Installation Training Manual 20-2-12 Rev0

Copyright HydroMax 2012 Issue 20-02-12
Training Manual
The Installation of Siphonic (HDPE) Pipework
The Engineered Rainwater Solution

Training Manual: The Installation of Siphonic (HDPE) Pipework
o Overview of Principals of Siphonic Drainage
o Interpreting Design Data and Drawings
o Methods of Jointing HDPE Pipework
o Welding Procedures
o Butt Welds
o Manual Welds
o Machine Welds
o Visual Check of Butt Welds
o Electro-Weld Couplings/Sleeves
o Performing the Weld
o Inserting a Fitting Into Installed Pipework
o Installation of Siphonic Pipework

o Horizontal Pipework
o Connecting to Outlets
o Vertical Pipework (Downpipes)
o Connection to Underground Drainage Pipework
o Testing Procedures
o Recommended Tools
o Safety
Overview of Principals of Siphonic Drainage
The HydroMax™ siphonic drainage solution was developed to advance the siphonic principles to
create a powerful means of literally sucking the rainwater from the roof. Using smaller diameter
pipework running at full-bore flow, HydroMax™ provides approximately ten times more flow
capacity than an equivalently sized gravity pipe.
To enable HydroMax™ to drain with such high performance, the system designer utilizes the
HydroTechnic™ analytical design software program to optimize an Engineered Drainage Solution
and use the whole building height to generate a siphonic flow condition.
The key to the functionality of any siphonic roof drainage system is the sizing of the pipe system to
balance flow rates in the roof drains.
Roof Drain
Roof
Tail-pipes
Horizontal collector pipe

– no pitch gradient
Drop pipe
Discharge
A key feature of our siphonic system is the specially designed HydroMaxTM roof drain. The unique
design incorporates an inducer (or baffle plate) above the roof drain pipe. The tailpipe below the roof
drain is of a relatively small diameter and a series of tail-pipes connect to a collector (or carrier)
pipe normally installed immediately below the roof. This collector pipe is installed horizontally at
high level and runs to a convenient point in the building where it drops to ground level with a single
connection into the underground drainage system.
As water builds up on the roof or in the gutter, the inducer of the HydroMaxTM roof drain becomes
submerged preventing air from entering the tailpipe and restricting vortex formation. Prior to the
rainfall event, the pipe has no water inside - only air. As the rain starts to fall further air ingress is
prevented at the roof drain and only water enters the pipe. The movement of the water quickly
draws the air out of the pipe in a process known as ‘priming’. When all of the air has been removed
from the system it is said to be fully primed and the pipe work is running full-bore with water. (See
following stages of priming)
In this condition the hydraulic driving force conveying water from the roof ceases to be the small
head of water built up around the roof drain as used in a traditional gravity drainage system and
instead becomes the head generated by the full height of the building. Siphonic systems are thus
able to efficiently remove large quantities of water in small diameter pipes.
The advanced HydroTechnicTM software enables the design engineer to create a piping system with
the correct pipe diameter sizes to ensure the best possible configuration, rapid prime and optimum
performance.
Roof Drain
Roof
Pressure
Tail-pipes
Horizontal collector pipe
Drop pipe
Discharge
Priming of main pipework
At the start of a rainstorm the pipework is empty and initial rainfall will flow through a gravity flow
pattern. The tailpipe will continue to discharge water into the collector pipe and as more water is
supplied to the main collector pipe it will also start to prime in a process that follows three further
flow phases.
Stage 1 – Wavy or Gravity Flow

Stage 1 – Wavy or Gravity Flow (continued)
Air above water
Gravity flow in pipework
Stage 2, Plug Flow:

The water surges to fill the pipe for short lengths and carries out pockets of air trapped between
these full bore sections of flow.
This flow pattern is typically achieved between 10% to 15% of the design rainfall intensity.
Importantly, self-scouring velocities are achieved at this stage.
Plug of water filling whole pipe at high velocities

which achieves self-scouring.
Air pockets driven down pipework

Tests have shown that self-cleaning can be achieved at as low as
10% to 15% of the design rainfall rate.
Stage 3, Bubble Flow:
As the rainfall intensifies the water almost fills the whole of the pipe and any remaining air is carried
out as bubbles entrained in the water.
Water filling whole pipe
Air bubbles in suspension at high velocity
Stage 4, Full-Bore Flow:

No air remains in the pipework leaving the pipes to run full bore.
The system is now utilizing the full height of the building to draw water off the roof.
Water filling whole pipe
Fully Primed System

Utilises Energy from the Whole Building Height
roof drain
Roof
Pressure
Tail-pipes
Horizontal Collector Pipe
Drop pipe
Discharge
When the piping system is fully primed, the whole height of the building is used to
provide the energy to create a powerful siphonic action.
Once the rain storm starts to abate, air will be admitted to the system and the flow patterns above
will reversed in a process known as de-priming. This takes place seamlessly in a smooth controlled
manner which mirrors the storm profile.
Furthermore, when the rainfall rate increases again, prime is quickly re-established therefore
providing a highly efficient Engineered Roof Drainage System.
Interpreting Design Data and Drawings

The installer should be supplied with a site file containing the following data:
A full set of Construction-Issue drawings including:-

Roof layout showing positions of siphonic outlets
Floor plans showing routes of high-level siphonic pipework
Typical sectional views and details
and for each individual siphonic system:-

List of prefabricated sections
Isometric Schematic Diagram (Not drawn to scale for clarity)
Bill of Materials
‘Overall Parameters’ data sheets
The Roof layout drawing is issued to the contractor prior to start date to allow the correct positioning and
installation of outlets. This drawing should be used by installers for guidance and information only.
The Floor plan(s) indicate the routes of siphonic pipework within the building and will clearly identify installation
heights of pipework above a suitable datum, diameters of pipework and will show distances to pipework from grid-
lines or points of reference. This drawing will also show locations of sectional views and details. All heights shown
on installation drawings are from datum to the top of pipe level which can be assumed to be constant throughout
runs of pipework unless specified otherwise.
The Sectional Details drawing is provided to show the typical configuration of tailpipes and main carrier pipes and
will indicate the height of pipework, bracketry required to support pipework from structure of building and how the
designer has envisaged the method of supporting pipework. Care should be taken to ensure that the building
structure matches that shown on this drawing. (See following section regarding the reporting of alterations and
variations)
The List of prefabricated sections should be read in conjunction with Isometric Schematic Diagram and will identify
the relative position of each fabricated section. The unique number of each fabricated section is indicated on this
diagram and will show the layout of individual siphonic systems. (See below for unique number identification)
The Bill of Materials lists all items supplied for each siphonic system and includes totals of materials used for
fabricated sections and remaining loose items (i.e. not prefabricated)
+z
Vertical
The Overall Parameters data sheets are output from the Hydrotechnic design
software and are used to determine the dimensions of items supplied loose for site
installation. (e.g. connections between tailpipes and outlets, if not prefabricated) -y +x
These sheets indicate the diameters, lengths and orientation of all pipework in each
siphonic system. The orientation of each item follows the co-ordinate system shown
in fig.1
It is essential that the above items are referred to throughout the installation of -x +y
siphonic pipework. Checks should be made to ensure that all drawing information
accurately reflects the actual layout of the building. Although every care is taken -z
during the design and drawing process, it is not uncommon to find discrepancies in Figure 1
locations of roof purlins, etc. Failure to install pipework exactly as designed and
supplied may adversely affect the siphonic action. Installer should immediately report to designer any issue
which may prevent the pipework from being installed exactly as designed.
For this purpose, a Request for Alteration form is supplied in each site file. Installer must complete this form with as
much information as possible – including a dimensioned sketch where applicable – and return to designer. The
designer will input this information into Hydrotechnic programme and advise installer of results.
No alteration should be carried out until confirmation of

approval has been received from designer.
All design documentation will share a unique numbering system for identification. The List of prefabricated
sections, Isometric Schematic Diagram, Bill of Materials and ‘Overall Parameters’ data sheets for a specific system
will share a filename which the designer shall determine but may be something like the following format:
Example Numbering System
05101 02 C00
Contract number Current Revision
System Identifier
Contract Number is 5-digit identifier used throughout job. First two digits refer to year of contract and following
three digits are unique to each contract.
System Identifier number refers to each individual Siphonic system.
Current Revision ensures that all information is current and consistent between design sheets/drawings.
Similarly, pre-fabricated pipework will be identified (physically marked on each section) using the following
numbering system:
05101 02 10
Contract number Fabrication section number

(cross-referenced with Fabrication
System Identifier sheets & Isometric drawing)
See also following reference sheets for examples.

HydroMax Inc
Balnagowan, Eassie,
Glamis, Forfar
DD8 1SG
Tel: +44 1307 840434
Fax: +44 1307 840468
e-mail:[email protected]
Methods of Jointing HDPE Pipework

There are two methods of jointing HDPE pipework and fittings: Butt fusion welds (Fig.2) and Electro-welds using
coupling/sleeve. (Fig.3)
Butt welding is a simple method of jointing pipework and fittings and

can be carried out at site or in the fabrication workshop.
Butt welds can be performed under site conditions using a portable

hotplate on pipe diameters between 50mm to 90mm.
This process is not suitable for ∅40mm pipe due to the loss of
effective internal diameter as weld bead is formed.
Pipes of diameters greater than 90mm should not be butt welded on

site as correct pressures can not be achieved without the use of a
welding machine. (See section on welding procedures)
The allowance in length for a butt weld is approximately equal to the

wall thickness of the pipe being welded and is given in the following
table.
Figure 2, Butt Weld
Pipe Diameter (mm) 40-75 90 110 125 160 200 250 315
Butt Weld (mm) 3 4 5 5 7 7 8 10
Electro-fusion couplings/sleeves are widely used for site installations

and repair or remedial work.
Couplings/sleeves can be used under most site conditions and are a

convenient method of performing simple, quick and reliable welds
between pipes and fittings.
Couplings/sleeves are used to weld the entire range of pipework from

∅40mm to ∅315mm.
Satisfactory welds using this method can only be achieved by the

correct preparation of pipework and the correct use of recommended
welding equipment. (See section on welding procedures)
Figure 3, Electro-fusion
coupling/sleeve
Welding Procedures
90°
General
Whether a butt weld or electro-fusion
coupling/sleeve is being used, it is essential to
ensure that the ends to be joined are cut

accurately to 90° as shown in fig.4a Figure 4a
Cut ends should be clean and free from burrs and

unevenness. De-burr with scraper tool if
necessary.

Figure 4b
Butt Welds
To ensure a satisfactory weld, the following criteria should be adhered to:
o The ends to be joined are to be cut at 90° (as fig.4a)

o Joining surfaces of pipework and heating surface of welding plate are to be fully cleaned and free from
debris or contaminants. Degrease as necessary to remove any residue from welding plate.
o The welding plate must be heated to operating temperature. (210 - 230°C) Refer to manufacturers
instructions for temperature indicator lights.
o The correct mating pressure must be maintained for the recommended time (see table1)
Manual welds (∅50mm to ∅90mm)

o Prepare the work area to protect pipework and equipment from the effects of weather and to ensure
unrestricted movement during the welding process.
o Check pipes for ovality or irregularities. Reject or correct as necessary.
o Bring the pipe ends onto heating element and press until a uniform bead of approximately 50% of pipe wall
thickness has formed on each pipe end. (See actual figures given in Table.1)
o Release pressure but hold against heating element to allow pipes to heat up for the allotted time (Table.1)
o Remove heating element and bring pipe ends immediately together ensuring correct alignment. Do not
twist or attempt to adjust pipes to correct any misalignment.
o Gradually apply the necessary fusion pressure and maintain for the allotted cooling time.
o Once cooled, visually check weld.
o Acceptable welds should appear as in fig.5.
o If in any doubt as to suitability of butt weld, cut out and re-weld.
Machine welds (∅50mm to ∅315mm)

o Prepare the work area to protect pipework and equipment from the effects of weather and to ensure
unrestricted movement during the welding process.
o Adjust machinery to suit the appropriate pipe diameter.
o Secure pipes in machine and plane faces if necessary.
o Bring the pipe ends onto heating element and apply pressure until a uniform bead of approximately 50% of
pipe wall thickness has formed on each pipe end. (See actual figures given in Table.1)
o Release pressure but hold against heating element to allow pipes to heat up for the allotted time (Table.1)
o Remove heating element and bring pipe ends immediately together ensuring correct alignment. Do not
twist or attempt to adjust pipes to correct any misalignment.
o Lock machine at the correct fusion pressure and hold for the allotted cooling time.
o Once cooled, release from welding machine and visually check weld.
o Acceptable welds should appear as in fig.5.
o If in any doubt as to suitability of butt weld, cut out and re-weld.
Table 1: Butt Welding of HDPE pipework
Pressure to
Pipe Diameter Bead size Soak Time Fusion Pressure Cooling Time
Form Bead
(mm) (mm) (no pressure) (kg) (under pressure)
(kg)
63 10 1.5 20 sec 15 1 min 15 sec
75 10 1.5 25 sec 15 1 min 20 sec
90 10 1.5 35 sec 20 1 min 30 sec
110 15 2.0 45 sec 25 1 min 45 sec
125 15 2.0 45 sec 30 2 min
160 20 2.0 45 sec 40 2 min 15 sec
200 25 2.0 1 min 15 sec 45 2 min 40 sec
250 35 3.0 1 min 55 sec 90 3 min 30 sec
315 60 3.0 2 min 40 sec 120 4 min
Visual check of Butt Welds
Both weld beads approximately equal in size. (See table.1)
Weld uniform around full circumference.

Little or no misalignment.
Figure 5, Acceptable Butt Weld
Beads too small. (See table.1)
Caused by insufficient pressure during fusion process.
Figure 5a, Small Welding Bead
Unequal welding beads.

Caused by uneven heating time or
temperatures.
Figure 5b, Unequal Welding Beads
Misalignment between materials.

Maximum allowable tolerance is 10% of wall thickness.

Figure 5c, Misalignment
Welding beads are too high and

narrow.
Caused by excessive pressure
during fusion process.
Figure 5d, Narrow / high Welding Beads
Visual check of Butt Welds (cont.)
Other possible reasons for inadequate welds are:
o Highly glossed surface of weld beads indicates an excessively high temperature of welding plate. In this
case check welding equipment for malfunction. Operating temperature can be tested by use of thermo-
chromatic paint / crayon.
o Bubbles or foaming of weld beads indicates the presence of moisture during welding process. Protect
workplace from inclement weather conditions.
Electro-weld Couplings / Sleeves

To ensure a satisfactory weld, the following criteria should be adhered to:
o The ends to be joined are to be cut at 90° (as fig.4a)

o Pipe end must be inserted correctly into coupling/sleeve as shown in fig.6a
o Welding surfaces of pipework are to be fully cleaned and free from debris or contaminants. Degrease as
necessary to remove any residue.
o The coupling/sleeve should be visually checked for damage especially to internal wires.
o The correct power supply is available and all cables and connectors are in good working order.
Figure 6a, Correct insertion and end

preparation

Figure 6b, Pipes not parallel

Figure 6c, Poor end preparation

Figure 6d, Incorrect insertion depth

Performing the weld

o Prepare the work area to protect pipework and equipment from the effects of weather.
o Using scraper tool or similar, form a slight chamfer on leading edge of outer diameter of pipes.
o Clean ends of pipes to be welded and roughen surface with abrasive cloth or similar. If sandpaper is used
for this purpose, ensure that no grit remains on pipework by wiping with damp cloth.
o Slide coupling/sleeve fully over pipe end (until internal stop block) and mark insertion depth on pipe. This
will ensure that coupling/sleeve does not slip before weld is completed.
o Assemble parts to be welded and support as necessary to ensure that no longitudinal or lateral forces can
occur during welding process.
o Connect welding machine to suitable power source and trailing cables to coupling/sleeve sockets.
o Depending on the type of welding equipment to be used, follow manufacturer’s instructions to begin
welding process.
o Do not move pipework during the welding process.
o When a weld has been completed satisfactorily, indicators in coupling/sleeve will be clearly visible.
o Allow welded coupling/sleeve to cool down fully before removing cables.
o If indicators do not show or if there is any doubt as to the integrity of the welded coupling/sleeve, allow to
cool down fully and attempt to re-weld.
A slight chamfer on pipe end should assist the fitting of coupling/sleeve over pipe. However, if coupling/sleeve does
not slide freely over pipe, tap lightly with rubber mallet to locate. Take great care to ensure that internal wires are
not damaged. Do not reduce outer diameter of pipe by scraping or otherwise as this will affect the integrity of the
weld.
Inserting a fitting into installed pipework

On occasion, it may be necessary to insert a fitting into pre-installed pipework. The following procedures should be
followed:
o Cut out section of pipework to the correct

length. This should be equal to the
overall length of the branch or fitting to
be inserted.
Figure 7a, Cut and remove section
o Carefully remove the internal stop blocks of pipe
from couplings/sleeves taking great care
to avoid damage to internal wires.
o Slide couplings/sleeves over pipe ends

and push outwards to allow clearance for
branch or fitting.
o Locate branch or fitting in correct position Figure 7b, Slide couplings/sleeves

over pipe ends
and slide couplings/sleeves back over
joints to be welded. It is vitally important
that insertion depth is clearly marked in
pipework during this operation to ensure
that couplings are located correctly
before welding.
o With all insertion marks visible and Figure 7c, Insert fitting and locate
pipework and fitting fully aligned, perform couplings/sleeves into final welding
welds as previously described. position
Weather conditions.
Preventative measures must be taken prior to attempting to weld a coupling during a period of rainfall. If welding
must be attempted under these conditions, installer must first ensure that no rainwater can enter the section of
pipework being welded.
Roof/gutter outlets must be plugged temporarily and pipework fully dried around area to be welded.
Electro-weld couplings/sleeves will not weld satisfactorily if pipework is damp or wet. All moisture must be fully
removed (internally & externally) before coupling/sleeve is fitted over pipe.
Temporary plugs should be removed from outlets and pipework at the earliest opportunity to prevent damage
caused by flooding or water ingress. Installer should be aware of the build-up of water on roof/gutter whilst outlets
are plugged.
Installation of Siphonic Pipework

Before beginning the installation of siphonic pipework, the installer should:
o Check all necessary materials – including pre-fabricated pipework, bracketry, loose items, etc. – are on site
and in good order. Whenever possible, a site container will be available for the storage of materials and
tools. An area of hard-standing will also be available for the lay-down of fabricated sections.
o Check that the siphonic outlets have been installed in roof/gutter and are accessible for connection.
o Check that the drawings supplied in site file accurately reflect the layout of building and that all heights and
reference dimensions are accurate and achievable.
o Check that the access equipment is suitable for site conditions.
If necessary, contact the relevant personnel to rectify any of the above points.
Horizontal Pipework
The horizontal (carrier) pipework will be suspended from the structure of the building by means of pre-determined
fixing methods. Generally, these will be one or more of the following:
o Purlin clips. See assembly detail drawing AD502

o Angle brackets. See assembly detail drawing AD503
o Concrete anchors See assembly detail drawing AD504
o Beam clamps See assembly detail drawing AD505
These drawings indicate the materials required for the various pipe diameters to be installed. All materials required
will be supplied.
On occasion, a method of fixing to building structure will be required which does not follow these details. In this
case, drawings will be supplied to clearly indicate how pipework is to be supported.
The number and location of fixings is shown in assembly detail drawing AD501.
Generally, fixings will be fitted at no more than 2metre centres (i.e. 3 fixings for each 6metre fabricated section)
In addition to these fixings, pipework should be bracketed to building structure to form lateral restraint at convenient
locations. e.g. to main steelwork or to blockwork if possible. Additional fixings will also be necessary where carrier
pipework changes direction. This is to reduce the possibility of movement and vibration during operating conditions.
The number and location of any additional brackets will be determined on site by installer and any additional
materials required should be ordered through design staff.
As the installation of horizontal carrier pipe progresses, checks should be made to ensure that specified heights to
top of pipe level can be achieved throughout run and that branches in carrier pipe coincide with outlet locations.
Adjacent fabricated sections are connected by means of electro-weld couplings/sleeves (pipework) and splice
plates (rail).
Splice plates have been designed to assist the installation of pipework by supporting one free end until bracketry
can be installed between rail and structure of building. Splice plate should be firmly fixed to one section of rail and
slid into rail of adjacent fabricated section.
Welding should be carried out as each fabricated section is fitted. Electro-weld couplings should be rotated in such
a manner that the weld indicators are clearly visible from floor level to enable a visual check to be carried out.
Alternatively, couplings/sleeves can be manually marked as having been fully welded by installer.
If support rail is to be fitted to pipework at site, installer should refer to assembly detail drawings AD500 and AD501
for bracketry requirements and correct number and spacing of brackets/supports. The spacing of brackets has
been calculated to restrain pipe under operating conditions and to avoid crushing of pipework due to internal
pressures. This spacing must be strictly adhered to. Similarly, if syphonic pipework is to be installed without support
rail, spacing of fixing brackets should follow that specified for railed pipework.
Connecting Roof Drains (Roof Outlets)

The vertical section of pipework from horizontal tailpipes and outlets is supplied as loose items and will require to
be assembled on site. Outlet stub-pipe will be pre-fitted to bottom flange of outlet and should be connected to
tailpipe with electro-weld coupling/sleeve. Installer must refer to design calculation sheets to identify correct lengths
of pipes, locations of reducers, etc for each outlet. An element of modification to standard fittings may be required
in these areas and achieving the correct configuration (as designed) is critical.
Vertical Pipework (Downpipes)

The vertical pipework (downpipe) will be supported from the structure of the building by means of pre-determined
fixing methods. Generally, these will be one or more of the following:
o Cantilever Bracket (from steel column). See assembly detail drawing AD510 & AD510A
o Concrete anchors See assembly detail drawing AD511 & AD511A
o Fixing to cladding rails
The above drawings indicate the materials required for the various pipe diameters to be installed. All materials
required will be supplied.
When fixing to cladding rails, a length of rail should first be attached to structural elements of cladding. Pipe
supports can then be positioned to suit locations as identified in assembly detail drawing AD501. The spacing of
brackets has been calculated to restrain pipe under operating conditions and to avoid crushing of pipework due to
internal pressures. This spacing must be strictly adhered to.
Generally, pipework will be designed to be as close as possible to supporting member with a nominal offset
allowed for in the design calculations to enable connection to underground pipework at low level. This offset can be
altered to suit specific site conditions.
An access point will also be supplied for the purpose of rodding underground pipework. Access points should be
fitted in such a manner to allow unrestricted entry to remove screw-cap. Generally, access point will be installed
between 0.5 – 1.0 metres above floor level.
Connection to Below Ground Drainage
A common method of connecting siphonic pipework to underground pipework is my means of a

transition adaptor coupling (e.g. Flex-Seal or similar).
Refer to assembly detail drawing below for typical layout.
Cleanout to provide access for

cleaning below grade gravity drain
Offset in downpipe, where necessary

to align downpipe with below grade
drain connection
Flexible adaptor coupling c/w stainless

steel bands (Flexseal or equal)
Below ground pipework to project

through floor slab 6” (150mm)
The diameter of the below ground drainage

should be sized to cater for the discharge flow
and not sized to match the siphonic pipe
diameter.
An alternative method of termination of siphonic pipework is to discharge into a below grade

chamber or manhole.
When siphonic pipework is designed to terminate in manhole, all sections of the below ground
pipework must be fully tested before trenching is in-filled. (See also later section on testing
methods).
Flare out the discharge piping prior to the diameter given on the design drawings to decrease the
velocity to less than 6 m/sec.
All of the above installation methods should be carried out in accordance with relevant working
codes of practice and to current safety codes. (See also section on Safety)
Siphonic Pipework must enter manhole chamber

higher than the invert level and be clear of any
standing water to ensure free discharge.
RAIL FASTENING BRACKETRY REQUIREMENTS FOR HydroMax™ HDPE

Testing Procedures
All siphonic pipework must be tested prior to the installation of insulation (where required) and the final handover to
client. Testing must be carried out as described in the relevant method statement.
Testing will generally follow the regulations for an air test stipulated in European Standard EN 12056-2:2000
(Inspection, testing & maintenance of completed installations) although installations outwith the European
community will be subject to local rules and regulations. All testing documentation will be supplied in the Site File.
In general, the testing procedure for siphonic pipework is as follows:
o All outlets are sealed using suitable plugs

o A pressure gauge (U-gauge) is fitted to the discharge point of the system by means of a plug fitted with test
nipple.
o Hand bellows are connected to test nipple and the system pressurized to 100mm wc.
o This pressure must be maintained for a period of 5 minutes.
o If there is no recorded loss of pressure over this period, the necessary paperwork should be completed,
verified and signed.
o If pressure drops within the 5 minute period, all pipework, outlets and welded joints should be checked and
replaced as necessary.
If a leak is apparent during the pressure test, installer should attempt to trace the source of the leak by dousing
couplings, gasketed joints, etc with soapy liquid. A positive pressure should be maintained within the pipework
during this process. Bubbling will indicate an escape of air. Faulty coupling, weld, etc should be cut out of system
and replaced.
If the source of leak is not found using this method, it will be necessary to cut pipework at relevant locations to
perform tests on parts of the system. The number and location of cuts in the system will be determined on site but
should be kept to a minimum. A full test must be performed after leak has been traced and rectified and all cut
sections of pipework have been fully re-welded.
Upon completion of test, all sealing plugs must be removed from outlets and pipework at the earliest opportunity to
prevent damage caused by flooding or water ingress.
NOTE: The Singapore Standard SS 525:2006 calls for a water test.
The test should be carried out before any pipework is concealed.
1. Securely plug the discharge (It may be preferential to weld a blanking plug because of pressure from a
standing column of water.
2. Fill the pipework to the level expected should a blockage occur.
3. Allow to stand for between 2 and 4 hours then complete a visual inspection for leakage.
4. The system should be tested for blockage – remove plug at discharge point and observe the pipe drains
the roofs.
NOTE – A complete siphonic flow test is not possible because constant water supply to each drain inflow capacity
cannot be obtained. Observing flow from drains following a flood test to the roof or gutter is the best compromise –
however all plugs on the drains should be removed simultaneously.
Recommended Tools
The following will form a basic tool kit for the installation of Hydromax siphonic pipework. This list is not exhaustive
and installers should complement these tools with any others deemed useful for the installation.
o Welding Box – 230v input (electro-coupling/sleeve welds)

o Combination Spanners, 2 of each of the following sizes: 13mm, 17mm, 19mm
o Tape Measure
o Screwdrivers, 1 with flat blade, 1 with posi-drive head
o Scraper
o Spirit Level (minimum recommended length of 600mm)
o Rubber Mallet
o Claw Hammer
o Hacksaw
o Wood Saw with fine-cut teeth (approximately 500mm blade)
Installers may also require additional items such as:
o Generator (with stabilised, 230 volts output)

o Welding machine (manual welds)
o Portable hot plate
o Welding Box (electro-coupling/sleeve welds)
o Transformer (230v output)
o Extension cables
o Circuit Breaker
o Angle Grinder
o Electric Drill
o Chop-saw
o Access equipment
Damaged electrical equipment should not be used under any circumstances.
It is the responsibility of the installer to ensure the good working order of these tools.
Periodic safety checks must be carried out on all electrical equipment.
Safety
All work described in this Training Manual must be carried out in accordance with the relevant codes of practice for
site working. All installers should be trained in safe working practices – including working at heights, materials
handling, etc.
Installers must also comply with local Health & Safety requirements for individual sites and relevant method
statements.
Provision will be made for the supply of Personal Protection Equipment to all installers. This equipment should be
used at all times as required.
General Piping Details.
Tail Pipes
Expansion in the Tail pipes
Tail pipes should not expand in the vertical if at all possible because it may be possible
for the water to jet through the increase in diameter which would fail to prime the tail-
pipe.
Expansion in the horizontal part of the tail is perfectly acceptable using concentric
reducers with the slope on the invert and will not affect priming.
Recommended – Not recommended –

Expansion in horizontal Expansion in vertical
Solution is to Siphonic action

expand in the may stop here
Horizontal
Where it is absolutely necessary to expand in the vertical, the designer will provide the
necessary pipe sizing information within the design information.
Sloping Tail-pipes are Not Recommended Solution – Use only Vertical

and Horizontal Sections
Siphonic
action may
stop here
Tail pipes should drop vertically and then horizontally, rather than slope at 45 degrees.
It is very likely that 45 degree tails will not prime efficiently, and so the tail will not
achieve the required capacity.
Expansion in vertical pipes
For similar reasons to those given for tailpipes, vertical pipes (or rainwater downpipes,
downspouts, downleaders or stacks as they are also known), should never expand in
the vertical. If the drop pipe requires a larger section for head loss reasons this must
always be in the upper section. If the drop pipe needs to be a larger diameter at its
base the following detail should be used.
Expansion in the vertical downpipe is not permitted.

Solution – Expand in Offset
Siphonic
action may
stop here
Sloping the Horizontal Collector Pipe is Not Recommended
If absolutely necessary to install sloping

Siphonic action may collector pipes, the designer can design-in
never start a reducer to force the priming process.
HydroMax Inc. Ltd.

Balnagowan, Eassie, Glamis, Forfar, UK, DD8 1SG

Installation Training Manual 20-2-12 Rev0

Uploaded by

Copyright:

Available Formats

Installation Training Manual 20-2-12 Rev0

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Installation Training Manual 20-2-12 Rev0

Uploaded by

Copyright:

Available Formats

Copyright HydroMax 2012 Issue 20-02-12

The Engineered Rainwater Solution

Training Manual: The Installation of Siphonic (HDPE) Pipework

o Overview of Principals of Siphonic Drainage

o Interpreting Design Data and Drawings

o Methods of Jointing HDPE Pipework

o Installation of Siphonic Pipework

Overview of Principals of Siphonic Drainage

Horizontal collector pipe

Horizontal collector pipe

Stage 1 – Wavy or Gravity Flow

Stage 1 – Wavy or Gravity Flow (continued)

Air above water

Gravity flow in pipework

Stage 2, Plug Flow:

Plug of water filling whole pipe at high velocities

Air pockets driven down pipework

Stage 3, Bubble Flow:

Air bubbles in suspension at high velocity

Stage 4, Full-Bore Flow:

Fully Primed System

Horizontal Collector Pipe

Interpreting Design Data and Drawings

A full set of Construction-Issue drawings including:-

and for each individual siphonic system:-

No alteration should be carried out until confirmation of

Example Numbering System

Contract number Current Revision

System Identifier number refers to each individual Siphonic system.

Contract number Fabrication section number

See also following reference sheets for examples.

Methods of Jointing HDPE Pipework

Butt welding is a simple method of jointing pipework and fittings and

Butt welds can be performed under site conditions using a portable

Pipes of diameters greater than 90mm should not be butt welded on

The allowance in length for a butt weld is approximately equal to the

Figure 2, Butt Weld

Electro-fusion couplings/sleeves are widely used for site installations

Couplings/sleeves can be used under most site conditions and are a

Couplings/sleeves are used to weld the entire range of pipework from

Satisfactory welds using this method can only be achieved by the

Cut ends should be clean and free from burrs and

To ensure a satisfactory weld, the following criteria should be adhered to:

o The ends to be joined are to be cut at 90° (as fig.4a)

Manual welds (∅50mm to ∅90mm)

Machine welds (∅50mm to ∅315mm)

Table 1: Butt Welding of HDPE pipework

Visual check of Butt Welds

Both weld beads approximately equal in size. (See table.1)

Weld uniform around full circumference.

Figure 5, Acceptable Butt Weld

Beads too small. (See table.1)

Caused by insufficient pressure during fusion process.

Figure 5a, Small Welding Bead

Unequal welding beads.

Misalignment between materials.

Welding beads are too high and

Visual check of Butt Welds (cont.)

Other possible reasons for inadequate welds are:

Electro-weld Couplings / Sleeves