Inspections, Tests and Safety Considerations

Published by The Plastics Pipe Institute, Inc.
Inspections, Test
and
Safety Considerations
Copyright, The Plastics Pipe Institute, Inc. 1999

i
Table of Contents
Foreword iv
Scope 1
Introduction 1
Handling and Storage 2
Receiving Inspection 2
Product Packaging 3
Checking the order 4
Load Inspection 5
Receiving Report & Reporting Damage 6
Unloading Instructions 6
Unloading Site Requirements 7
Handling Equipment 7
Unloading Large Fabrications, Manhole and Tanks 8
Pre-Installation Storage 9
Pipe Stacking Heights 10
Exposure to UV and Weather 11
Cold Weather Handling 11
General Conditions During Installation 12
Joining and Connections 12
Field Joining 12
Cleaning 13
Field Fusion Joining 13
Field Handling 14
Inspection and Testing 15
Pre-Construction 15
During Construction 15
Butt Fusion Joint Quality 15
Inspections, Tests and Safety Considerations
ii
Table of Contents (contd)
Soil Tests 17
Pipe surface Damage 17
Deflection Tests 18
Post Installation 20
Leak Testing 20
Pressure Test Precautions 21
References 21
Test Pressure 22
Test Duration 22
Pre-Test Inspection 22
Hydrostatic Testing 23
Monitored Make-up Water Test 23
Non-monitored Make-up Water Test 24
Pneumatic Testing 24
High Pressure Procedure 25
Low Pressure Procedure 25
Initial Service Testing 26
Test Procedure 26
Non-Testable Systems 26
Considerations for Post Start-Up and Operation 26
Disinfecting Water Mains 26
Cleaning 27
Squeeze-Off 27
Tools 28
Key Elements 29
Procedure 30
Routine or Emergency? 32
Repairs 33
iii
Table of Contents (contd)
Damage Assessment 33
Permanent Repairs 34
Temporary Repairs 35
Conclusion 35
References 36
List of Illustrations
Figure Page
Figure 1 Typical Silo Pack Truckload (40' Trailer) 3
Figure 2 Typical Bulk Pack Truckload (40' Trailer) 4
Figure 3 Typical Strip Load Truckload (40' Trailer) 5
Figure 4 Forklift Load Capacity 8
Figure 5 Loose Pipe Storage 9
Figure 6 Bent Strap Test Specimen 16
Figure 7 Determining Initial Deflection 18
Figure 8 Squeeze-off Stresses 30
Figure 9 Constrained Pipe Repair 34
List of Tables
Table Page
Table I Suggested Jobsite Loose Storage Stacking
Heights for Conventionally Extruded Pipe Lengths 9
Table II Suggested Jobsite Loose Storage Stacking
Heights for Extruded Profile Pipe 10
Table III Test Phase Make-up Amount 23
Table IV Squeeze Tool Bar Radius 29
iv
Foreword
Inspections, Tests and Safety Considerations is one of the chapters in the
Plastics Pipe Institutes PPI Handbook of Polyethylene Piping. Other topics
addressed in the handbook include design and installation of polyethylene
piping systems, joining procedures, and relevant codes and standards.
The PPI Handbook of Polyethylene Piping is produced by the PPI Municipal
and Industrial (M&I) Division. M&I membership consists of major North American
manufacturers of polyethylene (PE) pipe and fittings, PE piping materials,
machinery, and equipment used for joining and installing PE piping, related
test laboratories, and professional organizations.
PPI maintains additional divisions that address other applications such as
gas distribution. PPI and its divisions provide technical and promotional support
for the effective use and continued application of thermoplastics pipe and
related products, consistent with the best public interest. PPI membership
also includes producers of polyvinyl chloride (PVC), chlorinated polyvinyl chloride
(CPVC), polybutylene (PB) and crosslinked PE (PEX) piping products and
materials.
For a list of other publications available from PPI and/or further information,
please contact:
The Plastics Pipe Institute, Inc.
Toll free: 1-888-314-6774
http://www.plasticpipe.org
The information in this publication was prepared by PPI as a service to
its members and the industry. While prepared in good faith and believed to
be accurate, PPI, its members, and contributors disclaim all liability for any
loss or damage arising from reliance on this information by any person. PPI
does not endorse the proprietary products or processes of any manufacturer.
Consult the product manufacturer for specific information.
October 1999
Inspections, Tests and Safety
Considerations
Once a polyethylene piping system has been selected and designed for
an application, the design is implemented by securing the pipe, fittings and
other necessary appurtenances, installing the system, and placing it in ser-
vice. Piping installation involves setting various parts, people, and machines
in motion to obtain, assemble, install, inspect and test the piping system.
Whenever machinery, piping parts, and personnel are engaged in piping
system construction, safety must be a primary consideration.
This chapter presents some of the inspections, tests and safety
considerations related to installing polyethylene piping, placing an installed
system in service, and operating a polyethylene piping system.
This chapter does not purport to address all of the product
applications, inspections, tests, or construction practices
that could be used, nor all of the safety practices necessary
to protect persons and property. It is the responsibility of
the users of this chapter, and the installers, inspectors
and operators of piping systems to establish appropriate
safety and health practices, and to determine the
applicability of regulatory limitations before any use,
installation, inspection, test or operation.
Generally, piping system installation begins with obtaining the pipe, fittings,
and other goods required for the system. Assembly and installation follow,
then system testing and finally, release for operation. Throughout the
installation process, various inspections and tests are performed to ensure
installed system quality, and that the system when completed is capable of
functioning according to its design specifications. In the selection, design,
and installation of polyethylene piping systems, professional engineering
services, and qualified installers should be used.
Page 1
Scope
Introduction
Polyethylene piping products are integrated pipe and fitting systems for
a broad range of commercial, municipal, utility and industrial applications.
They may be buried, laid on the surface, supported above grade, installed
underwater, or floated on the surface of lakes or rivers.
Polyethylene piping products are manufactured from 1/4" (6 mm) diameter
through 120" (3050 mm) diameter under applicable industry standards
(ASTM, AWWA, etc.) for pressure, non-pressure and low pressure
applications. As well, polyethylene fittings, custom fabrications, special
structures and appurtenances are available for full pressure rated, reduced
pressure rated, or non-pressure rated applications.
Conventionally extruded polyethylene pipes have homogeneous walls
and smooth interior and exterior surfaces. Profile pipes are manufactured
by extruding a profile over a mandrel. These pipes have smooth interiors,
and may have a smooth or a profiled exteriors. Profile pipes are primarily
applied to non-pressure or low pressure applications.
Fittings, fabricated structures, tanks, and manholes are constructed for
pressure, low pressure and non-pressure applications. Smaller size fittings
are usually injection molded. Larger fittings, fabricated structures, tanks,
and manholes are fabricated in manufacturers facilities. Thermal joining
techniques used for fabrication usually limit the design pressure capacity of
the structure. Complex structures are generally not suitable for field
fabrication.
After the piping system has been designed and specified, the piping
system components must be obtained. Typically, project management and
purchasing personnel work closely together so that the necessary
components are available when they are needed for the upcoming
construction work.
Receiving Inspection
Few things are more frustrating and time consuming than not having
what you need, when you need it. Before piping system installation begins,
an important initial step is a receiving inspection of incoming products.
Construction costs can be minimized, and schedules maintained by checking
Page 2
Handling and Storage
incoming goods to be sure the parts received are the parts that were or-
dered, and that they arrived in good condition and ready for installation.
Polyethylene pipe, fittings, and fabrications are shipped by commercial
carriers who are responsible for the products from the time they leave the
manufacturing plant until they are accepted by the receiver. Pipe and
fabricated fittings and structures are usually shipped on flatbed trailers.
Smaller fittings may be shipped in enclosed vans, or on flatbed trailers
depending upon size and packaging. Molded fittings are usually boxed, and
shipped by commercial parcel services.
Product Packaging
Depending on size, polyethylene piping is produced in coils or in straight
lengths. Coils are stacked together into silo packs. Straight lengths are
bundled together in bulk packs or loaded on the trailer in strip loads. Standard
straight lengths for conventionally extruded pipe are 40' long, however,
lengths up to 60' long may be produced. Profile extruded pipes are typically
produced in 20' lengths. State transportation restrictions on length, height
and width usually govern allowable load configurations. Higher freight costs
will apply to loads that exceed length, height, or width restrictions. Although
polyethylene pipe is lightweight, weight limitations may restrict load size for
very heavy wall or longer length pipe.
Page 3
Pallet Silo Pack
Figure 1 Typical Silo Pack Truckload (40 Trailer)
Page 4
Extruded profile pipe lengths are usually shipped on standard 40' flatbed
trailers. Pipes are commonly packaged in bundles or as strip loads. Pipes
96" ID (2438 mm ID) and 120" ID (3048 mm ID) will exceed 8' overall width,
and are subject to wide load restrictions.
Figures 1 through 3 are general illustrations of truckload and packaging
configurations. Actual truckloads and packaging may vary from the
illustrations.
Small fittings are packaged in cartons which may be shipped individually
by package carriers. Large orders may be palletized and shipped in enclosed
vans. Large fittings and custom fabrications may be packed in large boxes
on pallets, or secured to pallets.
Occasionally, when coiled pipe silos and boxed fittings are shipped
together, fitting cartons are placed in the center of the silo packs. Tanks,
manholes, and large fittings and custom fabrications are usually loaded
directly onto flatbed trailers.
Checking the Order
When a shipment is received, it should be checked to see that the correct
products and quantities have been delivered. Several documents are used
Bulk Pack
Figure 2 Typical Bulk Pack Truckload (40 Trailer)
Page 5
here. The Purchase Order or the Order Acknowledgment lists each item by
its description, and the required quantity. The incoming load will be described
in a Packing List which is attached to the load. The descriptions and quantities
on the Packing List should match those on the Purchase Order or the Order
Acknowledgment.
The carrier will present a Bill of Lading that generally describes the load
as the number of packages the carrier received from the manufacturing plant.
The Order Acknowledgment, Packing List, and Bill of Lading should all be in
agreement. Any discrepancies must be reconciled among the shipper, the
carrier, and the receiver. The receiver should have a procedure for reconciling
any such discrepancies.
Load Inspection
There is no substitute for visually inspecting an incoming shipment to
verify that the paperwork accurately describes the load. Products are usually
identified by markings on each individual product. These markings should
be checked against the Order Acknowledgment and the Packing List. The
number of packages and their descriptions should be checked against the
Bill of Lading.
Strip Load Pack
Layer Seperation
Dunnage
Figure 3 Typical Strip Load Truckload (40 Trailer)
Page 6
This is the time to inspect for damage which may occur anytime products
are handled. Obvious damage such as cuts, abrasions, scrapes, gouges,
tears, and punctures should be carefully inspected.
When pipe installation involves saddle fusion joining, diesel smoke on
the pipes outside surface may be a concern because it may reduce the
quality of saddle fusion joints. Smoke damage is effectively prevented by
covering at least the first third of the load with tarpaulins. If smoke tarps are
required, they should be in place covering the load when it arrives.
Receiving Report & Reporting Damage
The delivering truck driver will ask the person receiving the shipment to
sign the Bill of Lading, and acknowledge that the load was received in good
condition. Any damage, missing packages, etc., should be noted on the bill
of lading at that time.
Shipping problems such as damage, missing packages, document
discrepancies, incorrect product, etc., should be reported to the product
supplier immediately. Shipping claims must be filed within 7 days.
Unloading Instructions
Before unloading the shipment, there must be adequate, level space to
unload the shipment. The truck should be on level ground with the parking
brake set and the wheels chocked. Unloading equipment must be capable
of safely lifting and moving pipe, fittings, fabrications or other components.
WARNING: Unloading and handling must be performed
safely. Unsafe handling can result in damage to property
or equipment, and be hazardous to persons in the area.
Keep unnecessary persons away from the area during
unloading.
WARNING: Only properly trained personnel should operate
unloading equipment.
Page 7
Unloading Site Requirements
The unloading site must be relatively flat and level. It must be large
enough for the carriers truck, the load handling equipment and its move-
ment, and for temporary load storage. Silo packs and other palletized pack-
ages should be unloaded from the side with a forklift. Non-palletized pipe,
fittings, fabrications, manholes, tanks, or other components should be un-
loaded from above with lifting equipment and wide web slings, or from the
side with a forklift.
Handling Equipment
Appropriate unloading and handling equipment of adequate capacity must
be used to unload the truck. Safe handling and operating procedures must
be observed.
Pipe must not be rolled or pushed off the truck. Pipe, fittings,
fabrications, tanks, manholes, and other components must not
be pushed or dumped off the truck, or dropped.
Although polyethylene piping components are lightweight compared to
similar components made of metal, concrete, clay, or other materials, larger
components can be heavy. Lifting and handling equipment must have
adequate rated capacity to lift and move components from the truck to
temporary storage. Equipment such as a forklift, a crane, a side boom tractor,
or an extension boom crane is used for unloading.
When using a forklift, or forklift attachments on equipment such as
articulated loaders or bucket loaders, lifting capacity must be adequate at
the load center on the forks. Forklift equipment is rated for a maximum
lifting capacity at a distance from the back of the forks. (See Figure 4.) If the
weight-center of the load is farther out on the forks, lifting capacity is reduced.
Before lifting or transporting the load, forks should be spread as wide
apart as practical, forks should extend completely under the load, and the
load should be as far back on the forks as possible.
WARNING: During transport, a load on forks that are too
short or too close together, or a load too far out on the
forks, may become unstable and pitch forward or to the
side, and result in damage to the load or property, or
hazards to persons.
Page 8
Lifting equipment such as cranes, extension boom cranes, and side boom
tractors, should be hooked to wide web choker slings that are secured around
the load or to lifting lugs on the component. Only wide web slings should be
used. Wire rope slings and chains can damage components, and should
not be used. Spreader bars should be used when lifting pipe or components
longer than 20'.
WARNING: Before use, inspect slings and lifting
equipment. Equipment with wear or damage that impairs
function or load capacity should not be used.
Unloading Large Fabrications, Manholes and Tanks
Large fabrications, manholes and tanks should be unloaded using a wide
web choker sling and lifting equipment such as an extension boom crane,
crane, or lifting boom. The choker sling is fitted around the manhole riser or
near the top of the tank. Do not use stub outs, outlets, or fittings as lifting
points, and avoid placing slings where they will bear against outlets or fittings.
Larger diameter manholes and tanks are typically fitted with lifting lugs.
WARNING: ALL lifting lugs must be used. The weight of
the manhole or tank is properly supported only when all
lugs are used for lifting. Do not lift tanks or manholes
containing liquids.
Figure 4 Forklift Load Capacity
Rated
Load
Capacity
Reduced
Load
Capacity
Page 9
Pre-Installation Storage
The size and complexity of the project and the components, will determine
pre-installation storage requirements. For some projects, several storage
or staging sites along the right-of-way may be appropriate, while a single
storage location may be suitable for another job.
The site and its layout should provide protection against physical damage
to components. General requirements are for the area to be of sufficient
size to accommodate piping components, to allow room for handling
equipment to get around them, and to have a relatively smooth, level surface
free of stones, debris, or other material that could damage pipe or
components, or interfere with handling. Pipe may be placed on 4-inch wide
wooden dunnage, evenly spaced at intervals of 4 feet or less.
Pipe Size Suggested Stacking Height* - Rows
DR Above 17 DR 17 & Below
4 15 12
5 12 10
6 10 8
8 8 6
10 6 5
12 5 4
14 5 4
Table I Suggested Jobsite Loose Storage Stacking Heights
for Conventionally Extruded Pipe Lengths (Ref. 1)
Figure 5 Loose Pipe Storage
Blocking prevents movement
Width to suit
# Rows per Table I
or Table II
Straight Pipes not tangled up
or crossing over each other
Page 10
*Stacking heights based on 6' for level terrain and 4' for less level terrain
Pipe Size Suggested Stacking Height*
Rows
18 4
21 3
24 3
27 2
30 2
33 2
36 2
42 1
48 1
54 1
60 1
66 1
72 1
84 1
96 1
120 1
*Suggested stacking heights based on 6' for level terrain and 4' for less level terrain.
Pipe Size Suggested Stacking Height* - Rows
DR Above 17 DR 17 & Below
16 4 3
18 4 3
20 3 3
22 3 2
24 3 2
26 3 2
28 2 2
30 2 2
32 2 2
36 2 1
42 1 1
48 1 1
54 1 1
63 1 1
Pipe Stacking Heights
Coiled pipe is best stored as-received in silo packs. Individual coils may be
removed from the top of the silo pack without disturbing the stability of the remaining
coils in the silo package.
Table II Suggested Jobsite Loose Storage Stacking
Heights for Extruded Profile Pipe (Ref. 2)
Page 11
Pipe received in bulk packs or strip load packs should be stored in the
same package. If the storage site is flat and level, bulk packs or strip load
packs may be stacked evenly upon each other to an overall height of about
6'. For less flat or less level terrain, limit stacking height to about 4'.
Before removing individual pipe lengths from bulk packs or strip load
packs, the pack must be removed from the storage stack, and placed on the
ground.
Individual pipes may be stacked in rows. Pipes should be laid straight,
not crossing over or entangled with each other. The base row must be
blocked to prevent sideways movement or shifting. (See Figure 5, Table I,
and Table II.) The interior of stored pipe should be kept free of debris and
other foreign matter.
Exposure to UV and Weather
Polyethylene pipe products are protected against deterioration from
exposure to ultraviolet light and weathering effects. Color and black products
are compounded with antioxidants, thermal stabilizers, and UV stabilizers.
Color products use sacrificial UV stabilizers that absorb UV energy, and are
eventually depleted. In general, non-black products should not remain in
unprotected outdoor storage for more than 2 years, however, some
manufacturers may allow longer unprotected outside storage. Black products
contain at least 2% carbon black to protect the material from UV deterioration.
Black products with and without stripes are generally suitable for unlimited
outdoor storage and for service on the surface or above grade. (Ref. 11, 12,
13, & 14)
Cold Weather Handling
Temperatures near or below freezing will affect polyethylene pipe by
reducing flexibility and increasing vulnerability to impact damage. Care should
be taken not to drop pipe, or fabricated structures, and to keep handling
equipment and other things from hitting pipe. Ice, snow, and rain are not
harmful to the material, but may make storage areas more troublesome for
handling equipment and personnel. Unsure footing and traction require
greater care and caution to prevent damage or injury.
Walking on pipe can be dangerous. Inclement weather can make pipe
surfaces especially slippery.
Page 12
WARNING: Keep safety first on the jobsite; do not walk on pipe.
Joining and Connections
For satisfactory material and product performance, system designs and
installation methods rely on appropriate, properly made connections. An
inadequate or improperly made field joint may cause installation delays, may
disable or impair system operations, or may create hazardous conditions.
Polyethylene piping products are connected using heat fusion,
electrofusion, thermal welding, and mechanical methods such as gasketed
bell-and-spigot joints, flanges, and compression couplings. Joining and
connection methods will vary depending upon requirements for internal or
external pressure, leak tightness, restraint against longitudinal movement
(thrust load capacity), gasketing requirements, construction and installation
requirements, and the product.
Connection design limitations and manufacturers joining
procedures must be observed. Otherwise, the connection
or products adjacent to the connection may leak or fail
which may result in property damage, or hazards to
persons.
The tools and components required to construct and install joints in
accordance with manufacturers recommendations should always be used.
However, field connections are controlled by, and are the responsibility of
the field installer.
A complete discussion on joining and connecting polyethylene piping
products is presented in PPIs Handbook of Polyethylene Pipe, chapter
entitled Polyethylene Joining Procedures. (Ref. 3)
Field Joining
All field connection methods and procedures require that the component
ends to be connected must be clean, dry, and free of detrimental surface
defects before the connection is made. Contamination and unsuitable surface
conditions usually produce an unsatisfactory connection. Gasketed joints
may require appropriate lubrication.
General Considerations During Installation
Page 13
Cleaning
Before joining, and before any special surface preparation, surfaces must
be clean and dry. General dust and light soil may be removed by wiping the
surfaces with clean, dry, lint free cloths. Heavier soil may be washed or
scrubbed off with soap and water solutions, followed by thorough rinsing
with clear water, and drying with dry, clean, lint-free cloths.
WARNING: Before using chemical cleaning solvents, the
potential risks and hazards to persons should be known
by the user, and appropriate safety precautions must be
taken. Chemical solvents may be hazardous substances
that may require special handling and personal protective
equipment.
The manufacturers instructions for use, and the material safety data
sheet (MSDS) for the chemical should be consulted for information on risks
to persons and for safe handling and use procedures. Some solvents may
leave a residue on the pipe, or may be incompatible with the material. See
PPI Technical Report TR-19, Thermoplastics Piping for the Transport of
Chemicals for additional information on chemical compatibility of polyethylene
materials. (Ref. 4)
Field Fusion Joining
Heat fusion joining requires specialized equipment for socket, saddle, or
butt fusion, or electrofusion. Heat fusion joining may be performed in any
season. During inclement weather, a temporary shelter should be set-up
over the joining operation to shield heat fusion operations from rain, frozen
precipitation, and cold winds.
WARNING: Most heat fusion equipment is not explosion-
proof. The fusion equipment manufacturers safety
instructions must be observed at all times and especially
when heat fusion is to be performed in a potentially volatile
atmosphere.
WARNING: When installing large diameter polyethylene
pipe in a butt fusion machine, do not bend the pipe against
an open fusion machine collet or clamp. The pipe may
suddenly slip out of the open clamp, and cause injury or
damage.
Page 14
Field Handling
Polyethylene pipe is tough, lightweight, and flexible. Installation does
not usually require high capacity lifting equipment. See Handling and Storage
for information on handling and lifting equipment.
WARNING: To prevent injury to persons or property, safe
handling and construction practices must be observed at
all times. The installer must observe all applicable Local,
State, and Federal Safety Codes, and any safety
requirements specified by the owner or the project
engineer.
Pipe up to about 8" (219 mm) diameter and weighing roughly 6 lbs per
foot (20 kg per m) or less can usually be handled or placed in the trench
manually. Heavier, larger diameter pipe will require appropriate handling
equipment to lift, move and lower the pipe. Pipe must not be dumped,
dropped, pushed, or rolled into a trench.
WARNING: Appropriate safety precautions must be
observed whenever persons are in or near a trench.
Coiled lengths and long strings of heat fused polyethylene pipe may be
cold bent in the field. Field bending usually involves sweeping or pulling the
pipe string into the desired bend radius, then installing permanent restraint
such as embedment around a buried pipe, to maintain the bend.
WARNING: Considerable force may be required to field
bend the pipe, and the pipe may spring back forcibly if
holding devices slip or are inadvertently released while
bending. Observe appropriate safety precautions during
field bending.
These paragraphs have attempted to convey the primary safety
and handling considerations associated with joining and connecting
polyethylene pipe. For a more thorough discussion on the joining
methods used with polyethylene pipe, the reader is referred to PPIs
Handbook of Polyethylene Pipe, Polyethylene Joining Procedures
chapter.
Page 15
Inspections and tests begin before construction. Jobsite conditions dictate
how piping may be installed and what equipment is appropriate for
construction. Soil test borings and test excavations may be useful to
determine soil bearing stress and whether or not native soils are suitable as
backfill materials.
In slipline rehabilitation applications, the deteriorated pipeline should be
inspected by remote TV camera to locate structurally deteriorated areas,
obstructions, offset and separated joints, undocumented bends, and service
connections. In some cases, a test pull, drawing a short section of slipliner
through the line, may be conducted to ensure that the line is free of
obstructions.
The installer should carefully review contract specifications and plans. It
is important that the specifications and plans fit the job. Different piping
materials require different construction practices and procedures. These
differences should be accurately reflected in the contract documents. Good
plans and specifications help protect all parties from unnecessary claims
and liabilities. Good documents also set minimum installation quality
requirements, and the testing and inspection requirements that apply during
the job.
All incoming materials should be inspected to be sure that sufficient
quantities of the correct products for the job are at hand, and that they arrived
in good condition, ready for installation.
During Construction
Tests and inspections performed during construction include butt fusion
joint quality tests, soil compaction and density tests, pipe deflection tests,
pressure tests, and other relevant inspections. Fusion joint qualification and
inspection guidelines for butt, socket and saddle fusions should be obtained
from the pipe or fitting manufacturer.
Butt Fusion Joint Quality
Visual inspection is the most common joint evaluation method for all sizes
of conventionally extruded polyethylene pipe. Visual inspection criteria for
butt fusion joints should be obtained from the pipe manufacturer. Computer
controlled ultrasonic inspection equipment is available for 12" IPS and smaller
pipes with walls 1" or less in thickness. Equipment for larger diameters and
wall thickness is being developed. X-ray inspection is generally unreliable
because x-ray is a poor indicator of fusion quality.
Pre-Construction
Inspection and Testing
Page 16
Cold fusion is a poor quality joint that should be removed and re-done. If
not repaired, joint failure can occur.
When butt fusion is between pipe and molded fittings, the fitting-side
bead may exhibit shape irregularities which are caused by the fitting
manufacturing process. A slightly irregular fitting-side bead may not indicate
an improper joint, provided that the pipe-side bead is properly shaped, and
the v-groove between the beads is correct. Contact the pipe or fitting
manufacturer if assistance is required.
Fusion joining may be destructively tested to confirm joint integrity,
operator procedure, and fusion machine set-up. A field-performed destructive
test is a bent strap test.
The bent strap test specimen is prepared by making a trial butt fusion,
usually the first fusion of the day, and allowing it to cool to ambient
temperature. A test strap that is at least 6" or 15 pipe wall thicknesses long
on each side of the fusion, and about 1" or 1-1/2 wall thicknesses wide is cut
out of the trial fusion pipe. (See Figure 6) The strap is then bent so that the
ends of the strap touch. Any disbondment at the fusion is unacceptable,
and indicates poor fusion quality. If failure occurs, fusion procedures and/or
machine set-up should be changed, and a new trial fusion and bent strap
test specimen should be prepared and tested. Field fusion should not proceed
until a test joint has passed the bent strap test.
t
15 t or 6 min 15 t or 6 min
1 - 1/2 t
or 1 min
Test Strap
Butt Fusion
Figure 6 Bent Strap Test Specimen
Page 17
WARNING: A test strap from thick wall pipe may require
considerable effort to bend. Further, the test strap may
spring back if the ends are inadvertently released while
bending. Appropriate personnel safety precautions should
be observed.
High-speed, tensile-impact testing, a destructive test of a tensile coupon
cut from the pipe joint, can provide a quantitative joint strength assessment.
Tensile impact strength of the joint may be compared to that of the base
pipe.
Soil Tests
During buried pipe installation, work should be checked throughout the
construction period by an inspector who is thoroughly familiar with the jobsite,
contract specifications, materials, and installation procedures. Inspections
should reasonably ensure that significant factors such as trench depth, grade,
pipe foundation (if required), quality and compaction of embedment backfill,
and safety are in compliance with contract specifications and other
requirements. To evaluate soil stability, density and compaction, appropriate
ASTM tests may be required in the contract specifications.
Pipe Surface Damage
Surface damage may occur during construction handling and installation.
Significant damage may impair the future performance of the pipeline. The
following guidelines may be used to assess surface damage significance.
For polyethylene pressure pipelines, damage or butt fusion misalignment
should not exceed 10% of the minimum wall thickness required for the
pipelines operating pressure. (Ref. 5) Deep cuts, abrasions or grooves
cannot be field repaired by hot gas or extrusion welding. Excessive damage
may require removal and replacement of the damaged pipe section, or
reinforcement with a full encirclement repair clamp. Misaligned butt fusions
should be cut out and redone.
If damage is not excessive, the shape of the damage may be a
consideration. Sharp notches and cuts should be dressed smooth so the
notch is blunted. Blunt scrapes or gouges should not require attention. Minor
surface abrasion from sliding on the ground or insertion into a casing should
not be of concern.
Page 18
Deflection Tests
Buried flexible pipes rely on properly installed backfill to sustain earthloads
and other loads. Proper installation requires using the backfill materials
specified by the designer, and installing the pipe as specified by the designer.
Large diameter extruded profile pipes, and larger diameter, high DR
conventionally extruded pipes are inherently flexible. Pipe deflection can be
used to monitor the installation quality. Improperly embedded pipe can
develop significant deflection in a short time, thus alerting the installer and
the inspector to investigate the problem. Inspection should be performed as
the job progresses, so errors in the installation procedure can be identified
and corrected.
Initial deflection checks of extruded profile pipe may be performed after
embedment materials have been placed and compacted. The inside diameter
D1
D2
Backfill placed
and compacted
Vertical diameter
Final Backfill placed
and compacted
Vertical diameter
Figure 7 Determining Initial Deflection
Page 19
of the pipe is measured after backfill materials have been placed to the pipe
crown, and compacted. This is D1. Then final backfill materials are placed
and compacted, and the pipe inside diameter is measured again at the exact
location where the prior measurement was taken. This is D2. (See Figure
7)
Percent initial deflection is calculated using the following:
%Deflection =
D1- D2
D1
100
where D1 and D2 are as defined above and depicted in Figure 7.

Another method to measure deflection is to pull a pre-sized mandrel through
the pipe. The mandrel should be sized so that if the pipe exceeds allowable
deflection, the mandrel is blocked.
To properly size the mandrel, the allowable vertical diameter of the pipe
must be established. It is necessary to account for pipe ID manufacturing
tolerances and any ovality that may occur during shipping. Pipe base ID
dimensions and tolerances should be obtained from the manufacturer. The
maximum mandrel diameter is calculated as follows:
M D
= D-
Dy
100
where D
M
= maximum mandrel diameter, in
D = base pipe ID, in
D=
D
-
A
+
B i
2 2
D
i
= nominal pipe ID, in
A = ID manufacturing tolerance, in
B = shipping ovality, in
B=0.03
Di
y = allowable deflection, percent
Deflection tests of conventionally extruded pipe may be performed in the
same manner. However, conventionally extruded pipe is manufactured to a
controlled outside diameter, so the inside diameter is subject to the combined
tolerances of the outside diameter and the wall thickness.
Page 20
Leak Testing
The intent of leak testing is to find unacceptable faults in a piping system.
If such faults exist, they may manifest themselves by leakage or rupture.
Leakage tests may be performed if required in the Contract Specifications.
Testing may be conducted in various ways. Internal pressure testing involves
filling the test section with a nonflammable liquid or gas, then pressurizing
the medium. Hydrostatic pressure testing with water is the preferred
and recommended method. Other test procedures may involve paired
internal or end plugs to pressure test individual joints or sections, or an initial
service test. Joints may be exposed to allow inspection for leakage.
Liquids such as water are preferred as the test medium because less
energy is released if the test section fails catastrophically. During a pres-
sure test, energy (internal pressure) is applied to stress the test section. If
the test medium is a compressible gas, then the gas is compressed and
absorbs energy while applying stress to the pipeline. If a catastrophic fail-
ure occurs, both the pipeline stress energy and the gas compression energy
are suddenly released. However, with an incompressible liquid such as
water as the test medium, the energy release is only the energy required to
stress the pipeline.
WARNING: Pipe system pressure testing is performed to
discover unacceptable faults in a piping system. Pressure
testing may cause such faults to fail by leaking or
rupturing. This may result in catastrophic failure. Piping
system rupture may result in sudden, forcible, uncontrolled
movement of system piping or components, or parts of
components.
WARNING: Pipe Restraint. The pipe system under test
and any closures in the test section should be restrained
against sudden uncontrolled movement from catastrophic
failure. Test equipment should be examined before
pressure is applied to insure that it is tightly connected.
All low pressure filling lines and other items not subject
to the test pressure should be disconnected or isolated.
Post Installation
Page 21
WARNING: Personal Protection. Take suitable
precautions to eliminate hazards to personnel near lines
being tested. Keep personnel a safe distance away from
the test section during testing.
Pressure Testing Precautions
The piping section under test and any closures in the test section should
be restrained or otherwise restricted against sudden uncontrolled movement
in the event of rupture. Expansion joints and expansion compensators should
be temporarily restrained, isolated or removed during the pressure test.
Testing may be conducted on the system, or in sections. The limiting
test section size is determined by test equipment capability. If the pressurizing
equipment is too small, it may not be possible to complete the test within
allowable testing time limits. If so, higher capacity test equipment, or a smaller
test section may be necessary.
If possible, test medium and test section temperatures should be less
than 100
0
F (38
0
C). At temperatures above 100
0
F (38
0
C), reduced test
pressure is required. Before applying test pressure, time may be required
for the test medium and the test section to temperature equalize. Contact
the pipe manufacturer for technical assistance with elevated temperature
pressure testing.
References
The following reference publications provide pressure testing information:
ASME B31.1 Power Piping, Section 137, Pressure Tests. (Ref. 6)
PPI TR-31 Underground Installation of Polyolefin Piping, Section 7,
System Testing. (Ref 1)
ASTM F 1417, Standard Test Method for Installation Acceptance of
Plastic Gravity Sewer Lines Using Low-Pressure Air. (Ref. 7)
Uni-Bell PVC Pipe Association Standard, Uni-b-6-90 Recommended
Practice for Low-Pressure Air Testing of Installed Sewer Pipe.
Page 22
The piping manufacturer should be consulted before using pressure
testing procedures other than those presented here. Other pressure testing
procedures may or may not be applicable depending upon piping products
and/or piping applications.
Test Pressure
Test pressure may be limited by valves, or other devices, or lower pressure
rated components. Such components may not be able to withstand the
required test pressure, and should be either removed from, or isolated from
the section being tested to avoid possible damage to, or failure of these
devices. Isolated equipment should be vented.
For continuous pressure systems where test pressure limiting
components or devices have been isolated, or removed, or are not
present in the test section, the maximum allowable test pressure is
1.5 Times the system design pressure at the lowest elevation in the
section under test.
If the test pressure limiting device or component cannot be removed
or isolated, then the limiting section or system test pressure is the
maximum allowable test pressure for that device or component.
For non-pressure, low pressure, or gravity flow systems, consult the
piping manufacturer for the maximum allowable test pressure.
Test Duration
For any test pressure from 1.0 to 1.5 times the system design pressure,
the total test time including initial pressurization, initial expansion, and time
at test pressure, must not exceed eight (8) hours. If the pressure test is not
completed due to leakage, equipment failure, etc., the test section should
be de-pressurized, and allowed to relax for at least eight (8) hours before
bringing the test section up to test pressure again.
Pre-Test Inspection
Test equipment and the pipeline should be examined before pressure is
applied to ensure that connections are tight, necessary restraints are in-
place and secure, and components that should be isolated or disconnected
are isolated or disconnected. All low pressure filling lines and other items
not subject to the test pressure should be disconnected or isolated.
Page 23
Hydrostatic testing
Hydrostatic pressure testing is preferred and is strongly recommended.
The preferred testing medium is clean water. The test section should be
completely filled with the test medium, taking care to bleed off any trapped
air. Venting at high points may be required to purge air pockets while the
test section is filling. Venting may be provided by loosening flanges, or by
using equipment vents. Re-tighten any loosened flanges before applying
test pressure.
Monitored Make-up Water Test
The test procedure consists of initial expansion, and test phases. During
the initial expansion phase, the test section is pressurized to the test pressure,
and sufficient make-up water is added each hour for three (3) hours to return
to test pressure. (Ref. 1)
Nominal Pipe Size, Make-Up Water Allowance
in (U.S. Gallons per 100 ft of Pipe)
1 Hour Test 2 Hour Test 3 Hour Test
1-1/4 0.06 0.10 0.16
1-1/2 0.07 0.10 0.17
2 0.07 0.11 0.19
3 0.10 0.15 0.25
4 0.13 0.25 0.40
5 0.19 0.38 0.58
5-3/8 0.21 0.41 0.62
6 0.3 0.6 0.9
7-1/8 0.4 0.7 1.0
8 0.5 1.0 1.5
10 0.8 1.3 2.1
12 1.1 2.3 3.4
13-3/8 1.2 2.5 3.7
14 1.4 2.8 4.2
16 1.7 3.3 5.0
18 2.0 4.3 6.5
20 2.8 5.5 8.0
22 3.5 7.0 10.5
24 4.5 8.9 13.3
26 5.0 10.0 15.0
28 5.5 11.1 16.8
Table III Test Phase Make-up Amount
Page 24
Nominal Pipe Size, Make-Up Water Allowance
in (U.S. Gallons per 100 ft of Pipe)
1 Hour Test 2 Hour Test 3 Hour Test
30 6.3 12.7 19.2
32 7.0 14.3 21.5
34 8.0 16.2 24.3
36 9.0 18.0 27.0
42 12.0 23.1 35.3
48 15.0 27.0 43.0
54 18.5 31.4 51.7
63
After the initial expansion phase, about four (4) hours after pressuriza-
tion, the test phase begins. The test phase may be one (1), two (2), or three
(3) hours, after which a measured amount of make-up water is added to
return to test pressure. If the amount of make-up water added does not
exceed Table III values, leakage is not indicated.
Non-monitored Make-Up Water Test
The test procedure consists of initial expansion, and test phases. For
the initial expansion phase, make-up water is added as required to maintain
the test pressure for four (4) hours. For the test phase, the test pressure is
reduced by 10 psi. If the pressure remains steady (within 5% of the target
value) for an hour, no leakage is indicated.
Pneumatic Testing
WARNING: Compressed air or any pressurized gas used
as a test medium may present severe hazards to personnel
in the vicinity of lines being tested. Extra personnel
protection precautions should be observed when a gas
under pressure is used as the test medium.
WARNING: Explosive FailurePiping system rupture
during pneumatic pressure testing may result in the
explosive, uncontrolled movement of system piping, or
components, or parts of components. Keep personnel a
safe distance away from the test section during testing.
Page 25
Pneumatic testing should not be used unless the Owner and the respon-
sible Project Engineer specify pneumatic testing or approve its use as an
alternative to hydrostatic testing.
Pneumatic testing (testing with a gas under pressure) should not be
considered unless one of the following conditions exists:
when the piping system is so designed that it cannot be filled with
a liquid; or
where the piping system service cannot tolerate traces of liquid
testing medium.
The testing medium should be non-flammable and non-toxic. The test
pressure should not exceed the maximum allowable test pressure for any
non-isolated component in the test section.
Leaks may be detected using mild soap solutions (strong detergent
solutions should be avoided), or other non-deleterious leak detecting fluids
applied to the joint. Bubbles indicate leakage. After leak testing, all soap
solutions or leak detecting fluids should be rinsed off the system with clean
water.
High Pressure Procedure
For continuous pressure rated pipe systems, the pressure in the test
section should be gradually increased to not more than one-half of the test
pressure, then increased in small increments until the required test pressure
is reached. Test pressure should be maintained for ten (10) to sixty (60)
minutes, then reduced to the design pressure rating, and maintained for
such time as required to examine the system for leaks.
Low Pressure Procedure
For components rated for low pressure service the specified rated test
pressure should be maintained for ten (10) minutes to one (1) hour, but not
more than one (1) hour. Test pressure ratings must not be exceeded.
Leakage inspections may be performed during this time. If the test
pressure remains steady (within 5% of the target value) for the one (1) hour
test time, no leakage is indicated.
Pressure testing of gravity-flow sewer lines should be conducted in
accordance with ASTM F 1417, Standard Test Method for Installation
Acceptance of Plastic Gravity Sewer Lines Using Low-Pressure Air. (Ref. 7)
Page 26
Initial Service Testing
An initial service test may be acceptable when other types of tests are
not practical, or where leak tightness can be demonstrated by normal service,
or when initial service tests of other equipment are performed. An initial
service test may apply to systems where isolation or temporary closures are
impractical, or where checking out pumps and other equipment affords the
opportunity to examine the system for leakage prior to full scale operations.
Test Procedure
The piping system should be gradually brought up to normal operating
pressure, and held at operating pressure for at least ten (10) minutes. During
this time, joints and connections should be examined for visual evidence of
leakage.
Non-Testable Systems
Some systems may not be suitable for pressure testing. These systems
may contain non-isolatable components, or temporary closures may not be
practical. Such systems should be carefully inspected during and after
installation. Inspections such as visual examination of joint appearance,
mechanical checks of bolt or joint tightness, and other relevant examinations
should be performed.
Disinfecting Water Mains
Applicable procedures for disinfecting new and repaired potable water
mains are presented in standards such as ANSI/AWWA C651, Disinfecting
Water Mains. (Ref. 8) ANSI/AWWA C651 uses liquid chlorine, sodium
hypochlorite, or calcium hypochlorite to chemically disinfect the main.
Disinfecting solutions containing chlorine should not exceed 12% active
chlorine, because greater concentration can chemically attack and degrade
polyethylene.
Considerations for Post Start-Up and Operation
Page 27
Cleaning
Pipelines operating at low flow rates (around 2 ft/sec or less) may allow
solids to settle in the pipe invert. Polyethylene has a smooth, non-wetting
surface that resists the adherence of sedimentation deposits. If the pipeline
is occasionally subject to higher flow rates, much of the sedimentation will
be flushed from the system during these peak flows. If cleaning is required,
sedimentation deposits can usually be flushed from the system with high
pressure water.
Water-jet cleaning is available from commercial services. It usually
employs high pressure water sprays from a nozzle that is drawn through the
pipe system with a cable.
Pressure piping systems may be cleaned with the water-jet process, or
may be pigged. Pigging involves forcing a resilient plastic plug (soft pig)
through the pipeline. Usually, hydrostatic or pneumatic pressure is applied
behind the pig to move it down the pipeline. Pigging should employ a pig
launcher and a pig catcher.
A pig launcher is a wye or a removable spool. In the wye, the pig is fitted
into the branch, then the branch behind the pig is pressurized to move the
pig into the pipeline and downstream. In the removable pipe spool, the pig
is loaded into the spool, the spool is installed into the pipeline, and then the
pig is forced downstream.
WARNING: A pig may discharge from the pipeline with
considerable velocity and force. The pig catcher is a
basket or other device at the end of the line designed to
receive the pig when it discharges from the pipeline. The
pig catcher provides a means of safe pig discharge from
the pipeline.
WARNING: Soft pigs must be used with polyethylene pipe.
Scraping finger type or bucket type pigs may severely
damage a polyethylene pipe and must not be used
Commercial pigging services are available if line pigging is required.
Squeeze-Off
Squeeze-off (or pinch-off) is a means of controlling flow in smaller diameter
polyethylene pipe and tubing by flattening the pipe between parallel bars.
Flow control does not imply complete flow stoppage in all cases. For larger
Page 28
pipes, particularly at higher pressures, some seepage is likely. If the situation
will not allow seepage, then it may be necessary to vent the pipe between
two squeeze-offs.
Polyethylene gas pipe manufactured to ASTM D 2513 is suitable for
squeeze-off; however, squeeze-off practices are not limited to gas
applications. Squeeze-off is applicable to polyethylene PE3408 and PE2406
pressure pipe up to 16" IPS, and up to 100 psi internal pressure. Larger
sizes and higher pressures may be possible, but suitable commercial
equipment is not presently available, so there is no demonstrated experience
with larger sizes or higher pressures.
WARNING: Squeeze-off is applicable ONLY to PE2406 and
PE3408 polyethylene pipe and tubing. The pipe or tubing
manufacturer should be consulted to determine if squeeze-
off is applicable to his product, and for specific squeeze-
off procedures.
Tools (Ref. 9)
Squeeze-off tools should have
parallel bars that are shaped to avoid pipe damage,
mechanical stops to prevent over-squeeze pipe damage,
safety mechanisms to prevent accidental release, and
a mechanism that controls the rate of closure, and the rate of
release.
Typical bar shapes are single round bars, twin round bars, or flat bars
with rounded edges. Other bar shapes may also be suitable so long as
edge radius requirements are met. See Table IV.
Positive mechanical stops between the bars are essential to prevent over
squeeze and pipe damage. The stops limit bar closure to 70% of twice the
maximum wall thickness. (Ref. 9) For DR or SDR sized polyethylene pipe
ONLY, (not tubing or schedule sized pipe), stop distance may be determined
by
g =1.568
D
DR
where g = stop gap, in

D = pipe outside diameter, in
DR = pipe dimension ratio
Page 29
Table IV Squeeze Tool Bar Radius
Consult the pipe manufacturer for stop gap dimensions for tubing sizes.
Typical squeeze-off tools use either a manual mechanical screw or
hydraulic cylinders. In either case, a mechanism to prevent accidental bar
separation is an essential safety feature of the tool.
Key Elements
Closing and opening rate are key elements to squeezing-off without
damaging the pipe. It is necessary to close slowly and release slowly, with
slow release being more important. The release rate for squeeze-off should
be 0.50 inches/minute or less as specified in ASTM F1041 (Ref. 10) or ASTM
F1563 (Ref. 9) The pipe must be allowed sufficient time to adjust to the high
compressive and tensile stresses applied to the pipes inside wall during
squeeze-off.
Research work performed under contract to the Gas Research Institute
indicates that the greatest damage potential is during release, especially
with heavier wall pipes. Flattening places high compressive stress on the
inside wall at the outer edges of the squeeze. Then releasing and opening
applies high tensile stress to the same area. The material must be given
ample time to accommodate these stresses. Opening too fast may cause
excessive strain, and may damage the inside wall.
Lower temperatures will reduce material flexibility and ductility, so in colder
weather, closure and opening time must be slowed further.
Pipe Diameter Minimum Bar Radius
0.750 0.50
> 0.750 2.375 0.63
> 2.375 4.500 0.75
> 4.500 8.625 1.00
> 8.625 16.000 1.50
Page 30
Testing of PE2406 and PE3408 polyethylene piping has shown that when
proper procedures and tools are used, squeeze-off can be performed without
compromising the expected service life of the system. However, pipe can
be damaged during squeeze-off
if the manufacturers recommended procedures are not followed, or
if the squeeze is held closed too long, or
from static electric discharge, or
by altering or circumventing the closure stops, or
by squeezing-off more than once in the same location.
WARNING: Pipe damaged during squeeze-off could leak
or fail at the squeeze-off point. Pipe known or suspected
to have been damaged during squeeze-off should be
removed from the system, or should be reinforced at the
squeeze-off point using a full encirclement clamp.
Procedure
From the installation of the squeeze-off tool to its removal, the total time
should not exceed 8 hours. Excessive time may damage the pipe.
Figure 8 Squeeze-off Stresses
High Compressive Stress
during flattening, then
High Tensile Stress
during opening
Page 31
1. Select the correct size squeeze tool for the pipe being squeezed.
Squeeze bar closure stops must be in place, and must be the correct size
for the pipes diameter and wall thickness or DR.
2. Fit the tool on the pipe so the pipe is centered in the tool, and the tool
is square to the pipe. The squeeze off tool must be at least 3 pipe diameters,
or 12 inches, whichever is greater, away from any butt fusion, or any socket,
saddle, or mechanical fitting.
WARNING: Static electricity control. When pipe conveying
a compressed gas is being flattened, the gas flow velocity
through the flattened area increases. High velocity, dry
gas, especially with particles present in the flow, can
generate a static electric charge on pipe surfaces which
can discharge to ground. Before flattening the pipe, the
tool should be grounded and procedures to control static
charge build-up on pipe surfaces should be employed.
Grounding and static control procedures should remain
in place for the entire procedure.
3. Operate the bar closing mechanism, and at a controlled rate, flatten
the pipe between the bars.
3.1 For 3" IPS and larger pipe, pause at least 1 minute when
the pipe is flattened halfway and another minute when
3/4 closed. For all pipe sizes, pause 1 minute when the
pipe inside walls make contact.
3.2 After pausing 1 minute when the pipe inside walls make
contact, continue closing at about half the prior closing
rate until the tool bars contact the closure stops.
3.3 If temperatures are near freezing or lower, closure rates
should be halved and pauses should be doubled.
4. If necessary, engage the accidental release prevention mechanism.
5. Perform the necessary work downstream of the squeeze off.
WARNING: Venting may be required for 100% shut-off.
Squeeze-off may not stop all flow. If 100% shut-off is
required, it may be necessary to install two squeeze-off
tools at two points along the line, and vent between them.
Any work performed must be downstream of the second
squeeze-off. Do not remove or alter the closure stops, or
place anything (rags, sticks, etc.) between the bars and
the pipe.
Page 32
6. When work is complete, disengage the accidental release mechanism
(if required), and open the squeeze-off tool bars at a controlled rate no faster
than the Step 3 closure rate. Opening must include a 1 minute pause at the
wall contact point, and, 1 minute pauses at 1/4 open (3/4 closed) and 1/2
open points for 3" IPS and larger pipes.
7. When the squeeze-off tool has been completely opened, rotate the
tool 90 degrees around the pipe, and slowly re-round the pipe.
7.1. Re-round the pipe by closing the tool part-way until the pipe is
circular. It may be necessary to close slightly past circular, so
that the pipe is round when the tool is again released. Re-
rounding closure rate should not exceed the Step 3 closure
rate.
7.2. Re-rounding is partial closure, sufficient to make the pipe
circular again. DO NOT completely flatten the pipe.
8. Open the bars, and remove the squeeze-off tool.
9. Identify the squeezed-off area by wrapping tape around the pipe, or
installing a full encirclement clamp over the area.
WARNING: Do not squeeze-off more than once in the same
place. Doing so will damage the pipe.
Additional information on squeeze-off may be found in ASTM F 1041,
Standard Guide for Squeeze-off of Polyolefin Gas Pressure Pipe and Tubing.
Routine or Emergency?
Squeeze-off procedures may be used for routine, scheduled changes to
piping systems, or as an emergency procedure to control gasses or liquids
escaping from a damaged pipe. For scheduled piping changes, the above
procedure should be followed, and if followed, the pipes service life is not
expected to be compromised.
However, an emergency situation may require quickly flattening the pipe
and controlling flow because the escaping fluid may be an immediate hazard
of greater concern than damaging the pipe.
WARNING: If an emergency situation requires rapid
flattening, then the pipe or tubing will probably be
damaged.
Page 33
Repairs
Repair situations may arise if a polyethylene pipe has been damaged.
Damage may occur during shipping and handling, during installation, or after
installation. Damage may include scrapes or abrasions, breaks, punctures,
kinks, or emergency squeeze-off. Permanent repair usually involves
removing and replacing the damaged pipe or fitting. In some cases, temporary
repairs may restore sufficient serviceability and allow time to schedule
permanent repairs in the near future.
Damage Assessment
Damaged pipe or fittings should be inspected and evaluated. Pipe, fittings,
fabrications or structures with excessive damage should not be installed.
Damage that occurs after installation may require that the damaged pipe or
component be removed and replaced.
WARNING: Scrapes or gouges in pressure pipe cannot be
repaired by filling-in with extrusion or hot air welding. The
damaged section should be removed and replaced.
WARNING: Improperly made fusion joints cannot be
repaired.
Improper butt fusions must be cut-out and re-done from the beginning.
Poorly joined socket or electrofusion fittings must be removed and replaced.
Poorly joined saddle fittings must be removed by cutting out the main pipe
section, or, if the main is undamaged, made unusable by cutting the branch
outlet or chimney off the saddle fitting, and installing a new saddle fitting on
a new section of main.
WARNING: Broken or damaged fittings cannot be repaired
and, as such, should be removed and replaced.
WARNING: Kinked pipe must not be installed and cannot
be repaired.
Kinked pipe must be removed and replaced.
WARNING: Pipe damaged during an emergency squeeze-
off cannot be repaired.
Squeeze-off damaged pipe must be removed and replaced.
Page 34
Permanent Repairs
For buried large diameter polyethylene pipe that has been poorly
backfilled, excessive deflection may be correctable using point excavation
to remove backfill, then reinstalling embedment materials in accordance with
recommended procedures.
Where replacement is required, any joining method appropriate to the
product and service requirements is generally acceptable. Butt and socket
fusion joining procedures require that one of the components move
longitudinally. However, constrained installations, such as buried pipes, may
not allow such movement.
Permanent repair of constrained pipe typically employs techniques that
do not require longitudinal movement of one or both pipe ends. Techniques
include deflecting one pipe end to the side, using a mechanical or
electrofusion coupling, or installing a flanged spool. See Figure 9. Typical
methods for joining repair pipe sections include flanges, electrofusion
couplings, and fully restrained mechanical couplings.
To repair using a flanged spool, cut out, remove and discard the damaged
pipe section. Install flanges on the two pipe ends. Measure the distance
between the flange sealing surfaces, and prepare a flanged pipe spool of
the same length. Install the flanged spool.
Repair using an electrofusion coupling or a fully restrained mechanical
coupling is limited to pipe sizes for which such couplings are available.
Mechanical or electrofusion coupling repairs are made by deflecting one
pipe end to the side for the coupling body to be slipped on. The pipe ends
are then realigned, and the coupling joint fitted up. To allow lateral deflection,
a length of about 10 times the pipe outside diameter is needed.
Replacement using Electrofusion
or Fully Restrained Mechanical Coupling
Figure 9 Constrained Pipe Repair
Replacement with Flanged Spool
Page 35
Temporary Repair
Until permanent repairs can be effected, temporary repairs may be needed
to seal leaks or punctures, to restore pressure capacity, or to reinforce
damaged areas. Temporary repair methods include but are not limited to
mechanical repair couplings and welded patches.
A successful piping system installation is dependent on a number of
factors. Obviously, a sound design and the specification and selection of
the appropriate quality materials are paramount to the long term performance
of any engineered installation. The handling, inspection, testing, and safety
considerations that surround the placement and use of these engineered
products is of equal importance.
In this chapter, we have attempted to provide fundamental guidelines
regarding the receipt, inspection, handling, storage, testing, and repair of
polyethylene piping products. While this chapter cannot address all of the
product applications, test and inspection procedures, or construction
practices, it does point out the need to exercise responsible care in planning
out these aspects of any job site. It is the responsibility of the contractor,
installer, site engineer, or other users of these materials to establish
appropriate safety and health practices specific to the job site and in
accordance with the local prevailing codes that will result in a safe and
effective installation.
Conclusion
Page 36
1. Plastics Pipe Institute, TR-31, Underground Installation of Polyolefin
Pipe, Washington, DC.
2. Gilroy, H.M., Polyolefin Longevity for Telephone Service, Antec
Proceedings, 1985.
3. Plastics Pipe Institute, Handbook of Polyethylene Pipe, Chapter on
Polyethylene Joining Procedures, Washington, DC.
4. Plastics Pipe Institute, TR-19, Thermoplastics Piping for the Transport
of Chemicals, Washington, DC.
5. American Gas Association, AGA Plastic Pipe Manual for Gas Service,
AGA, 1994.
6. American Society of Mechanical Engineers, B31.1, Section 137.
7. American Society for Testing and Materials, ASTM F1417, Standard
Test Method for Installation Acceptance of Plastic Gravity Sewer Lines
Using Low Pressure Air, West Conshohocken, PA, 1998.
8. American Water Works Association, AWWA Standard for Disinfecting
Water Mains, Denver, CO, 1992.
Specification for Tools to Squeeze-off Polyethylene (PE) Gas Pipe or
Tubing, West Conshohocken, PA, 1998.
Guide for Squeeze-off of Polyethylene Gas Pressure Pipe or Tubing,
West Conshohocken, PA, 1998.
11. American Society for Testing and Materials, ASTM D2104, Standard
Specification for Polyethylene (PE) Plastic Pipe, Schedule 40, West
Conshohocken, PA, 1998.
Specification for Polyethylene (PE) Plastic Pipe (SIDR-PR) Based
on Controlled Inside Diameter, West Conshohocken, PA, 1998.
Specification for Polyethylene (PE) Plastic Pipe, Schedules 40 and
80, Based on Outside Diameter, West Conshohocken, PA, 1998.
References
Page 37
Specification for Polyethylene (PE) Plastic Pipe (DR-PR) Based on
Controlled Outside Diameter, West Conshohocken, PA, 1998.
The Plastics Pipe Institute, Inc.
Toll Free: (888) 314-6774
www.plasticpipe.org

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where D1 and D2 are as defined above and depicted in Figure 7.

where g = stop gap, in

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