OD > 200 to DN/OD ≤ 630For information about AWADUKT HPP SN16 beyond this, see table ”Backfilling materials“.

In-situ soil- Requirements for the in-situ soil to be reused are:- Meeting the design requirements- Compactable, if specified- Free from all materials likely to damage the pipe (e.g. “oversized

particles” - depending on the pipe material, wall thickness and diameter, tree roots, waste, organic material, lumps of clay > 75 mm, snow and ice).

Supplied building materialsThe materials listed below are suitable. These can also be recycled materials. Granular, non-bonded materials include:- single-grain gravel- material with graded grain size- sand- granular mixtures (all-in)- crushed materials- liquid soil

Hydraulically bonded materialsHydraulically bonded materials include:- stabilised ground- lightweight concrete- lean concrete- unreinforced concrete- reinforced concrete- liquid soilThese must meet the planning requirements.

Other building materialsBuilding materials other than those mentioned in the “Building materials” section can be used for the pipe zone if their suitability has been properly tested. Natural or artificial materials that may damage the pipe and chambers are not suitable. Eects on the environment should be investigated

Building materials for the main backfillBuilding materials for the main backfill must meet the planning requirements. All building materials specified in the “Building materials” section the pipe zone, may be used for the main backfill.Excavated material containing stones up to a maximum grain size of 300 mm or the thickness of the cover or equal to half of the thickness of the layer to be compacted, whichever is the lower, can be used for the main backfill. This value can also be reduced further depending on the ground conditions, the groundwater and the pipe material. Special conditions can be stipulated for rocky ground.

Creating the pipe trench

TrenchesTrenches are to be sized and designed in such a way that aprofessional and safe installation of the pipes is assured.If during the building works, access is required to the outer wall of structures lying underground, e.g. chambers, a safe minimum working space of 0.5 m in width is to be maintained.If two or more pipes are to be laid in the same trench or under the same embankment, the minimum horizontal working space for the

b) in embankmentsa) in the trench

Bedding

Pipe

zon

e

Minimum thickness of bedding (Aufl) acc.to p. 7

Trench bottom Auf

Bedding angle 2a

94

area between the pipes has to be maintained. Where nothing is given to the contrary, 0.35 m is to be observed for pipes up to and including DN/OD 710 and 0.50 m for pipes larger than DN/OD 710. Where necessary, suitable safety measures should be taken to protect other utility and wastewater pipes and channels, building structures or the surfaces against impairment.

Trench widthGreatest trench widthThe width of the trench should not exceed the greatest width according to the static survey. The planner should be presented with the circumstances if this is not possible.

Minimum trench widthTake the minimum width from the following tables, based on the trench depth or DN/OD. The greater of these two values is decisive.

Minimum trench width acc. to DIN 4124/EN 1610 depending on the nominal width DN/OD

DN/OD Minimum trench width (OD + x) msheetedtrench

non-sheeted trenchß > 60° ß ≤ 60°

≤ 200 OD + 0.40 OD + 0.40≥ 250 to 315 OD + 0.50 OD + 0.50 OD + 0.40≥ 400 to 710 OD + 0.70 OD + 0.70 OD + 0.40≥ 800 OD + 0.85 OD + 0.85 OD + 0.40

For the details OD + x corresponds to x/2 the minimum space between the pipe and the trench wall or the trench sheeting.Here OD is the outside diameter in m and ß the slope angle of the non-sheeted trench.

β

Minimum trench width based on the depth the trench

Trench depth m Minimum trench width m

< 1.00 no minimum trench width specified≥ 1.00 to ≤ 1.75 0.80> 1.75 to ≤ 4.00 0.90

> 4.00 1.00

Exceptions to the minimum trench widthThe minimum trench width may be changed under the following conditions:- If personnel never enter the trench, e.g. where automated installa-

tion techniques are used- If personnel never enter the space between the pipe and the trench

wall- At narrow points or in avoidable situations.In each case, special precautions are required in planning and for carrying out the building work.

Stability of the trenchStability of the trench should be achieved either by means of a suitable sheeting or by embankment or other appropriate measures. The trench sheeting should, in compliance with the static load analysis, be removed in such a way that the pipe is neither damaged nor its position changed.

Trench bottomThe slope and material of the trench bottom must correspond to the definitions in the planning requirements. The bottom of the trench should not be disturbed. If it has been disturbed, appropriate measures should be taken to achieve the original load-bearing capacity again.Where pipes are laid on the trench bottom, it must be prepared in accordance with the required slope and the shape to permit the pipe shaft to rest on the bottom. Depressions for pipe sockets must be created as appropriate in the lower bedding layer or in the trench bottom and tamped again correctly once the pipes have been connected. In the case of frost, it may be necessary to protect the trench bottom so that frozen layers do not remain underneath or around the pipeline. Where the trench bottom is unstable or the soil does not have sucient load-bearing capacity, suitable precautions should be taken (see pipeline zone and sheeting).

95

Calculated trench widthThe statically eective calculated trench width is the interval between the trench walls at the level of the sot. Where the trench or trenches are lined, the calculated trench width is therefore equal to the clear width of the trench plus the thickness of the trench sheeting. The minimum values of the clear width of the trench are set out in the relevant standard (DIN 4124/DIN EN 1610)

B

H

d

b = 90°

α

B

H

d

*) Auflagerwinkel 2α

Pipe zone and sheeting

GeneralBuilding materials, bedding, sheeting and layer thickness of the pipe zone have to meet the planning requirements. Building materials should be selected according to the section “Components and building materials”. Building materials for the pipe zone as well as their grain size and any sheeting are to be selected, taking into account- the pipe diameter- the pipe material and the thickness of the pipe wall- and the soil properties.The width of the bedding therefore has to agree with the width of the trench, provided nothing is stipulated to the contrary. With pipes under embankments the width of the bedding must correspond to four times the outside diameter, provided nothing is stipulated to the contrary. Minimum values for the thickness of the cover (c) are 150 mm above the pipe shaft and 100 mm above the socket connection. Soft subsoil available on site of diering thickness beneath the bottom of the trench should be removed and replaced with suitable material for the bedding. A further static load analysis may be required where larger quantities are found.

Construction and beddingBedding type 1 to DIN EN 16100Type 1 may be used for every pipe zone that enables the pipes to be supported across their entire length and is created taking the required layer thicknesses a and b into account. Where nothing is stipulated to the contrary, the thickness of the lower bedding layer a, measured beneath the pipe shaft, should not exceed the following values:- 100 mm in normal soil conditions- 150 mm on rocks or solid ground.The thickness b of the top layer of bedding must match the static load analysis.

*) Auflagerwinkel 2α

bc

OD

a

Minimum dimensions bmin (mm)

DN/OD Bedding angle (2a)60° 90° 120°

110 10 20 30125 10 20 30160 15 25 40200 15 30 50250 20 40 65315 25 50 80400 30 60 100500 35 75 125630 40 90 150800 55 120 200

Bedding type 2 to DIN EN 1610Bedding type 2 may be used in an even, relatively loose, fine-grained soil, which enables the pipes to be supported across their entire length. Pipes may be installed directly on the pre-formed and prepared trench bottom. The thickness b of the top layer of bedding must match the static load analysis.

b OD

*) Bedding angle 2a

96

Bedding type 3 to DIN EN 1610Bedding type 3 may be used in an even, relatively fine-grained but good bearing soil, which enables the pipes to be supported across their entire length. Pipes may be installed directly on the prepared trench bottom. The thickness b of the top layer of bedding must match the static load analysis.

b

OD

Special designs of bedding or load supporting structuresIf the trench base only has little bearing capacity for the pipe bedding, or major settlement or settlement dierences are to be expected, special precautions have to be put in place.This is likely to occur in unstable soils, such as peat or quicksand. Special measures can include soil replacement, soil stabilisation or supporting the pipeline on piled structures or load-bearing longitudinal beams. In any case, it is to be ensured that the pipes are laterally supported. If supported on rigid longitudinal bars, a bedding layer between the fixed reinforced steel beams and pipe is to be installed as

a “damping layer” i.e. the pipe is to be completely encased in concrete or insulation.Please contact our technical applications department for detailed information.

BackfillingSide backfill and main backfill may only be carried out if the pipe connections and bedding are able to take the loads. The creation of the pipe zone and the main backfill as well as the removal of the sheeting should be designed so that the load-bearing capacity of the pipes meets the planning specifications.

CompactionThe degree of compaction has to correspond to the information in the static load analysis for the pipe. The required degree of compaction can be verified by measurement (e.g. by means of a load plate test). Compaction of the covering directly above the pipe should be carried out by hand or with lightweight compaction equipment, where required. The mechanical compaction of the main backfill directly above the pipe should only start once a layer with a minimum thickness of 300 mm has been placed over the sot of the pipe. The selection of compaction equipment, the number of compaction passages and the thickness of the layer to be compacted should be adapted to the material to be compacted and the pipe that is going to be installed. Compacting the main or side backfill by washing-in is only permitted in exceptional cases, and then only for suitable, non-cohesive soil.

Ground compaction, fill height and the number of junctions

Compaction categoryService V1 V2 V3weight Suit- Fill Nbr Suit- Fill Nbr. Suit- Fill Nbr.

Type of equipment [kg] ability height cm junct. ability height cm junct. ability height cm junct.1. Lightweight compaction equipment (principally for pipe zone)Vibratory rammer light -25 + -15 2-4 + -15 2-4 + -10 2-4

medium 25-60 + 20-40 2-4 + 15-30 3-4 + 10-30 2-4Frog rammer light -100 O 20-30 3-4 + 15-25 3-5 + 20-30 3-5Vibratory plates light -100 + -20 3-5 O -15 4-6 - - -

medium 100-300 + 20-30 3-5 O 15-25 4-6 - - -Vibration rollers light -600 + 20-30 4-6 O 15-25 5-6 - - -22. Average and heavy compaction equipment (above the pipe zone)Vibratory rammer medium 25-60 + 20-40 2-4 + 15-20 2-4 + 10-30 2-4

heavy 60-200 + 40-50 2-4 + 20-40 2-4 + 20-30 2-4Frog rammer medium 100-500 O 20-30 3-4 + 25-35 3-4 + 20-30 3-5

heavy 500 O 30-50 3-4 + 30-50 3-4 + 30-40 3-5Vibratory plates medium 300-750 + 30-50 3-5 O 20-40 4-5 - - -

heavy 750 + 40-70 3-5 O 30-50 4-5 - - -Vibration rollers heavy 600-8000 + 20-50 4-6 + 20-40 5-6 - - -

+ recommended V1 = non-cohesive or low-cohesion soil types (e.g. sand and gravel)

O mostly unsuitable V2 = cohesive, mixed grain soil (gravel and sand with higher clay and rubble content)

- unsuitable V3 = cohesive, fine-grained soil (clays and coarse silts)

V3 soils above the pipe zone can be compacted e.g. with so-called pad foot drum rollers. Please see the permissible fill heights in the compact-ing equipment manufacturer’s information.

97

Construction of the pipe zoneThe pipe zone should be designed in such a way that ingress of in-situ soil or the displacement of material from the pipe zone into the in-situ soil is prevented. Under certain circumstances, the use of geotextiles or filter gravel may be required to secure the pipe zone, in particular in the groundwater area. Suitable measures should be taken where flowing groundwater is able to transport fine soil components or where the groundwater level falls.Bedding, side backfill and cover are designed in accordance with the planning requirements.

The pipe zone should be protected against foreseeable damaging change to its load-bearing capacity, stability or position that could be caused by:- eects of groundwater- other adjacent earthworks- removal of the sheeting.If parts of the pipeline have to be anchored or reinforced, this should be carried out prior to installation of the pipe zone.Particular care should be taken prior to installation of the pipe zone that:- the direction and elevation of the pipe should not be changed- the top bedding layer is to be carefully installed to ensure that all

spaces under the pipe are filled with compacted material.

Carrying out the main backfillThe main backfill is be carried out in accordance with the planning requirements to prevent surface settlement. Particular care should be taken when removing the sheeting.

Removing the sheetingThe sheeting should be removed gradually while the pipe zone is being created.

Removing the sheeting from the pipe zone or the areas beneath after the main backfill has been installed can

have serious consequences for the bearing capacity, direction and elevation due to the formation of voids and loose ground.

Special measures are required where it is not possible to remove the sheeting prior to completing the backfilling, e.g. sheet pilling, sheeting systems, e.g.- Special static load analysis; parts of the sheeting remain in the

ground- Special selection of building material for the pipe zone

Restoring the surfaceAfter backfilling is completed, the surfaces are to be restored as required.

98

INFORMATION FOR SPECIAL LAYING SITUATIONSPipe systems

Slope sectionsIt may become necessary in the case of a downward thrust risk to secure the pipeline depending on geology, slope, compaction etc. Concrete bars have proven eective as a protection against shearing. The number of concrete bars and the design depend upon the slope of the pipe and the nature of the soil. If installed across the entire width of the trench, the concrete bars prevent the groundwater from flowing along the backfilled trench and therefore largely prevent fine material from being flushed out of the pipe backfilling.In order to prevent shear forces on the pipes and penetration of concrete into the socket coupler connection, relevant measures are required, such as covering the pipes with a 5-6 mm thick nonwoven.

Baugrubenauüllung

Betonabstützung

Vlies

gewachsener

BodenRohrumhüllung

(gut verdichten)

Shear protection made of concrete

Conventional steep section drainage

and with energy

conversion chambers

Possible slope water arising must be diverted away through drainage.

Trench drainageThe pipe-supporting surface must be free from water for problem-free pipe laying and expert compaction in the pipe zone. This can also be achieved by means of seeping water drain packing or drainage pipes or by dewatering. If no permanent drainage is required or intended, the drainage pipe is to be closed gradually depending on the progress of construction.A permanent drainage eect by the seeping water drain packing can be eliminated by using a sealing course in the pipe trench made from cohesive material.

Laying in groundwaterWhere there is insucient superimposed load, pipes laid in the groundwater should be secured against buoyancy by anchoring or by extra loading (e.g. concrete). We recommend that a static load analysis be arranged due to the occurrence of increased buckling pressure with groundwater.

DrainageTrenches are to be kept free from water, e.g. stormwater, percolating water, spring water or water from leaks. The type and manner of drainage should not aect the pipe zone and the pipe. Precautions should be taken to ensure that fine material does not migrate during dewatering. Wrapping the pipe sheathing with nonwovens eciently prevents the fine particles from being flushed out.The eect of drainage measures on the movement of the groundwater and the stability of the surrounding area are to be taken into account. On completion of the dewatering measures, any construction drains shall be adequately sealed.

Concrete casingA concrete casing can increase the load-bearing capacity of the pipeline. The dimensions of this casing are important depending on whether the concrete is being used to protect against natural ground or against sheet piling, for example.Pulling the sheet piling will reduce the load releasing eect of the horizontal earth pressure. With concrete casings care should be taken that the casing has to be designed as the sole supporting structure without any involvement by the pipe and therefore only a complete casing must be considered. The minimum wall thickness of the concrete casing is to be determined based on the structural require-ments. Before concreting, the socket gap should be sealed with a PVC/PP compatible adhesive tape to prevent the ingress of cement mortar. In order to prevent shear forces at the entry or exit of the pipelines into or out of the concrete, relevant measures are

Non-woven

naturalgroundPipe backfilling

(compact well)

Excavation pit backfill

Concrete support

99

required such as covering the pipeline in this area with a 5-6mm thick non-woven, e.g. RAUMAT E or similar (see sketch). A concrete of at least C 8/10 should be used as a concrete casing. The pipeline is to be secured, where necessary, from buoyancy upwards up into the fresh concrete. The pipe should be filled with water to better absorb the setting temperature of the concrete and minimise the buoyancy force. Construction joints can be secured by means of short reinforc-ing bars. It may be advisable to divide the concrete casing at suitable intervals on the pipe connections by means of transverse joints. Reinforcement can be provided where necessary, in which case concrete of at least C12/15 or C16/20 should be used, however.If the pipes are to be completely encased in concrete, they also have to be secured against buoyancy. The increased hydrostatic pressure during concreting is to be taken into account. A leakage test is to be carried out to DIN EN 1610 prior to concreting.

Example of a construction with full concrete casing

30°

¼ DN/OD mm,

min. 100 mm

¼ DN/OD mm,

min. 100 mm

Betonummantelung Vliesummantelung

ca. 30 cm ca. 30 cm

ca. 60 cm

Minimum (safety) distances from buildings and other pipelinesThe minimum distances are to be determined taking to the following objectives into consideration:- No inadmissible transfer of force- No inadmissible eect of temperature, e.g. through district heat

pipes or high-voltage cables- Sucient workspace for the construction of pipelines and

maintenance- Clearance distance to avoid any dangerous proximities between

pipes and cables- Eective electrical separation between metal conductors with

respect to cathodic corrosion protection and against parasitic voltage

- No influence through wastewater or other harmful substances

Distance from structuresThe horizontal clear distance of 0.4 m to foundations and similar underground facilities should not be exceeded.The vertical distance from foundations should be ≥ 15 cm (comment on DIN 1986.

Distance from pipes and cablesFor (lateral) proximities or parallel guidance with other pipes or cables, a minimum distance of 0.4 m must be observed.A distance of 0.2 m should be maintained in narrow spaces. If the distance falls below this limit value for technical reasons, direct contact should be avoided by means of suitable measures that are to be agreed between the operators.(Source DVGW). Crossing pipes and cablesA distance of 0.2 m should be maintained where pipes and cables cross. Where this is not possible, contact should be prevented, e.g. by means of an intervening layer of non-conductive trays or plates. The transmission of power is to be eliminated. Special measures are to be agreed between the operators.

Distance between drinking water and drainage pipesThe drinking water pipes should be positioned higher than the drainage pipe. If the drinking water pipe lies at the same level or lower than the parallel drainage pipe, the minimum distance of 1 m should not fall below this value, except in the case of constraining points.

Overground pipelines, pipe bridges, pipelines on bridgesPipe bridges can be the most economical solution for intersections. In individual cases such as torrents or deep gorges, they are the only appropriate crossing type.Lower costs are incurred when the pipeline can be attached to existing bridges. When building new bridges it is recommended that an early agreement be reached regarding the joint use.Pipelines on bridges are to be designed in such a way that additional impact, e.g. vibrations because of trac and changes in length caused by the eect of temperature, can be absorbed. PP and PVC pipes can bridge small spans unsupported. Special structures are to be provided for greater spans. If settlement is likely, statically

Concrete casing Non-woven covering

approx. 30 cm approx. 30 cm

approx. 60 cm

100

determined structures are advisable.Pipes should be protected against all damaging environmental influences.Pipelines on bridges with low throughput should be protected from freezing.When laying pipes over ground (e.g. tunnel, bridges) the pipeline should be secured with pipe clamps based on the below-mentioned spacing. The pipe clamps are to be arranged in such a way that each pipe connection is supported to avoid inadmissible deflection, which is possible because of the gap in the pipe connection. Equally, all fittings are to be supported accordingly.Because of fluctuations in temperature to which exposed pipelines are subject, fixing-point clamps have to be fitted behind each socket coupler. Every double socket coupler (e.g. with AWADUKT PP SN10) is to be set as a fixed point. Equally, loose clamps have to be used to compensate for the elongation in the sockets. A loose clamp is required for each 1 m of installation length, e.g. BL = 3 m: 2 loose clamps + 1 fixed point. Installation lengths of up to a max. of 3 m should be used. The clamps should be attached at as uniform an interval as possible and a loose clamp should be attached as close to the socket of the next pipe as possible. The pipe is to be pushed up to the base of the socket and pulled back by approx. 20 mm. We recommend to use a lubricant based on silicone in order to ensure a

long-term unrestricted sliding eect.As a result of the shearing forces that can arise with changes in direction as a result of the medium flowing through the pipe (e.g. elbow, branches), these parts of the pipeline are to be adequately supported. Clamps with soft inserts, e.g. rubber should be used. Minimum clamp width 60 mm.These details relate to 20°C. For higher operating temperatures, the distances between the pipe supports should be shortened by installing additional clamps.Please contact our technical applications department if you have any questions about special fields of application.

Linear expansion in the case of temperature fluctuationsThe length change of AWADUKT components caused by temperature fluctuations is significantly greater than for metallic and ceramic components. The following are to be borne in mind when calculating the length change:1. The temperature prevalent during installation2. The anticipated lowest and highest pipe wall temperature when

operating the facility The length change (mm) is equal to: pipe length (m) x temperature dierence x coecient of expansion.

Calculation example for length change of AWADUKT PVC pipes

∆l = L · ∆T · 0.08 mm/mKCalculation example:Pipe length: 3 mLaying temperature: + 10 °C

The lowest expected pipe wall temperature: + 5 °C=> Temperature difference 5 K

The highest expected pipe wall temperature: + 20 °C=> Temperature difference 10 K

The greatest expected shortening:∆l1 = 3 m x 5K x 0,08 mm/mK = 1.2 mm

The greatest expected extension:∆l2 = 3 m x 10K x 0,08 mm/mK = 2.4 mm

For example:If the pipe wall temperature changes by 30 K, a 3 m long pipe is shortened or extended by ∆l = 7.2 mm.

Determining the temperature-based, lengthwise expansion

Ch

an

ge in le

ng

th

Pipe length

101

Calculation example for length change of AWADUKT PVC pipes

∆l = L · ∆t · 0.14 mm/mKCalculation example:Pipe length: 3 mLaying temperature: + 10 °C

The lowest expected pipe wall temperature: + 5 °C=> Temperature difference 5 K

The highest expected pipe wall temperature: + 20 °C=> Temperature difference 10 K

The greatest expected reduction:∆l1 = 3 m x 5K x 0.14 mm/mK = 2.1 mm

The greatest expected extension:∆l2 = 3 m x 10K x 0.14 mm/mK = 4.2 mm

For example:If the pipe wall temperature changes by 40 K, a 3 m long pipe is shortened or extended by ∆l = 16.8 mm.

Double-pipe system designFor application in areas that require particular protection (e.g. in Water Protection Areas) AWADUKT pipes can be used to create a double-pi-pe system.Special spacers are to be used to run and centre the medium pipe inside the protective pipe. Special fittings can be fabricated with filler-free polypropylene. Our technical applications department will be happy to oer advice if there are any questions on designing a double-pipe system.

Laying in temporarily liquid soilsLiquid soil is a mixture of a base material, water and a special formulation of additives. Virtually all soils, or even recycled constructi-on materials, can be used as the base material. The formulations, which are specially adapted to the soil and the requirement profile, contain aggregates, e.g. cement, bentonite or chalk. The liquid soil can be produced both on the construction site and also in the plant. Liquid soil is temporarily liquid to mushy and can therefore be installed without any compaction measures or cavities. The shrinkage of the liquid soil is extremely low. Liquid soil is used if e.g. laying segments in tight areas do not allow the trench to be compacted suciently, normal compaction is forbidden e.g. due to buildings in close proximity to the construction site being susceptible to vibration or the excavated soil material only being suitable for re-use with prior treatment.Permeability, consistency, setting speed and even the damping behaviour can be set by adjusting the formulation.

AWADUKT HPP and AWADUKT PP SN10 pipes are ideally suited to be laid in temporarily liquid soil due to their high degree of stiness and robustness. The pipes become very buoyant when the liquid soil is applied, against which they need to be secured. The buoyancy force is significantly reduced through filling the pipes with water.The bedding and buoyancy safeguards matched to the diameter, slope and density of the liquid soil are important during installation. This can be achieved for example with sand bags, plastic liquid soil or with special locating devices. Please contact our technical applications department for further information about e.g. bedding clearance.

Determining the temperature-based

lengthwise expansion

Ch

an

ge

in

le

ng

th

Pipe length

102

Trenchless installation of AWADUKT PP pipesThe welding solution AWADUKT PP SN10 / HPP SN16 Fusion is suitable both for conventional installation as well as for various trenchless installations and renovations, such as:

Burst-lining

Burst-lining is used to replace damaged pipelines in trenchless laying retaining or enlarging the hydraulic cross-section. The broken material pressed into the soil area forms an annular space with the in-situ soil on bursting; the new pipeline attached to the bursting unit is pulled into this annular space.

Sliplining

In sliplining, a new solid-wall pipe is pulled into a defective old pipe through a trench. The result is a standalone, stable new pipe that can be written o by the network operator as for a new installation. During sliplining, it is essential to test the pipe hydraulics as the pipe cross-section is decreased in relation to the old pipe. In this process, the free, straight cross-section of the old pipe must be larger than the maximum outside diameter of the new pipe.

Horizontal directional drilling (HDD)

On dierent levels, soil material is pierced with a drill head and cleared using supporting and flushing liquid. In the first step, the pipe channel is produced using a pilot hole. In subsequent steps, the final pipe channel is widened and the pipe is pulled in using puller equipment. In the HDD process, it is possible to run the pipeline underneath obstacles such as water courses, railway lines and roads, for example.

103

Material characteristics, permissible tensile forces, bending radii, welding parameters for REHAU AWADUKT PP SN10 / HPP SN16

Maximum tensile force for AWADUKT PP SN10 at pipe wall temperatures of 20 °CDN/OD Wall thickness

min.[mm]

Max. permissibletensile force* [kN]

160 6.2 53200 7.7 82250 9.6 128315 12.1 203400 15.3 325500 19.1 508630 24.1 807

* Tensile force without safety factor for primarily straight pipe runs

Maximum tensile force for AWADUKT HPP SN16 at pipe wall temperatures of 20 °CDN/OD Wall thickness

min.[mm]

Max. permissibletensile force*[kN]

160 7.3 62200 9.1 96250 11.4 150315 14.4 239400 18.2 384500 22.8 601630 28.7 954

* Tensile force without safety factor for primarily straight pipe runs

Comments:- With pipe wall temperatures of 40 °C, the values should be multiplied by a factor of 0.7.- The tables above apply for a welding factor of 0.9.- With butt-welded pipes, the welding bead on the outside and where applicable on the inside should be removed using suitable equipment.- The specifications for tensile strength, bending radii and ring stiness relate to undamaged pipes without grooves, notches or similar.- The maximum tensile forces are given without guarantees and should be aligned with the relevant building plans.

Bending radii

Bending radii Pipe wall temperature Calculation of minimum bending radius R

for PP-HM 0 °C 85 x DN/OD10 °C 55 x DN/OD20 °C 30 x DN/OD

Check the bending radii using the following equation:

R =

f = inside micrometerBend A - B = pipe

c =

Calculation of the required trench length

R

H

2H

L*

R

WP

WP*

R

L

The pipeline can be pulled in using roller or digger support

L = √H x (4 x R – H)

With small pipe dimensions, the trench length can be reduced in accordance with the following equation by lifting the PP pipe run:

L* = √H x (2 x R – H)

Notes on implementation:Adjust the required additional safety values to the conditions of your building project.The overhang should be adjusted to the ground conditions and should be reduced to a minimum for static reasons (support eect of the ground). To ensure the stability of the pipeline, we recommend force-locked filling any potential annular space between the pipe and the ground or pipe and old pipe with stable insulating material.

2 x f

f² + c²

2

Bend A - B

c c

f

M

0

BA

R

N

L Length of the starting pit in mH Pipe bottom depth in mR Permissible bending radius in m

104

Welding parameters for butt fusion jointing conforming to DVS 2207-11The specifications of the DVS Directive 2207-11 and the relevant national regulations must be observed.At temperatures around 5 °C, the warm-up times should be increased by approx. 10%. The required safety factors should be modified in line with the site conditions. The welds should be documented in a welding record.

Guideline values for butt fusion jointing of AWADUKT HPP SN16 at an external temperature of approx. 20 °C and moderate air movementDN/OD Nom.

wall thick.

[mm]

Press on (heated plate temp. 210 °C ±10 °C) Bead height on heated plate at the end of the pressing time (pressing under 0.10 N/mm²) (minimum values)

[mm]

Heat (heated plate temp. 210 °C ±10 °C) (Heat ≤ 0.01 N/mm²) Heating time

[s]

Changeover Changeover time

(maximum time)[s]

Joining Joining pressure build-up time

[s]

Joining Cooling timeunder joining pressure(p= 0.10 N/mm² ±0.01)

(minimum values)[min]

160 7,3 0,5 179 6 7 13200 9,1 1,0 204 6 9 15250 11,4 1,0 237 7 10 19315 14,4 1,0 274 8 13 23400 18,2 1,0 320 8 16 29500 22,8 1,5 368 10 20 35630 28,7 2,0 421 12 24 44

Guideline values for butt fusion welding of AWADUKT HPP SN10at an external temperature of approx. 20 °C and moderate air movementDN/OD Nom.

wall thick.

[mm]

Press on (heated plate temp. 210 °C ±10 °C) Bead height on heated plate at the end of the pressing time (pressing under 0.10 N/mm²) (minimum values)

[mm]

Heat (heated plate temp. 210 °C ±10 °C) (Heat ≤ 0.01 N/mm²) Heating time

[s]

Changeover Changeover time

(maximum time)[s]

Joining Joining pressure build-up time

[s]

Joining Cooling timeunder joining pressure(p= 0.10 N/mm² ±0.01)

(minimum values)[min]

110 4,2 0,5 135 5 6 6160 6,2 0,5 162 6 7 10200 7,7 1,0 185 6 8 13250 9,6 1,0 211 7 9 16315 12,1 1,0 246 7 11 20400 15,3 1,0 285 8 14 25500 19,1 1,5 331 9 17 30630 24,1 1,5 381 10 21 37

Material parameters for static load analysis

Material PP-HMDensity of the material yR [kN/m³] 9Poisson’s ratio v 0.38

short-term long-termModulus of elasticity ER [N/mm²] 1700 425Radial bending pressure strength 39 17Radial bending tensile strength σRBZ [N/mm²] 39 17Ring tensile strength σRZ [N/mm²] 39 17

105

SUGGESTED CONSTRUCTION SITE RECORDfor burst-lining

Please fax to your nearest REHAU Sales Oce or send by email to abwassertechnik@rehau.com

static dynamic

Record no. __________________________________ Date: __________________________________

Executing company: ____________________________________ Responsible specialist: __________________________________

Construction project: ____________________________________ Framework conditions

Town / Street: ____________________________________ Bodenart: __________________________________

Client: ___________________________ _________ Condition: moist dry

Data of the old pipeline Data of the new pipe run

Medium: _____________________ Pressure rating: _______________ bar Medium: _____________________ Pressure rating: ____________ bar

Material: ____________________ Nominal width: ________________ mm Material: ___________________ Nominal width: ____________ mm

Section length: _______________ m from: _________ to: __________ Connection type: ________________ Wall thickness: ____________ mm

Route position: Footpath Street Cut length Winding length (only PE) ______ m

Top fill height: _______________________________________ m Production date: _____________ Identification: _______________

Obstacles

Obstacle type: __________________________________ Removal method: ____________________________________________________

Record no.: __________________________________ removed on: ________________ by: ________________

Replacement

Date/time ________________ from: _________ to: __________ by: ____________________________________________________

Pulling device: ________________ max. pulling force: __________ kN Device number: ____________________________________________________

Compressor / Drive station: _______________________________________________ Device number: ____________________________________________________

Impact mole/Expansion

Shape: __________________________________ Diameter: __________ mm

Expansion (diameter): _______________________________ mm

Tensile force monitoring

Traction gauge Device no.: _______________________________ measured max.: ____________ kN perm. new pipe __________ kN

Overload protection (rated breaking point)

Visual inspection for absence of damage in the trenches

orderly faulty

Measures initiated: ____________________________________________________________________________

____________________________________________________________________________

Comments: _______________________________________________________________________________________________________

____________________________________________________________________________________________________________________

___________________________________________ ___________________________________________________________________________

Person keeping the record Responsible specialist

Recommendation:From a geometrical standpoint, we do not recommend partial bursting. For example, a DN/OD 200 pipe is not suitable for being

pulled into a DN/ID 200 pipe. Socket osets and minor dimensional losses can result in serious problems here.

106

FINAL INSPECTIONand/or checking the pipelines and chambers following installation

Once laying is completed, suitable inspections and/or checks are to be carried out.

Visual inspectionVisual inspection comprises:- Direction and elevation- Joints- Damage or unequal deformation- Connection

TightnessThe tightness of the pipeline, including connections, chambers and inspection openings should be checked.It is essential that a test is carried out after pipe zone has been created, before backfilling the construction trench, in order to detect possible defects at an early stage.

Pipe zone and main backfillThe required construction of the pipe zone can be proven by testing the compaction and/or the pipe deformation; the construction of the main filling can be proven by checking the compaction.

CompactionThe level of compaction of the bedding, the side backfill, surface backfilling and the main backfill is to be checked where requested.

Pipe deformationIf requested, it is to be checked that the vertical change in the diameter coincides with the static load analysis.

Processes and requirements for checking gravity pipelines

GeneralThe test for the tightness of pipelines, chambers and inspection openings should either be carried out with air (process „L“) or with water (process „W“). The separate inspection of pipes and fittings, chambers and inspection openings, e.g. pipes with air and chambers with water, is permitted. In the case of process L, there is no limit to the number of corrective measures and repeat tests in case of failure. In the case of one-o or repeated failed tests with air, it is permitted to change over to testing with water and then only the result of the test with water is decisive. If during the test, the groundwater level is above the sot of the pipe, an infiltration test may be carried out with specifications applicable to the particular case. A preliminary test may be carried out prior to applying the side backfill. For the acceptance test, the pipe is to be checked after it has been backfilled and the sheeting has been removed; the client shall decide whether to test with air or water.

Checking with air (process “L”)The test times for the pipelines without chambers and inspection openings are to be taken from the following table, considering the pipe diameters and test methods (LA; LB; LC; LD). The client should decide the test procedure. Suitable airtight closures are to be used in order to rule out errors with measurements as a result of the testing apparatus. It is recommended to check chambers with water for safety reasons. Testing chambers and inspection openings with air is dicult to carry out in practice.

For safety reason, special care is required when testing large diameters with air as the shut-o devices can be

flung away explosively in the event of their failure.

Until there is sucient experience for testing chambers and inspection openings with air, it is recommended

that test times be used that are half as long those for pipelines with the same diameter.

An initial pressure that exceeds the required test pressure p0 by around 10% is initially to be maintained for around 5 minutes. The pressure for Δp should then be set based on test pressure contained in the following table for the processes LA, LB, LC or LD.The pipe meets the requirements if the reduction in pressure measured after the test time is lower than the value given in the following table.

107

Test pressure, pressure drop and test times for testing with air

Test method

P0*) Permitted Test time [min]mbar ∆p**) DN/OD DN/OD DN/OD DN/OD DN/OD[kPa] mbar [kPa] 110-200 250-315 400 500-630 710-800

LA 10(1)

2.5(0.25)

5 7 10 14 19

LB 50(5)

10(1)

4 6 7 11 15

LC 100(10)

15(1.5)

3 4 5 8 11

LD 200(20)

15(1.5)

1.5 2 2.5 4 5

*) Pressure above atmospheric pressure **) Pressure drop

For the measurement of the test time, the error limit is 5 s.

Test requirements for the air test with negative pressure are not included in this European standard

because at present there is insucient experience with this process. The equipment used to measure the pressure drop must ensure the measurement with an error limit of 10 % Δp. For the measurement of the test time, the error limit is 5 s.

Testing with water (process “W”) Test pressureThe test pressure is the pressure of the chamber lying upstream or downstream depending on the specification, that arises from filling the test section up to ground level, of a maximum of 50 kPa and at least 10 kPa, measured at the sot.Higher test pressures can be specified for pipelines designed to be operated under continuous or temporary excess pressure levels.Preparation timeA preparation time may be required after filling the pipelines and/or chamber and achieving the required test pressure.

Generally 1 hour is sucient.

Test durationThe test period must be 30 ± 1 min.Test requirementsThe pressure is to be maintained within 1 kPa of the test pressure specified by filling up with water.The total water volume that was added during the test to meet this requirement, as well as the water level at the required test pressure, are to be measured and recorded.

- The test requirement is met if the volume of water added is not greater than:

- 0.15 l/m2 in 30 min for pipelines- 0.20 l/m2 in 30 min for pipelines including chambers- 0.40 l/m2 in 30 min for chambers and inspection openings.

m2 describes the wetted inner surface.

Testing individual connectionsUnless otherwise specified, the testing of individual connections rather than testing the complete pipeline, normally > DN/OD 1000, can be accepted. For testing individual pipe connections, the surface for the „W“ test should be selected according to the surface of a 1 m long pipe section, unless otherwise specified. The test requirements can be found in the details provided above.

QualificationsThe following qualification factors are to be taken into account:- appropriately trained and experienced personnel should be used to

monitor and implement the constructions project- contractors appointed by the customer should have the necessary

qualifications required to carry out the work- customers should ensure for themselves that contractors have the

necessary qualifications

Start

Perform test with water

Localise and eliminate the cause

Water loss within required

limits

Test passed

No

Yes

108

STATIC LOAD ANALYSISaccording to worksheet ATV-DVWK-A 127, third edition, August 2000

Technical principlesPipelines and chambers are technical constructions, where the interaction of components, embedding and filling is the basis for the stability and operational safety. The parts supplied, such as pipes, fittings and seals, together with the services to be provided on site, like bedding, creating the pipe connections, side and main backfill, are important factors for ensuring that the proper function of the structure is assured.

GeneralPlastic pipes and fittings installed underground are elastic,i.e. they are more flexible than the surrounding soil material. By a deliberate minor deformation, the pipes and fittings elude the load and activate the supporting forces of the sheathing. The static load analysis takes into consideration the loads, the soil characteristics as well as the pipe parameters.For unstable soils, it is to be ensured that bedding and pipe sheathing cannot press into the in-situ soil, which would reduce the supporting forces significantly. In order to prevent this from happening, we recommend covering the pipe sheathing with a tear-proof non-woven/geosynthetic fabric and, if required, stabilise the excavation trench bottom.

Guaranteeing the load assumptionsBefore the start of the building project, the load-bearing capacity of a pipeline must be verified, decided or stipulated according to EN 752-3 and EN 1295-1.The work should be controlled in such a way that the load assump-tions that arise from the planning documents are assured or adapted to the dierent conditions.The load assumptions are influenced by the following factors and their changes:- dierence between the implemented trench width and the calculated

trench width- dierence between the implemented trench depth and the calcula-

ted trench depth- type of trench sheeting and eect on its distance- level of compaction in the pipe zone- level of compaction of the main backfill- pipe bedding and trench bottom- site trac and occasional loads- types of soil and ground characteristics (e.g. subsoil, trench walls

and filling)- trench shape (e.g. stepped trenches, trenches with sloped walls)- condition of the subsoil (e.g. through frost and dew, rain, snow and

floods)- groundwater level- further pipelines in the same trench

- wastewater temperature: Also exceeding the recommended temperature ranges (table “Fields of application/Type overview) can adversely influence the function/stability of the system The reduced modulus of elasticity in case of high wastewater temperatures (in places 90 °C for short periods) should be taken into account in the static load analysis.

Top fill heightsInformation about top fill heights for dierent installation conditions and pipe types can be found in the standardised statics in this chapter We recommend a static load analysis (see project questionnaire) in cases of doubt, e.g. In case of diering top fill heights.

Design fundamentals

PVC-UModulus of elasticity:Short-term: 3600 N/mm2

Long-term: 1750 N/mm2

Short-term flexural strength: 90 N/mm2

Long-term flexural strength: 50 N/mm2

PP-B/PP-HMModulus of elasticity: Short-term: 1700 N/mm2

Modulus of elasticity: Long-term: 312 N/mm2 425 N/mm2

Short-term flexural strength: 39 N/mm2

Long-term flexural strength: 17 N/mm2

Permitted deformationAll AWADUKT pipe systems are flexurally elastic, flexible structural components. A controlled deformation in the assembled condition is desirable, as the pipe and base form a load-bearing system.

Long-term deformation (max): 6 % for a security factor of 2.5 or 9 % in justified individual cases with non-linear proof toATV-DVWK worksheet A 127 (third edition).

Please note that according to ATV-DVWK-A 127“Static load analysis of wastewater pipes and

sewers“, section 9.7.4., proof of protection against failure with loads that are not primarily static is required when pipes are laid in the railway embankments of German Railways or under aviation areas. Below a top fill height of 1.5 m, this evidence may also be required under roads.On request we can provide evidence of this as part of the static load analysis.

109

Soil types

Group Density internal friction angle

Deformation module EB in N/mm2 with degree of compaction Dpr in %

B

kN/m3 Dpr = 85 90 92 95 97 100G 1 20 35 2.0 6.0 9 16 23 40G 2 20 30 1.2 3.0 4 8 11 20G 3 20 25 0.8 2.0 3 5 8 13G 4 20 20 0.6 1.5 2 4 6 10

Specification of soil groups G1-G4Group 1: Non-cohesive soils

Grain size Grain sizeDescription < = 0.06 mm > 2 mm Identifying feature Examples

GE Narrow-graded gravels < = 5 % > 40 % Steep grain-size curve due to a prevailing grain size range

River and beach gravel. terrace gravel. moraine gravel. volcanic slag and ash

GW Wide-graded gravel-sand mixtures

< = 5 % > 40 % Grain-size curve running continuously across several grain size ranges

River and beach gravel. terrace gravel. moraine gravel. volcanic slag and ash

GI Intermittently graded gravel-sand mixtures

< = 5 % > 40 % Stepped grain-size curve due to the lack of one or more grain size ranges

River and beach gravel. terrace gravel. moraine gravel. volcanic slag and ash

SE Narrow-graded sands < = 5 % < = 40 % Steile Körnungslinie infolge Vorherrschens eines Korngrößenbereiches

Dune or shifting sand. valley sand (Berlin sand). basin sand. tertiary sand

SW Wide-graded sand-gravel mixtures

< = 5 % < = 40 % Steep grain-size curve due to a prevailing grain size range

Moraine sand. terrace sand.beach sand

SI Intermittently graded sand-gravel mixtures

< = 5 % < = 40 % Stepped grain-size curve due to the lack of one or more grain-size ranges

Moraine sand. terrace sand. beach sand

Group 2: Low-cohesive soils

Grain size Grain size

Description < = 0,06 mm > 2 mm Identifying feature ExamplesGU Gravel-silt mixtures 5-15 % > 40 % Wide- or intermittently graded grain-size curve.

fine-grain content is siltyWeathered gravel. run-of-hill scree. loamy gravel. boulder clay

GW Gravel-clay mixtures 5-15 % > 40 % Wide- or intermittently graded grain-size curve. fine-grain content is clayey

Weathered gravel. run-of-hill scree. loamy gravel. boulder clay

SU Sand-silt mixtures 5-15 % < = 40 % Wide- or intermittently graded grain-size curve.fine-grain content is silty

Sand loess

ST Sand-clay mixtures 5-15 % < = 40 % Wide- or intermittently graded grain-size curve.fine-grain content is silty

Loamy sand. sand marl

110

Group 3: Cohesive mixed soils, silt

Grain size Grain size

Description < = 0,06 mm > 2 mm Identifying feature Examples

GŪ Gravel-silt mixtures 15-40 % > 40 % Wide- or intermittently graded grain-size curve. fine grain content is silty

Weathered gravel. run-of-hill scree. loamy gravel. boulder clay

GT Gravel-clay mixtures 15-40 % > 40 % Wide- or intermittently graded grain-size curve. fine grain content is clayey

Weathered gravel. run-of-hill scree. loamy gravel. boulder clay

SŪ Sand-silt mixtures 15-40 % < 40 % Wide- or intermittently graded grain-size curve. fine grain content is silty

Alluvial clay. sand loess

ST Sand-clay mixtures 15-40 % < 40 % Wide- or intermittently graded grain-size curve. fine grain content is clayey

Boulder clay. marly till

UL Slightly plastic silts > 40 % Low dry strength. fast vibration test reaction. none to slight plasticity during knead test

Loess. high-flood loam

UM Moderately plastic silts > 40 % Low to medium dry strength. slow vibration test reaction. slight to medium plasticity during knead test

Lake clay. basin silt

Group 4: Cohesive soils

Grain sizeDescription < = 0,06 mm Identifying feature Examples

TL Slightly plastic clays > 40 % Medium to high dry strength. none to slowvibration test reaction; slight plasticity during knead test

Marly till. varved clay

TM Moderately plastic clays > 40 % High dry strength. no vibration test reaction.medium plasticity during knead test

Loess loam. basin clay. saliferious marl

TA Highly plastic clays > 40 % Very high dry strength. no vibration test reaction. high plasticity during knead test

Tarras. septarian clay. jurassic clay

OU Silts with organic additions andinorganic silts

> 40 % Medium dry strength. slow to very quick vibration test reaction. medium plasticity during knead test

Lake marl. infusorial earth. topsoil

OT Clays with organicadditions andorganogenic clays

> 40 % Very high dry strength. no vibration test reaction. distinct plasticity during knead test

Mud. clay containing sea silt

OH Coarse to mixed grained soil with humic type additions

< = 40 % Additions of vegetal type. mostly of dark colour. musty smell. ignition loss up to approx. 20 per cent by weight

Topsoil

OK Coarse to mixed grained soil with chalky. pebbly formations

< = 40 % Additions of non-vegetal type. mostly of light colour. lightweight. highly porous

Calcareous sand. tuff sand

UA Silts filled up withforeign substances

- - Waste. slag. rubble. industrial waste

111

HYDRAULIC DIMENSIONINGto worksheet ATV-DVWK-A 110

The hydraulic dimensioning of sewer pipes made from polymeric materials is based on physically and experimentally founded formula of Prandtl-Colebrook. Calculations are based on the ATV-DVWK worksheet A110 “Guideline for the hydraulic dimensioning of sewer pipes“.

Based on the type and design of sewers, the guideline makes a distinction between normal sewer pipes with side inlets and access chambers and straight sewer pipes without side inlets and access chambers.The details required for the hydraulic dimensioning based on ATV-DVWK-A 110 are summarised in the project questionnaire.

Partial filling diagram for AWADUKT pipes

Partial filling diagram

tV0 0.40 0.80 1.00 1.20

0.90

0.70

0.50

0.30

0.10

0

H t

Hv

Qt = 0.75Qv

V t = 1.16V v

:Qt

Qv

Vv

Q V

Qt = drainage with partial filling in l/sQv = drainage w.complete filling in l/svt = flow velocity with partial filling in m/svv = flow velocity with complete Vollfüllung in m/sHt = filling height w. partial fillingHv = filling height w. complete filling (= pipe inside diameter)

Solution:From complete filling diagram; HPP; wastewater pipe DN 200 (DN 160 is too small)Vv ≈ 2.01 m/sQv ≈ 51.9 l/sQt 40 l/s = ≈ 0.77 Q

v 51.9 l/s

Example: given:Flow rate 40 l/sSlope 25 ‰kb-value 0.25sought:Dimensions of the AWADUKT PP SN10 pipeFlow velocity

Aus Abb. (partial filling) Qt = 0.77 Q

v

vt ≈ 1.16 v

v

vt ≈ 1.16 · vv

vt ≈ 2.3 m/s

112

Complete filling AWADUKT HPP SN16 kb value 0.25

Slope DN/OD 160 DN/OD 200 DN/OD 250 DN/OD 315 DN/OD 400 DN/OD 500 DN/OD 630 in ‰ Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s]

2 7.8 0.47 14.1 0.55 25.5 0.63 47.1 0.73 88.5 0.86 159.4 0.99 293.1 1.143 9.6 0.58 17.4 0.67 31.5 0.78 58.1 0.91 109.1 1.05 196.4 1.21 360.8 1.404 11.2 0.68 20.2 0.78 36.6 0.91 67.4 1.05 126.5 1.22 227.6 1.41 418.0 1.635 12.6 0.76 22.7 0.88 41.0 1.01 75.5 1.18 141.8 1.37 255.1 1.58 468.4 1.826 13.8 0.83 25.0 0.97 45.1 1.12 83.0 1.29 155.7 1.50 280.0 1.73 514.0 2.007 15.0 0.91 27.0 1.04 48.8 1.21 89.8 1.40 168.5 1.63 302.9 1.87 555.9 2.168 16.1 0.97 29.0 1.12 52.2 1.29 96.1 1.50 180.4 1.74 324.2 2.00 594.9 2.329 17.1 1.03 30.8 1.19 55.5 1.37 102.1 1.59 191.5 1.85 344.2 2.13 631.6 2.46

10 18.0 1.09 32.5 1.26 58.6 1.45 107.7 1.68 202.1 1.95 363.2 2.25 666.3 2.5915 22.2 1.34 40.0 1.55 72.1 1.78 132.5 2.07 248.3 2.40 446.1 2.76 818.2 3.1820 25.7 1.55 46.3 1.79 83.4 2.06 153.3 2.39 287.4 2.78 516.1 3.19 946.3 3.6825 28.8 1.74 51.9 2.01 93.5 2.31 171.7 2.68 321.7 3.11 577.7 3.57 1,059.1 4.1230 31.6 1.91 56.9 2.20 102.5 2.54 188.3 2.94 352.8 3.41 633.5 3.92 1,161.2 4.5240 36.6 2.21 65.9 2.55 118.6 2.94 217.8 3.40 408.0 3.94 732.4 4.53 1,342.3 5.2250 41.0 2.48 73.8 2.86 132.8 3.29 243.8 3.80 456.7 4.41 819.7 5.07 1,502.0 5.8560 45.0 2.72 80.9 3.13 145.6 3.60 267.4 4.17 500.6 4.84 898.5 5.56 1,646.3 6.4170 48.6 2.94 87.4 3.38 157.4 3.90 289.0 4.50 541.1 5.23 971.0 6.00 1,779.1 6.9280 52.0 3.14 93.6 3.62 168.4 4.17 309.1 4.82 578.7 5.59 1,038.5 6.42 1,902.6 7.4090 55.2 3.33 99.3 3.84 178.7 4.42 328.0 5.11 614.1 5.93 1,101.9 6.81 2,018.7 7.86

100 58.2 3.51 104.7 4.05 188.5 4.67 345.9 5.39 647.5 6.26 1,161.8 7.18 2,128.4 8.28

Complete filling AWADUKT HPP SN16 kb value 0.5

Slope DN/OD 160 DN/OD 200 DN/OD 250 DN/OD 315 DN/OD 400 DN/OD 500 DN/OD 630 in ‰ Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s]

2 7.3 0.44 13.2 0.51 23.8 0.59 44.0 0.69 82.7 0.80 149.1 0.92 274.3 1.073 9.0 0.54 16.2 0.63 29.3 0.73 54.1 0.84 101.8 0.98 183.3 1.13 337.0 1.314 10.4 0.63 18.8 0.73 34.0 0.84 62.7 0.98 117.8 1.14 212.1 1.31 389.9 1.525 11.7 0.71 21.1 0.82 38.1 0.94 70.2 1.09 131.9 1.27 237.5 1.47 436.5 1.706 12.8 0.77 23.1 0.89 41.8 1.03 77.0 1.20 144.7 1.40 260.5 1.61 478.6 1.867 13.9 0.84 25.0 0.97 45.2 1.12 83.3 1.30 156.5 1.51 281.6 1.74 517.4 2.018 14.8 0.89 26.8 1.04 48.4 1.20 89.1 1.39 167.4 1.62 301.2 1.86 553.4 2.159 15.8 0.95 28.4 1.10 51.4 1.27 94.6 1.47 177.7 1.72 319.7 1.98 587.3 2.29

10 16.6 1.00 30.0 1.16 54.2 1.34 99.8 1.56 187.4 1.81 337.2 2.08 619.3 2.4115 20.4 1.23 36.8 1.42 66.5 1.65 122.5 1.91 230.0 2.22 413.7 2.56 759.7 2.9620 23.6 1.43 42.6 1.65 76.9 1.90 141.6 2.21 265.8 2.57 478.2 2.96 878.0 3.4225 26.5 1.60 47.7 1.85 86.1 2.13 158.5 2.47 297.5 2.87 535.0 3.31 982.3 3.8230 29.0 1.75 52.3 2.02 94.4 2.34 173.7 2.71 326.1 3.15 586.3 3.62 1,076.5 4.1940 33.6 2.03 60.5 2.34 109.1 2.70 200.8 3.13 376.8 3.64 677.6 4.19 1,243.9 4.8450 37.6 2.27 67.7 2.62 122.1 3.02 224.7 3.50 421.5 4.07 757.9 4.69 1,391.3 5.4160 41.2 2.49 74.2 2.87 133.8 3.31 246.2 3.84 462.0 4.46 830.6 5.14 1,524.6 5.9370 44.5 2.69 80.2 3.10 144.6 3.58 266.1 4.15 499.2 4.82 897.4 5.55 1,647.2 6.4180 47.6 2.87 85.8 3.32 154.7 3.83 284.5 4.43 533.8 5.16 959.6 5.93 1,761.3 6.8590 50.5 3.05 91.0 3.52 164.1 4.06 301.9 4.71 566.3 5.47 1,018.0 6.29 1,868.4 7.27

100 53.3 3.22 96.0 3.71 173.0 4.28 318.3 4.96 597.0 5.77 1,073.3 6.64 1,969.8 7.67

113

Complete filling AWADUKT PP SN10 kb value 0.25 Slope DN/OD 110 DN/OD 160 DN/OD 200 DN/OD 250 DN/OD 315 DN/OD 400 DN/OD 500 DN/OD 630 DN/OD 800in ‰ Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s]

2 3.0 0.37 8.1 0.47 14.6 0.55 26.5 0.64 48.9 0.74 91.9 0.86 165.2 0.99 304.0 1.15 568 1.343 3.7 0.46 10.0 0.59 18.1 0.68 32.7 0.79 60.3 0.91 113.3 1.06 203.5 1.22 374.2 1.42 699 1.644 4.3 0.53 11.6 0.68 21.0 0.79 37.9 0.91 70.0 1.06 131.3 1.23 235.9 1.42 433.5 1.64 809 1.905 4.8 0.60 13.1 0.77 23.6 0.89 42.6 1.02 78.5 1.19 147.3 1.38 264.4 1.59 485.8 1.84 907 2.136 5.3 0.66 14.3 0.84 25.9 0.97 46.8 1.13 86.2 1.31 161.7 1.52 290.2 1.75 533.0 2.02 995 2.347 5.7 0.71 15.5 0.91 28.1 1.06 50.6 1.22 93.3 1.41 174.9 1.64 313.9 1.89 576.5 2.18 1076 2.538 6.2 0.76 16.7 0.98 30.1 1.13 54.2 1.30 99.9 1.51 187.2 1.76 336.0 2.02 617.0 2.34 1151 2.719 6.5 0.81 17.7 1.04 31.9 1.20 57.6 1.39 106.1 1.61 198.8 1.87 356.7 2.15 655.0 2.48 1222 2.87

10 6.9 0.86 18.7 1.10 33.7 1.27 60.8 1.46 112.0 1.70 209.8 1.97 376.3 2.26 690.9 2.62 1289 3.0315 8.5 1.06 23.0 1.35 41.5 1.56 74.8 1.80 137.7 2.08 257.8 2.42 462.3 2.78 848.5 3.21 1582 3.7220 9.9 1.23 26.7 1.57 48.1 1.81 86.6 2.08 159.3 2.41 298.3 2.80 534.8 3.22 981.3 3.71 1829 4.3025 11.1 1.38 29.9 1.76 53.9 2.03 97.0 2.33 178.4 2.70 334.0 3.14 598.6 3.60 1,098.3 4.16 2047 4.8130 12.2 1.51 32.8 1.93 59.1 2.22 106.4 2.56 195.7 2.96 366.2 3.44 656.4 3.95 1,204.1 4.56 2244 5.2840 14.1 1.75 38.0 2.23 68.4 2.57 123.1 2.96 226.3 3.43 423.5 3.98 758.9 4.57 1,392.0 5.27 2594 6.1050 15.8 1.96 42.5 2.50 76.6 2.88 137.8 3.32 253.4 3.84 474.0 4.45 849.3 5.11 1,557.5 5.90 2902 6.8260 17.3 2.15 46.6 2.74 84.0 3.16 151.1 3.64 277.8 4.21 519.7 4.88 931.0 5.60 1,707.2 6.46 3181 7.4870 18.7 2.33 50.4 2.96 90.8 3.41 163.3 3.93 300.3 4.55 561.6 5.27 1,006.1 6.05 1,844.8 6.98 3437 8.0780 20.0 2.49 53.9 3.17 97.1 3.65 174.7 4.21 321.2 4.86 600.7 5.64 1,076.0 6.47 1,973.0 7.47 3676 8.6490 21.3 2.65 57.3 3.36 103.1 3.88 185.4 4.46 340.8 5.16 637.4 5.99 1,141.7 6.87 2,093.3 7.92 3900 9.17

100 22.4 2.79 60.4 3.55 108.7 4.09 195.5 4.71 359.4 5.44 672.1 6.31 1,203.8 7.24 2,207.1 8.35 4112 9.66

Complete filling AWADUKT PP SN10 kb value 0.5 Slope DN/OD 110 DN/OD 160 DN/OD 200 DN/OD 250 DN/OD 315 DN/OD 400 DN/OD 500 DN/OD 630 DN/OD 800in ‰ Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s]

2 2.8 0.34 7.5 0.44 13.7 0.51 24.7 0.60 45.7 0.69 85.9 0.81 154.5 0.93 284.5 1.10 532 1.253 3.4 0.43 9.3 0.55 16.8 0.63 30.5 0.73 56.2 0.85 105.6 0.99 190.0 1.14 349.5 1.32 653 1.544 4.0 0.49 10.8 0.63 19.5 0.73 35.3 0.85 65.1 0.99 122.3 1.15 219.8 1.32 404.4 1.53 756 1.785 4.5 0.55 12.1 0.71 21.9 0.82 39.5 0.95 73.0 1.10 137.0 1.29 246.1 1.48 452.7 1.71 846 1.996 4.9 0.61 13.3 0.78 24.0 0.90 43.4 1.04 80.0 1.21 150.2 1.41 269.9 1.62 496.4 1.88 927 2.187 5.3 0.66 14.4 0.84 26.0 0.98 46.9 1.13 86.5 1.31 162.4 1.53 291.8 1.76 536.6 2.03 1002 2.368 5.7 0.71 15.4 0.90 27.8 1.05 50.2 1.21 92.6 1.40 173.8 1.63 312.2 1.88 574.0 2.17 1072 2.529 6.0 0.75 16.3 0.96 29.5 1.11 53.3 1.28 98.3 1.49 184.4 1.73 331.3 1.99 609.1 2.31 1138 2.67

10 6.4 0.79 17.2 1.01 31.2 1.17 56.2 1.35 103.7 1.57 194.5 1.83 349.4 2.10 642.3 2.43 1200 2.8215 7.8 0.97 21.2 1.24 38.3 1.44 69.0 1.66 127.3 1.93 238.7 2.24 428.7 2.58 787.9 2.98 1471 3.4620 9.1 1.13 24.5 1.44 44.3 1.66 79.8 1.92 147.2 2.23 276.0 2.59 495.5 2.98 910.6 3.45 1700 4.0025 10.1 1.26 27.4 1.61 49.5 1.86 89.4 2.15 164.7 2.49 308.8 2.90 554.4 3.34 1,018.7 3.86 1902 4.4730 11.1 1.38 30.1 1.77 54.3 2.04 98.0 2.36 180.5 2.73 338.5 3.18 607.6 3.66 1,116.4 4.23 2084 4.9040 12.9 1.60 34.8 2.04 62.8 2.36 113.3 2.73 208.7 3.16 391.2 3.67 702.1 4.23 1,290.0 4.88 2408 5.6650 14.4 1.79 38.9 2.29 70.3 2.64 126.7 3.05 233.5 3.53 437.6 4.11 785.4 4.73 1,442.9 5.46 2693 6.3360 15.8 1.96 42.7 2.51 77.1 2.90 138.9 3.34 255.9 3.87 479.6 4.50 860.7 5.18 1,581.1 5.98 2951 6.9470 17.1 2.12 46.1 2.71 83.3 3.13 150.1 3.61 276.5 4.19 518.2 4.87 930.0 5.60 1,708.2 6.47 3188 7.4980 18.3 2.27 49.4 2.90 89.1 3.35 160.5 3.86 295.7 4.48 554.1 5.20 994.4 5.98 1,826.6 6.91 3409 8.0190 19.4 2.41 52.4 3.08 94.5 3.55 170.3 4.10 313.7 4.75 587.9 5.52 1,054.9 6.35 1,937.7 7.33 3616 8.50

100 20.4 2.54 55.2 3.24 99.6 3.75 179.6 4.32 330.7 5.01 619.8 5.82 1,112.2 6.69 2,042.8 7.73 3812 8.96

114

Complete filling AWADUKT PVC SN8 pipes kb value 0.25

Slope DN/OD 110 DN/OD 160 DN/OD 200 DN/OD 250 DN/OD 315 DN/OD 400 DN/OD 500in ‰ Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s]

2 3.2 0.38 8.6 0.48 15.5 0.56 28.1 0.65 51.9 0.75 97.5 0.88 175.6 1.013 3.9 0.46 10.6 0.60 19.2 0.69 34.8 0.80 64.0 0.93 120.2 1.08 216.3 1.244 4.6 0.55 12.3 0.69 22.3 0.80 40.3 0.93 74.3 1.08 139.4 1.25 250.7 1.445 5.1 0.61 13.9 0.78 25.0 0.90 45.3 1.04 83.3 1.21 156.3 1.40 281.0 1.616 5.6 0.66 15.2 0.85 27.5 0.99 49.7 1.14 91.5 1.32 171.5 1.54 308.4 1.777 6.1 0.72 16.5 0.93 29.8 1.07 53.8 1.24 99.0 1.43 185.6 1.67 333.6 1.928 6.5 0.77 17.7 0.99 31.9 1.15 57.6 1.32 106.0 1.53 198.7 1.78 357.1 2.059 7.0 0.83 18.8 1.06 33.9 1.22 61.2 1.41 112.6 1.63 211.0 1.89 379.1 2.18

10 7.4 0.88 19.8 1.11 35.8 1.29 64.6 1.48 118.8 1.72 222.6 2.00 400.0 2.3015 9.1 1.08 24.4 1.37 44.1 1.59 79.5 1.83 146.0 2.11 273.5 2.46 491.3 2.8220 10.5 1.25 28.3 1.59 51.0 1.83 92.0 2.11 169.0 2.45 316.5 2.84 568.3 3.2625 11.8 1.40 31.7 1.78 57.2 2.06 103.1 2.37 189.3 2.74 354.3 3.18 636.2 3.6530 12.9 1.53 34.8 1.95 62.7 2.25 113.1 2.60 207.6 3.00 388.6 3.49 697.5 4.0140 15.0 1.78 40.3 2.26 72.6 2.61 130.8 3.01 240.1 3.48 449.3 4.03 806.5 4.6350 16.8 1.99 45.2 2.54 81.3 2.92 146.5 3.37 268.8 3.89 502.9 4.51 902.5 5.1860 18.4 2.18 49.5 2.78 89.1 3.20 160.6 3.69 294.7 4.27 551.3 4.95 989.3 5.6870 19.9 2.36 53.5 3.00 96.3 3.46 173.6 3.99 318.5 4.61 595.8 5.35 1,069.1 6.1480 21.3 2.53 57.3 3.22 103.1 3.71 185.7 4.27 340.7 4.93 637.3 5.72 1,143.4 6.5790 22.6 2.68 60.8 3.41 109.4 3.93 197.1 4.53 361.5 5.23 676.2 6.07 1,213.2 6.97

100 23.9 2.84 64.1 3.60 115.4 4.15 207.8 4.77 381.2 5.52 713.0 6.40 1,279.2 7.35

Complete filling AWADUKT PVC SN8 pipes kb value 0.5

Slope DN/OD 110 DN/OD 160 DN/OD 200 DN/OD 250 DN/OD 315 DN/OD 400 DN/OD 500in ‰ Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s] Q [l/s] v [m/s]

2 3.0 0.36 8.0 0.45 14.5 0.52 26.3 0.60 48.5 0.70 91.2 0.82 164.3 0.943 3.6 0.43 9.9 0.56 17.9 0.64 32.4 0.74 59.7 0.86 112.1 1.01 201.9 1.164 4.2 0.50 11.5 0.65 20.7 0.74 37.5 0.86 69.1 1.00 129.8 1.17 233.7 1.345 4.7 0.56 12.9 0.72 23.2 0.83 42.0 0.97 77.4 1.12 145.4 1.31 261.6 1.506 5.2 0.62 14.1 0.79 25.5 0.92 46.1 1.06 84.9 1.23 159.4 1.43 286.9 1.657 5.6 0.66 15.3 0.86 27.6 0.99 49.9 1.15 91.8 1.33 172.4 1.55 310.2 1.788 6.0 0.71 16.3 0.92 29.5 1.06 53.4 1.23 98.3 1.42 184.4 1.66 331.8 1.919 6.4 0.76 17.4 0.98 31.3 1.13 56.7 1.30 104.3 1.51 195.7 1.76 352.2 2.02

10 6.8 0.81 18.3 1.03 33.1 1.19 59.8 1.37 110.0 1.59 206.4 1.85 371.4 2.1315 8.3 0.98 22.5 1.26 40.6 1.46 73.4 1.69 135.1 1.96 253.3 2.27 455.6 2.6220 9.6 1.14 26.0 1.46 47.0 1.69 84.9 1.95 156.2 2.26 292.9 2.63 526.7 3.0325 10.8 1.28 29.2 1.64 52.6 1.89 95.0 2.18 174.8 2.53 327.7 2.94 589.2 3.3830 11.8 1.40 32.0 1.80 57.7 2.07 104.2 2.39 191.6 2.77 359.2 3.22 645.8 3.7140 13.7 1.63 37.0 2.08 66.7 2.40 120.4 2.77 221.4 3.20 415.1 3.73 746.3 4.2950 15.3 1.82 41.4 2.32 74.6 2.68 134.7 3.10 247.7 3.59 464.4 4.17 834.8 4.8060 16.8 1.99 45.4 2.55 81.8 2.94 147.7 3.39 271.5 3.93 508.9 4.57 914.8 5.2570 18.2 2.16 49.0 2.75 88.4 3.18 159.6 3.67 293.4 4.25 549.8 4.94 988.4 5.6880 19.4 2.30 52.4 2.94 94.5 3.40 170.6 3.92 313.7 4.54 588.0 5.28 1,056.9 6.0790 20.6 2.44 55.6 3.12 100.3 3.61 181.0 4.16 332.8 4.82 623.8 5.60 1,121.2 6.44

100 21.8 2.59 58.7 3.30 105.7 3.80 190.9 4.39 350.9 5.08 657.6 5.90 1,182.0 6.79

115

CHEMICAL RESISTANCEof AWADUKT pipes made of PVC-U, PP

Pipe materialsThe AWADUKT pipes, fittings and sealing rings are characterised by their very high resistance to many chemicals that arise in wastewater. This chemical resistance is guaranteed at pH values between 1 (acid) and 13 (alkaline). To drain away industrial waste, the chemical resistance needs to be checked irrespective of the pH value. Detailed information about this - in particular with respect to the concentration and temperature of the various chemicals - is defined in the following supplementary sheets to relevant DIN standards and REHAU material data sheets.

PVC-USupplementary sheet 1 to DIN 8061: Pipes made of plasticiser-free polyvinyl chloride. Chemical resistance of pipes and pipe system components made of PVC-U.AVO200: REHAU material data sheet

PPSupplementary sheet 1 to DIN 8078: Pipes made of polypropylene (PP). Chemical resistance of pipes and parts of pipelines AV0030: REHAU material data sheet. The data in the tables to these standards provides information about a change in test specimens, which are not influenced by any external stress, when aected by given chemicals. These results therefore cannot not readily be transferred to all applications. The mechanical behaviour can therefore be aected in stress conditions and with the simultaneous presence of chemicals (stress cracking corrosion).

Rubber sealing ringsThe types of rubber used have a good chemical resistance, however components of esters, ketones and aromatic and chlorinated carbon hydrogen in wastewater can cause considerable swelling that can damage the connection.AWADUKT HPP SN16 and AWADUKT PP SN10 are supplied with EPDM seals as a standard. Alternatively, AWADUKT HPP SN16 and AWDUKT PP SN10 pipes can be supplied with NBR seals resistant to oil, grease and petrol. AWADUKT PP SN4 and AWADUKT PVC-U pipes are generally delivered with SBR sealing rings. In cases of doubt, it is advisable to have the suitability of pipe sealant material tested. Contact our technical applications department, if required. An enquiry form can be found at www.rehau.de/tiefbau-service.

116

OTHER APPLICABLE STANDARDSSpecifications and guidelines

AWADUKT PP SN4, SN10 and HPP SN16

DIN EN 1852:Plastic piping systems for non-pressure underground drainage and sewerage - polypropylene (PP)

AWADUKT PVC SN8

DIN EN 1401-1:Plastics piping systems for non-pressure underground drainage and sewerage - Structured-wall piping systems of unplasticised polyvinyl chloride) (PVC-U)

General

DIN EN 476:General requirements for components used in drains and sewers for gravity drain systems

DIN EN 681:Elastomeric seals - Material requirements for pipe joint seals used in water and drainage applications

DIN EN 752-3:Drain and sewer systems outside buildings – Part 3: Planning Planning

DIN 1054:Subsoil – permissible loading of subsoil

DIN 1055:Part 2: Design loads for buildings

DIN 1072:Road and foot bridges; design loads

DIN EN 1610:Construction and testing of drains and sewers

DIN 1986:Drainage systems on private ground

DIN 4022:Subsoil and groundwater

DIN 4060:Elastomeric sealants for pipe joints in drains and sewers

DIN 4124:Excavations and trenches

DIN 18300:German construction contract procedures (VOB) - Part C: General technical specifications in construction contracts (ATV) - Earthworks

DIN 18305:German construction contract procedures (VOB) - General technical specifications in construction contracts (ATV) - Groundwater lowering

DIN 18306:German construction contract procedures (VOB) - General technical specifications in construction contracts (ATV) - Underground drainage

Data sheet for the drainage of airportspublished by the Forschungsgesellschaft für Straßenwesen e.V. (Road Research Institute)

Data sheet for ground compression in road construction,published by the Forschungsgesellschaft für Straßenwesen e.V. (Road Research Institute)

ZTV A-StB 97Additional technical contractual terms and guidelines for excavations in trac zones

ZTVE-StB 94:Guidelines for groundworks in road construction, published by the German Federal Ministry for Trac, as a supplement to ZTVE-StB 94

ATV-DVWK-A 127:Guidelines for the static load analysis of drains and sewers ATV-DV-WK-A 139: Installation and testing of drains and sewers

ATV-DVWK-A 139:Installation and testing of drains and sewers

ATV-DVWK-A 142:Sewers and drains in water catchment areas

The accident prevention guidelines of the trade associations and labour inspection boards and possibly other participating bodies must be observed.

117

SUGGESTED TEST RECORDLeak test to DIN EN 1610

Download at www.rehau.de/tiefbau-service

Construction project:

Client: Installer:Specifier:

Street: Post code/place

Tel./Fax/E-Mail:

Contact:

Sewer pipe system: AWADUKT HPP SN16 AWADUKT PP SN4

AWADUKT PP SN10

AWADUKT PVC SN8 .......................................

Connection channel from to

Main channel from to

Nominal width DN/OD

Inspection chamber no. no. no.

Test length m

Preparation time generally 1 hour, testing time 30 ± 1 minute

Water pressure test to DIN EN 1610

Filling quantity in l/m, pprox

Target values Max. permissible water addition Test pressure in bar ResultAddition of water in l/sect/c (litre/section/chamber)in l/m l/Hltg

DN/OD 110: 8.5 Max. test pressure 0.5 bar DN/OD 110: 0.04 Max.DN/OD 125: 11 Min. test pressure 0.1 bar DN/OD 125: 0.05 Min.DN/OD 160: 18 DN/OD 160: 0.07DN/OD 200: 28 Addition of water. in relation to the DN/OD 200: 0.09DN/OD 250: 44 wetted internal surface DN/OD 250: 0.11DN/OD 315: 71 max. 0.15 l/m² for pipelines DN/OD 315: 0.14

DN/OD 400: 113 max. 0.20 l/m² for pipelines DN/OD 400: 0.17

DN/OD 500: 177 incl. chambers DN/OD 500: 0.22DN/OD 630: 283 max. 0.40 l/m² for chambers DN/OD 630: 0.28

DN/OD 710: 361 and inspection openings DN/OD 710: 0.31DN/OD 800: 460 DN/OD 800: 0.36ChambersDN/ID 1000: 785

Requirements met yes no not carried out

118

Air pressure test to DIN EN 1610

Excess pressure

Negative pressure (not to DIN EN 1610)

Test Test pressure max. Test time in min Result

procedure* p0 in mbar permissible Pressure drop

pressure drop in mbar

p in mbar

DN/OD DN/OD DN/OD DN/OD DN/OD

110 - 200 250 - 315 400 500 - 630 710 - 800

LA 10 2.5 5 7 10 14 19

LB 50 10 4 6 7 11 15

LC 100 15 3 4 5 8 11

LD 200 15 1.5 2 2.5 4 5

Pre-filling time min. 5 minutes

Requirements met yes no not carried out

Remarks/Additions:

Date:

Signatures:

* normally, the LD test procedure is applied; in case of large nominal widths (> 800 mm) we recommend, for work safety reasons, to apply the LC procedure or conduct a test

using water.

119

QUESTIONNAIRE FOR HYDRAULIC DIMENSIONINGof gravity pipelines

Download from our homepage at www.rehau.de/tiefbau - Dimensioning to ATV-DVWK-A 110 -Please fax to your nearest REHAU sales oce or email to:abwassertechnik@rehau.com

Construction project:

Client: Installer:Specifier:

Street: Post code/plac

Tel./Fax/E-Mail:

Contact:

Phase: Planning Quotation Order

Sewer pipe system: AWADUKT HPP SN16 AWADUKT PP SN4

AWADUKT PP SN10

AWADUKT PVC SN8 .......................................

Measurement No. 1 No. 2 No. 3

Complete filling Details:

Pipe diameter (DN/OD) ..................mm ..................mm ..................mm

Min. flow required ....................l/s ....................l/s ....................l/s

Slope .....................% .....................% .....................%

Sought:

Pipe diameter (DN/OD)

Flow rate in m/s

req. minimum slope in %

Flow rate in l/s

Partial filling Details:

Fill level ..................mm ..................mm ..................mm

Flow ....................l/s ....................l/s ....................l/s

Sought:

Flow in l/s

Flow velocity in m/s

Fill level in mm

Remarks/Additions:

Date:

Signature:

120

QUESTIONNAIRE FOR STATIC LOAD CALCULATIONof gravity pipelines

Download at www.rehau.de/tiefbau-service- Calculation to ATV-DVWK-A 127 -Please fax to your nearest REHAU sales oce or email to: abwassertechnik@rehau.com

Construction project:

Client: Installer:Specifier:

Street: Post code/plac

Tel./Fax/E-Mail:

Contact:

Phase: Planning Quotation Order

Sewer pipe system: AWADUKT HPP SN16 AWADUKT PP SN4

AWADUKT PP SN10

AWADUKT PVC SN8 .......................................

Dimensions: DN/OD.................. DN/OD.................. DN/OD..................

Quantity [lfm]: appr ....................m appr ....................m appr ....................m

Top fill height above soffit: min h = .............m min h = .............m min h = .............m

max h = .............m max h = .............m max h = .............m

Groundwater: present - Height above pipe bottom ................m - at top fill height ................m

not present

present - Height above pipe bottom ................m - at top fill height ................m

not present

present - Height above pipe bottom ................m - at top fill height ................m

not present

Water filling, e.g. storage sewer:

Dimensions: DN/OD DN/OD DN/OD

Soil groups according to ATV-DVWK-A 127 and DIN 18196:

G1: non-cohesive soilsG3: cohesive mixed soils

G2: low-cohesive soilsG4: cohesive soils

Cover fill Degree of compactionDPr = ...............%

Degree of compactionDPr = ...............%

Degree of compactionDPr = ...............%

Soil groups according to ATV-DVWK-A 127

G1 G2 G3 G4

G1 G2 G3 G4

G1 G2 G3 G4

Pipe zone Degree of compactionDPr = ...............%

Degree of compactionDPr = ...............%

Degree of compactionDPr = ...............%

Soil groups according to ATV-DVWK-A 127

G1 G2 G3 G4

G1 G2 G3 G4

G1 G2 G3 G4

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In-situ soil Degree of compactionDPr = ...............%

Degree of compactionDPr = ...............%

Degree of compactionDPr = ...............%

Soil group according to ATV-DVWK-A 127

G1 G2 G3 G4

G1 G2 G3 G4

G1 G2 G3 G4

Subsoil under the pipe Degree of compactionDPr = ...............%

Degree of compactionDPr = ...............%

Degree of compactionDPr = ...............%

Soil groups according to ATV-DVWK-A 127

G1 G2 G3 G4

G1 G2 G3 G4

G1 G2 G3 G4

1

2

2

3 3

4

Trench shape: Single trench Single trench Single trench

Stepped trench Stepped trench Stepped trench

Multiple trench Multiple trench Multiple trench

Embankment Embankment Embankment

Trench width: b = ...................m b = ...................m b = ...................m

Slope angle: b

ß

ß = ...................° ß = ...................° ß = ...................°

Dimensions: DN/OD DN/OD DN/OD

Cover fill conditions for the trench fillingTrench filling above the pipeline zone according to ATV-DVWK-A 127

A1 Trench filling compacted in layers against the natural ground (without evidence of the degree of compaction); also applies to horizontal timber sheeting (Berlin support system).

A2 Vertical sheeting of the pipe trench with sheet steel piles that are only removed after backfilling Trench-lining plates or equipment that are removed in stages when filling the trench. Uncompacted trench backfill.Injecting the backfill (only suitable for soils of group G1).

A3 Vertical sheeting of the pipe trench with sheet piling. lightweight piling profiles. timber planks. trench-lining plates and devices which are only removed after backfilling

A4 Layers of compacted trench filling against the natural ground with evidence of the degree of compaction required according to ZTVE-StB; also applies to horizontal timber sheeting (Berlin sheeting). The cover fill condition A4 cannot be applied for soils of group G4

Bedding conditions for the trench backfill Bedding in the pipe zone

B1 Layers of compacted bedding against the natural ground and/or bedding compacted in layers in the embankment (without evidence of the degree of compaction); also applies for horizontal timber sheeting (Berlin sheeting)

B2 Vertical sheeting within the pipe zone with trench sheets extending to the trench bottom that are only removed after backfilling and compaction Trench-lining plates or equipment under the condition that the compaction of the soil is carried out after removing the sheeting

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Dimensions: DN/OD.................. DN/OD.................. DN/OD..................

B3 Vertical sheeting within the pipe zone with sheet piling or light-weight piling profiles and compaction against the sheeting extending below the trench bottom

B4 Bedding compacted in layers against the natural ground or in layers in the embankment with evidence of the degree of compaction required according to ZTVE-StB. Bedding condition B4 cannot be applied for soils of group G4.

Piling depth: ts = ...................m ts = ...................m ts = ...................m

Traffic load: none none none

LKW 12 LKW 12 LKW 12

SLW 30 SLW 30 SLW 30

SLW 60 SLW 60 SLW 60

UIC 71 single track UIC 71 single track UIC 71 single track

UIC 71 multi track UIC 71 multi track UIC 71 multi track

Aircraft load BFZ ..............

Aircraft load BFZ ..............

Aircraft load BFZ ..............

Other surface load

..............kN/m2

Other surface load

..............kN/m2

Other surface load

..............kN/m2

Road surface: yes no yes no yes no

Dynamic load capacity (evidence of the safety of AWADUKT PP SN10/HPP with a load that is not primarily static)

required required required

Bedding for stress analysis [2α]

60° 60° 60°

90° 90° 90°

120° 120° 120°

Other ............° Other ............° Other ............°

Sketch for special laying situations

Remarks/Additions:

Date:

Signature:

2α

ts

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Standardised statics AWADUKT HPP SN16 according to DIN EN 1852

DN 110 to DN 630

Static load analysis to ATV-DVWK-A 127

Standard installation cases

1. Basic conditionsTraffic load: SLW 60 with road surfaceBedding material. pipe zone: Non-cohesive soil G1Degree of compaction. pipe zone: Dpr = 95 %Natural ground/ Cover fill: Cohesive mixed soil G3Degree of compaction. in-situ soil/cover fill: Dpr = 92 %Trench width (depending on dimension to DIN 4124 or DIN EN 1610): 0.8 m - 1.7 mBedding/cover fill condition:

B1/A1 in layers against natural ground or A2/B2 for workin the sheeting

Slope angle: 60° / 90° (sheeting)Pipe bedding angle: 90°

2. Results

Taking into account the calculation assumptions given above. AWADUKT HPP SN16 DN 160-630 can be used in the following installation cases:

Top fill height above soffit Groundwater above soffit Results, long-termDeformation Safety against buckling

0,5 m - o.k. o.k.0,5 m 0.3 m o.k. o.k.8,0 m - o.k. o.k.8,0 m 6.0 m o.k. o.k.

Limit values according to ATV-DVWK-A 127:Deformation: max. 6 % (normal case) or max. 9 % (justified exceptions)Safety against buckling: min. 2.5

AWADUKT HPP SN16 can be used from 0.5 m to 8 m below SLW 60 without individual verification of structural strength.

With diering installation conditions, please complete the static questionnaire in full and fax or email to your relevant sales oce.

You also have the possibility of calculating an online static load analysis for your building project at www.rehau.de/rohrstatik-rechner.

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Standardised statics AWADUKT SN10 according to DIN EN 1852

DN 110 to DN 800

Static load analysis to ATV-DVWK-A 127

Standard installation conditions

1. Basic conditionsTraffic load: SLW 60 with road surfaceBedding material. pipe zone: Non-cohesive soil G1Degree of compaction. pipe zone: Dpr = 95 %Natural ground/ Cover fill: Cohesive mixed soil G3Degree of compaction. in-situ soil/cover fill: Dpr = 92 %Trench width (depending on dimension to DIN 4124 or DIN EN 1610): 0.8 m - 1.7 mBedding/cover fill condition:

B1/A1 in layers against natural ground or A2/B2 for workin the sheeting

Slope angle: 60° / 90° (sheeting)Pipe bedding angle: 90°

2. Results

Taking into account the calculation assumptions given above. AWADUKT HPP SN16 DN 160-630 can be used in the following installation cases:

Top fill height above soffit Groundwater above soffit Results, long-termDeformation Safety against buckling

0.5 m - o.k. o.k.0.5 m 0.3 m o.k. o.k.6.0 m - o.k. o.k.6.0 m 5.0 m o.k. o.k.

Limit values according to ATV-DVWK-A 127Deformation: max. 6 % (normal case) or max. 9 % (justified exceptions)Safety against buckling: min. 2.5

AWADUKT HPP SN16 can be used from 0.5 m to 8 m below SLW 60 without individual verification of structural strength.

With diering installation conditions, please complete the static questionnaire in full and fax or email to your relevant sales oce.

You also have the possibility of calculating an online static load analysis for your building project at www.rehau.de/rohrstatik-rechner.

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