Durfuse Installation

G0009/1
TECHNICAL
GPS
POLYETHYLENE
Innovation in polyethylene pipe systems for water, gas and other applications
Installation
& Technical
Guidelines
GPS Market Oriented
GPS products find a broad range of
applications in the industrial and
Customer Focus
The key to our success lies in a
commitment to provide the highest
utilities markets on a worldwide basis. quality service and support. We are
Introduction
The utilities of water and gas a team of highly motivated and
GPS is part of the worlds largest distribution are important sectors for experienced individuals.
manufacturer and supplier of high high integrity products where the
performance plastic piping products maintenance of water quality and the We place the utmost importance in
and offers the best and most cost safe transport of gaseous fuels are of meeting the needs of our customers,
effective pipe systems for its paramount importance. Industrial constantly evolving our extensive
customers. GPS specialises in applications include alternative energy product portfolio to meet the ever
polyethylene pipe systems for gas and installations in landfill gas systems to changing demands of the water and
water transportation in the utilities and effluent transportation and mineral gas utilities, industrial and offshore
industrial markets. slurries. Products are widely used in markets.
In GPS, the amalgamation of pipeline installation, repair and
three market-leading companies - maintenance. Quality
Durapipe, Stewarts & Lloyds Plastics Many of the brands in the GPS GPS is a results-driven business -
and Calder - brings together over one portfolio have a long record of its people, products and service.
hundred years of experience in the innovation in meeting the needs of the Designed, manufactured and supplied
development, manufacture and water and gas utilities. One of the under an BS EN ISO 9001: 2000
marketing of plastic piping, fittings, foremost pioneers in polyethylene pipe accredited Quality Management
and associated products for low and systems, GPS is continually improving System, GPS products comply with
medium pressure applications. and updating its offering to meet the relevant national, European and
ever growing needs of the distribution international product standards to
engineer, ensuring they stay at the ensure complete peace of mind for our
forefront of world gas and water customers.
distribution/treatment systems.
Certificate No. FM 34819 Manufactured in the UK, our products The Environment
are sold to more than 60 countries Committed to sustainable manufacture
worldwide. and systems, GPS operates and
maintains an environmental policy
fully accredited to ISO 14001.
Certificate No. E 51385
World leaders in the design, manufacture, marketing and sales of high

performance, high integrity plastic and composite piping systems.
GPS
POLYETHYLENE
CONTENTS
Pages
GPS PE Products Overview 2-5
Quality and Environmental Standards 6-7
Product Markings 8
Material and Pipe Properties & Compatibility 9-11
Pressure Ratings, Flow Characteristics & Testing 12-19
Squeeze-Offs of GPS PE Pipes 20
Health & Safety 21
Handling & Storage 22-24
Procedures & Techniques for PE Pipeline Installations 25-31
Electrofusion Jointing Procedures 32-34
Durafuse Jointing Procedures 35-37
FRIALEN Large Diameter Electrofusion Couplers & Jointing Procedures 38-40
Durafuse Jointing Procedures for Tapping Tees and Branching Saddles (top loading and underclamped) 41-43
Butt-fusion Jointing Procedures 44-48
Friatop Assembly & Operating Instructions 49-51
Flanged Connections 52-53
Protecta-Line Preparation, Jointing Procedures & Testing 54-60
Secura-Line Preparation & Jointing Procedures 61
Push-Fast System Procedures 62-63
Duck Foot Bend Assembly Instructions 64
website: www.gpsuk.com email: enquiries@gpsuk.com

GPS
POLYETHYLENE
G P S P O LY E T H Y L E N E P R O D U C T S
GPS offers complete piping systems manufactured

primarily from polyethylene for pressure
applications.
The advantages of polyethylene pressure pipe
systems have been appreciated in the gas and
water industries and by general industrial users for
many years. Polyethylenes toughness, immunity
from corrosion, excellent resistance to chemicals
and light weight have contributed to its continued
appeal for use in situations where cost-effective
and reliable systems are required.
Polyethylene pipes and fittings from GPS offer the
following advantages:
High quality approved products, designed and
manufactured within an approved and registered
BS EN ISO 9001: 2000 quality system.
Wide choice of systems.
Up to 16bar rated at 20C when carrying water
and certain other liquids.
Up to 10bar rated at 20C when carrying natural
gas.
No anchor or thrust blocks needed. (Most
systems are fully end load resistant).
Ease of use.
Four jointing methods - Electrofusion, Butt-
fusion, Mechanical Fittings and Push-Fast (a
mechanical integrated spigot and socket system).
Polyethylene systems from GPS are manufactured
to meet the exacting standards imposed by gas and
water bodies.
GPS polyethylene systems are available in different
colours and are offered in high quality PE80
polymer, formerly known as MDPE (Medium
Density Polyethylene) and PE100 (Excel) formerly
known as HPPE (High Performance Polyethylene).
Excel being the GPS brand name for pipe made
from PE100 polymer.
2
Tel: +44 (0)1480 52121 Fax: +44 (0)1480 458829 Technical Support: +44 (0)1480 442620
GPS
POLYETHYLENE
Protecta-Line
Protecta-Line is an
award winning
innovative PE
pipeline solution
specifically designed
for the safe
transportation of
drinking water
through brownfield
sites & other types of
contaminated land.
With WRAS and DWi
approval, the system provides total peace of mind to the
Conventional
highest standards and meets all of the safety legislation
PE Pipes
demanded by water companies and customers alike.
Pipes are available in
Protecta-Line combines all of the advantages of
6 and 12 metre
conventional high quality PE pipe with an aluminium
straight lengths.
barrier layer to prevent permeation and is offered in pipe
Other lengths can be
diameters from 25mm through to 180mm. Protecta-Line
supplied to order.
pipes can be butt fused where local water bylaws permit,
Pipe up to 180mm
or by any of 3 different types of fittings:
OD is also available
mechanical compression up to 63mm, fluid compression
in coils of 50m,
from 63m - 180mm & electrofusion above 63mm where
100m and 150m
local water bylaws allow.
and can be supplied
in longer lengths on
drums. Pipe can also be extruded with four co-axial
stripes to identify the contents being conveyed or to
identify the application.
Pipes are extruded in two basic materials - PE80 (MDPE)

and PE100 (Excel) in the following colours: Secura-Line
Secura-Line is a
Blue - For potable water supply below ground. polypropylene coated
Yellow/Orange - For Gas supply below ground. PE pipe originally
Black - For global water and gas supplies, UK potable developed for pipe
water supplies above the ground and industrial bursting and other
(sewage, mining and quarry) applications above and applications requiring
below ground. extraordinary
resistance to external
abrasion, providing
enhanced protection
against damage and
eliminating the need
for pipe end cleaning and scraping prior to electrofusion.
Manufactured from standard PE100 polymer with a 1mm
layer of polypropylene which can quickly and easily be
removed, Secura-Line saves both time and money in the
field. Secura-Line can be butt-fused using the same
parameters as standard PE pipe.
3
GPS
POLYETHYLENE
Sleeved
Sub-Coil
Sleeved Sub-Coil is a
low cost
rehabilitation system
for distribution mains
and small trunk
mains manufactured
by GPS in co-
operation with
Subterra (a division
of Enterprise
Managed Services
Ltd) and United Utilities Ltd. Sleeved Sub-Coil is a PE
liner which has been factory folded into a C shape and
held in that form by a continuous thin sleeve. This folded Long Spigot &
geometry gives the annular clearance necessary to allow Pupped Fittings
fast insertion into the host pipe. Pressurisation parts the The GPS Long Spigot
sleeve allowing the subcoil liner to revert back to its range offers a
original circular shape. The liner forms a close fit with comprehensive
the host pipe, sealing against leakage and preventing choice of fittings
further host bore corrosion. suitable for butt-
fusion without the
need for pupping
(Provided that
machines with
DuraFuse - narrow clamps are
Electrofusion used). Products are
Fittings offered in PE80 Yellow, Blue or Black as well as PE100
DuraFuse (Excel) Blue or Black. A range of fittings is also offered
electrofusion fittings with factory fitted half metre pups to facilitate jointing on
are easy to use and site.
offer high
performance and a
rapid, convenient,
means of joining
polyethylene pipes.
Their design ensures
optimum melt
pressure because the energising coils of wire are precisely
positioned to ensure uniform melting and to minimise the
risk of accidental wire damage. Each fitting features a
bar code label to enable suitable electrofusion control
units (ECUs) to scan the bar code in order to determine
the fusion parameters. DuraFuse fittings are offered in
PE80 (MDPE) Yellow or PE100 (Excel) Blue or Black and
in PE size up to 400mm.
In addition to the DuraFuse range, GPS also offers a range

of larger diameter electrofusion fittings. The Frialen range
is offered in Black PE100 with bar code labelling which is
necessary for fusion and data-logging purposes.
FRIALEN SDR11 fittings are rated at 10 bar for gas and
uti 16 bar for water whilst SDR17 fittings are rated at
5.5 bar for gas and 10 bar for water.
4
GPS
POLYETHYLENE
SlimFlange
SlimFlange is a
unique product
developed by GPS to
allow size-for-size
connection of a PE
pipeline to a metal
fitting or pipe, i.e.
without any change
to the nominal bore.
SlimFlange features
a steel reinforced PE
face which allows the
PE shoulder height to be reduced significantly, while at the
same time the strength of the joint is actually increased.
SlimFlange is available in both PE80 (MDPE) and PE100
(Excel) complete with gasket and backing ring.
Push-Fast
Fittings
The Push-Fast spigot
and socket type
Calder Jointing
system features
individual
Equipment and
elastromeric sealing Tools
and internal grip The Calder brand is a
rings. Unlike similar comprehensive range
spigot and socket of user-friendly
systems offered in electrical and
other materials, mechanical tooling
Push-Fast resists the comprising of electro-
end thrust generated by the internal pressure, so anchors fusion control units
or thrust blocks are not usually required. This product is (ECUs), clamps,
offered in both PE80 (MDPE) and PE100 (Excel) scrapers and other
materials in blue or black and is rated up to 16bar. This associated tools for
product is not recommended for gas applications. joining polyethylene pipe. All ECUs are designed for
arduous site conditions and are equipped with combined
carrying and protective frames. Machines are available
for both manual and automatic operation. Special
machines can be supplied with the ability to read bar
codes using a light pen in order to determine the fusion
parameters of the particular fitting. These units also
include data logging facilities to ensure traceability of
fusion data for retrieval at a later time and transfer to a
database or printer.
5
GPS
POLYETHYLENE
Certificate No. E 51385 Certificate No. FM 34819
QUALITY
GPS operates a quality assurance system in

accordance with BS EN ISO 9001: 2000 which is
audited on a regular basis by BSI.
The quality assurance system imposes stringent
standards of control throughout design,
APPROVALS
development and subsequent production and
inspection processes, as well as the provision of
The GPS range of polyethylene pipes, DuraFuse
Certificates of Conformity for all raw materials, i.e. electrofusion fittings and long spigot fittings are approved
polymer and resistance wire etc. for use in many countries. Examples of where
second/third party certification has been achieved are
Products are subjected to the following range of
given below:
checks and tests, some being applied to every pipe
and fitting, whilst others are carried out on a UK British Gas/NGT/
sample basis: Advantica Technologies Ltd
Water Regulations Advisory Scheme
Coupon tensile tests DWI Regulation 31
Argentina Argentinian Gas Institute
Dimensional control
Austria VGW/N/FI/TGM
Hydrostatic pressure tests at 20C and 80C Australia WSAA
Stress cracking tests Belgium Becetel
Czech Republic TSU
Surface finish
Denmark DS
Crush tests carried out on pipe fused into France GDF
electrofusion sockets as part of joint Germany DVGW
performance tests Greece DEPA
Joint pull-out tests Hungary Hungarian Mining Office
Italy IIP-UNI (PE80 and PE100 (Excel))
Detailed records are kept of dimensional and AEM
performance tests for each production batch. Each Malaysia Lembaga Air Perak
batch is given a unique identification number Ibupejabat, Jabatan
which is reproduced on every fitting or pipe. Penang Water Authority
Moldova Centrul de Expertiza Technica
Poland IGNIG
Romania Central Laboratory
Russia Hygiene Approval
Spain Gas Natural
Sweden Tumab
ENVIRONMENT Switzerland SVGW (PE100 (Excel))
For a more detailed listing of products covered by these
approvals, please contact our sales department.
We operate an environmental management system
that has been successfully assessed against the BS
EN ISO 14001 environmental management
standard.
6
GPS
GPS polyethylene range is designed to comply with the requirements of one or more of the standards shown POLYETHYLENE
on this page.
WATER STANDARDS GAS STANDARDS
BS EN ISO 15494:2003 Specifications for polyethylene Transco PL2

components and system. Part 1 - 1998 Specification for polyethylene pipe
BS6437 - 1984 Polyethylene pipes (type 50) in and fittings for natural gas and
metric diameters for general suitable manufactured gas
purposes. Part 4 - 1998 Fusion fittings with integral heating
BS6572 - 1985 Specification for blue polyethylene elements
pipes up to nominal size 63 for Part 6 - 1997 Spigot end fittings for electrofusion
below ground use for potable water. and/or butt-fusion purposes
BS 6572 Part 8 - 1998 Pipes for use at pressures up to
BS6730 - 1986 Specification for black polyethylene 7bar
pipes up to nominal size 63 for Transco PL3 - 2002 Specification for Self-anchoring
above ground use for potable water. Mechanical Fittings/Joints for
BS5306:Part 2 - 1990 Fire extinguishing installations and Polyethylene (PE) Pipe for natural
equipment on premises. gas and suitable for manufactured
WIS 4-24-01 - 1998 Specification for mechanical fittings gas
and joints including flanges for ECE1 Specification for electrofusion
polyethylene pipes for the control boxes
conveyance of cold potable water BGES/F2 Specification for Main to Service
for the size range 90 to 1000 Pipe Fittings (for use up to 2bar);
including those made of metal or
plastics or a combination of both. BS2494G Specification for Elastomeric
Materials used in the Manufacture
WIS 4-32-08 - of Seals (for gas mains and fittings
Issue 3:April 2002 Specification for the fusion jointing up to 7bar); (BSEN 682)
of polyethylene pressure pipeline ISO161-1:1996 Thermoplastic Pipes nominal
systems using PE80 and PE100 outside diameters and nominal
(Excel) materials. pressures.
WIS 4-32-14 - 1995 Specification for PE80 and PE100 ISO 4065:1996 Thermoplastic Pipes Universal
(Excel) Electrofusion fittings for wall thickness tables
nominal sizes up to and including
630mm. ISO 4437:1997 Buried PE pipes for the supply of
gaseous fuels.
WIS 4-32-15 - 1995 Specification for PE80 and PE100
(Excel) spigot fittings and drawn BS ISO 11922-1:1997 Thermoplastic pipes for the
bends for nominal sizes up to and conveyance of fluids Dimensions
including 1000mm. and tolerances. Metric series.
WIS 4-32-17 BS6437 - 1984 Polyethylene pipes (type 50) in
metric diameters for general
Issue 2 - 2001 Polyethylene pressure pipes for purposes.
pressurised water supply and
sewerage duties including BS ISO 8085:2001
Secura-Line.(kite mark for water Part 1 General Polyethylene fittings for use with
WIS 4-32-17
applications only) polyethylene Requirements pipes for the supply of gaseous
DIN8074 - 1999 Pipes of high density polyethylene fuels
(HDPE) type 2 dimensions. Part 2 Spigot fittings for butt-fusion or
DIN8075 - 1999 Pipes of high density polyethylene socket fusion using heated tools
(HDPE) type 2 testing. and for the use with electrofusion
fittings
DIN16963 Part 1-1980 High density polyethylene (HDPE)
fittings dimensions, type 2. Part 3 Electrofusion fittings
ISO4427-1996 PE pipes for water supply BS EN 1555 Plastic piping systems for supply of
gaseous fuels polyethylene.
BS EN 12201 Plastic piping systems for water
supply polyethylene.
BS EN 13244 Plastic piping systems for general
purpose water, drainage and
sewerage - polyethylene
UNI 10910:2001 Polyethylene piping systems for
water distribution
WIS standards are Water Industry Specifications currently issued
in the UK by UK Water Industry Research Ltd.
7
GPS
POLYETHYLENE
Product Packaging
PRODUCT MARKINGS In addition to information marked directly on the products
the following information is supplied on the product
packaging.
Electrofusion Fittings
Fitting type
Where applicable, most fittings incorporate the following
information on the outer surface. Application information (Gas or Water)
Material designation Certifying symbols and standards
Standard Dimension Ratio (SDR) System voltage (if applicable)
SDR fusion range (max/min) Pressure rating
Nominal size (mm)

Weight (kg) Pipes
Fusion time indicated underneath the following logo in Where applicable pipes incorporate the following
seconds. information marked indelibly, linearly, at intervals along
the pipe.
GPS Pipe Marking

Where applicable pipe incorporate the following
information marked indelibly, linearly, at intervals along
Cooling time indicated underneath the following logo in the pipe. e.g.
minutes.
GPS 180mm SDR11 PE100 S 14143004 H
Plant Code
Shift Code (an
Name and trademark 8 digit code
Relevant certifying symbol and standards number denoting
Machine, Shift,
In addition to the above information, all product Week & Year)
manufactured within a specific batch is marked with an
identification number, unique to that batch Material manufacturers
identification code
This unique number consists of 7 digits which can be
interpreted, as follows: Material designation
(i.e. PE80 or PE100)
1 2 3 4/5 6/7
Standard Dimensional Ratio value
SDR value
Nominal pipe outside diameter (OD) in mm

The last two digits of the
year Manufacturer/Trademark
International Standard week

GPS pipe is also marked with the name of any industry
number
standard to which it conforms.
Blue water pipe also carries reference to the bar rating of
The day of the week: 1 = Monday the pipe (usually after the OD) and is marked at three
7 = Sunday separate intervals within the coding with the word
WATER for high visibility and identification purposes.
Batch reference: the number of the batch in a For identification purposes, Protecta-Line and Secura-Line
particular shift, usually 1. pipes are also marked with four brown stripes to indicate
that they are multi-layered pipes.
Shift period: day = 1

night = 2
8
GPS
POLYETHYLENE
MATERIAL PROPERTIES & COMPATIBILITY
Materials
GPS manufactures polyethylene systems in both PE80
and PE100 (Excel). The numbers relate to the MRS
(Minimum Required Strength) values of the material.
PE80 This is the term used to denote the polyethylene
material which has been widely used for gas, water and
industrial applications for many years. The terms MDPE
and HDPE were commonly used for this material,
although MDPE PE80, as historically supplied by GPS,
has a much higher long term stress crack resistance than Standard Dimensional Ratio (SDR)
traditional HDPE PE80.
One of the items of information contained on both pipe
PE100 (Excel) This is a term used to denote high and fittings is the standard dimensional ratio.
performance polyethylene, and PE100 pipes are sold by
In all but the smallest sizes of PE pipe (< 25mm) the
GPS under the brand name of Excel. PE100 (Excel) is a
ratio between wall thickness and outside diameter remains
higher density material than PE80 and demonstrates
constant for a given pressure rating of the pipe. This
exceptional resistance to rapid crack propagation as well
relationship, called the standard dimensional ratio or SDR,
as to long-term stress cracking.
can be expressed as an equation:
Moreover, the higher performance of Excel permits thinner
pipe walls than PE80 for the same operating pressure. It nominal (minimum) outside diameter
SDR =
therefore uses less polymer and provides for a larger bore minimum wall thickness
and increased flow capacity for a given nominal pipe size. Example:
This can result in significant cost savings at certain sizes SDR 11 = 180
and pressure ratings. 16.4
PE80 and PE100 (Excel) are not recommended for
continuous pressure operation at temperatures above
60C for liquids, including sewerage and industrial
effluents, or 30C for gaseous fluids. PE100 (Excel) has
180mm
advantages over PE80 at low temperatures, since it is OD
extremely crack resistant down to -30C. When
considering applications which exceed the limits stated
above, ask our Technical Support Department for advice. 16.4mm wall thickness
Property Method PE80 PE100 Relationship between wall thickness and outside
of Test Units MDPE (Excel) diameter (OD)
Melt flow rate -
2.16kg load BS2782 g/10min 0.2 <0.15
ISO 1133 Expansion and Contraction
5kg load BS2782 g/10min 1.0 <0.5 The average coefficients of linear thermal expansion
ISO 1133 between 20C and 60C for PE80 (MDPE)(1.3 x 10 -4 C-1)
Density BS3412 kg/m3 yellow 940 orange 951 and PE100 (Excel)(1.5 x 10-4 C1) are approximately ten
(Mean Values) ISO 1872 blue 943 blue 951 times greater than for metal. Allowance must be made for
black 950 black 957
this when designing polyethylene pipeline installations
Tensile where significant temperature variation is expected (eg.
strength at BS2782 MPa 18 23
above ground). If the above length change is re-stated as
yield ISO R527
8mm for PE80 and 9mm for PE100 (Excel) per 6m pipe
Elongation at BS2782 % >600 >600
break ISO 527 length per 10C of temperature change, the magnitude of
potential thermal movement can be better appreciated.
Flexural BS2782 MPa 700 1000
Modulus ISO R527 In above-ground installations the natural flexibility of the
Vicat softening
pipe, coupled with judicious sitting of anchor and support
point BS2782 C 116 124 brackets, will conveniently accommodate expansion and
Brittleness ASTM D746 C <70 <100 contraction at changes of direction, etc. In installations
temperature ISO 9784 where fully end-load bearing joints are used, the
Linear thermal compressive or tensile forces set up in the pipeline due to
4 4
expansion ASTM D696 C 1.5 x 10 1.3 x 10 constraint of thermal movement will not detract from
Thermal BS874 W/mK 0.4 0.4 long-term performance, but the effects of these forces on
conductivity DIN 52612
Further details may be obtained from GPS Technical Support Department.
9
GPS
POLYETHYLENE
pipe support, ancillary equipment and so on, must be radius values apply only if pipe is bent in the same
considered and allowance made. direction as it was previously coiled.
The potential for thermal movement is a particular issue
where a (fully end-load bearing) PE system is connected Insulation
to any non end-load bearing mechanically jointed system. Polyethylene is a good insulator and will help prevent
It is essential that such transitions are securely anchored, freezing of liquid pipe contents to an appreciable extent.
to obviate the risk of any joints in the mechanically Even if freezing does occur, the pipe will not fail since it
jointed system separating. can safely expand to accommodate increased volume.
It is also prudent to allow a newly installed pipeline time Nonetheless, the pipeline system may still need to be
to conform to ambient temperature before end protected against freezing temperatures to prevent flow
connections are made. restriction. Should you require any information or
assistance on designing a PE pipe system, please
Support contact our Technical Support Department.
Recommendations for maximum support spacing are
given in the table below. They are based on a mid-span Abrasion resistance of polyethylene
deflection of 6.5mm when the pipe is full of water and PE has significant advantages over other pipe materials
assume a long term flexural modulus of 200MPa at an where internal resistance to abrasion is required - for
ambient temperature of 20C. Pipe clips used for example if the pipe is intended for transporting abrasive
anchorage and support should have flat, non-abrasive media such as particulate slurry. This resistance to
contact faces, or be lined with rubber sheeting, and abrasion, combined with flexibility, ruggedness and
should not be over-tightened. The width of support immunity from corrosion, makes PE ideal where
brackets and hangers should normally be either 100mm traditional pipe materials would be unsuitable. Abrasion
or half the nominal pipe bore diameter, whichever is the resistance depends on slurry characteristics and flow
greater. parameters, but is predictable in many cases.
Polyethylene pipe has been used successfully for pumped
Above Ground Pipework abrasive media such as fly ash, china clay slurry and
Maximum Support Spacing (metres) various industrial effluents.
Pipe SDR11 SDR17 SDR26 In addition, it has been proven that, during installation,
32mm 0.9 the abrasive elements of typical soils and backfills make a
63mm 1.1
90mm 1.3 1.2 negligible impression on PE pipe. However in the unlikely
110mm 1.5 1.3 event of a notch or groove being cut into the external
125mm 1.6 1.4
160mm 1.8 1.6 1.5 surface by more than 10 per cent of the wall thickness,
180mm 1.9 1.7 1.6 the pipe section should be rejected.
200mm 2.0 1.8 1.7
225mm 2.1 1.9 1.8
250mm 2.2 2.0 1.9 Chemical Resistance - General
280mm 2.3 2.1 2.0
315mm 2.5 2.3 2.1 Polyethylene material is renowned for its good resistance
355mm 2.6 2.4 2.2 to chemical attack. The degree of resistance to a specific
400mm 2.8 2.5 2.3 chemical will depend on concentration, temperature and
450mm 2.9 2.7 2.5
500mm 3.1 2.8 2.6 working pressure, each of which will affect the long term
560mm 3.3 3.0 2.8 life of any system. Polyethylene does not rot, rust, pit,
630mm 3.5 3.2 2.9
710mm 3.4 3.1 corrode or lose wall thickness through chemical or
800mm 3.6 3.3 electrical reaction with the surrounding soil. Polyethylene
900mm 3.8 3.5 does not normally support the growth of, nor is affected
1000mm 4.0 3.7
by, algae, bacteria or fungi.
Note: Figures given are for horizontal support spacings; and may be doubled for vertical In broad terms the most common harmful chemicals can
support spacings. be grouped into oxidisers, cracking agents and certain
solvents.
Pipe bending radii for PE
The minimum bend radius for GPS PE pipes is 15 times Chemical Resistance - Special Cases
the pipe OD under optimum conditions (ie. warm ambient Special care is required in industrial applications where
effluents contain particular chemicals. Under certain
temperature and thick-wall/low SDR pipe). A more typical
conditions of pressure and temperature, the chemicals
safe bending radius for SDR11 and SDR17 pipes is 25
listed hereunder may be detrimental or permeate the pipe
times, increasing to 35 times the pipe OD in very cold
wall and taint water supplies.
weather. For thin-walled SDR26 and SDR33 pipes, these
If you are in any doubt, seek the advice of our Technical
values should be increased by 50%. Electrofusion or Support Department.
mechanical joints and fittings should not normally be
Oils: animal; vegetable or mineral such as
incorporated in sections of pipework which are to be bent.
petrol, creosote, turpentine and
Instead a formed bend or elbow should be welded into
silicone fluids.
the pipeline in order to prevent excessive stress. In the
case of pipe supplied in coils or drums, the above bend
10
GPS
POLYETHYLENE
Organic solvents: petrol and diesel; amylacetate and Material and SDR Compatibility Summary
other esters; acetaldehyde; benzene
and its compounds; carbon disulphide;
carbon tetrachloride; chloroform; (a) Dissimilar materials and dissimilar wall thicknesses
dichlorethylene; trichlorethylene; can be jointed by electrofusion.
ethers and turpenes; coal tar.
Halogens: fluorine; chlorine; bromine in high
NB. The maximum working pressure should not exceed
concentrations.
the lower value for the two pipes.
Acids: glacial acetic acid; chlorosulphonic
acid; cresylic acid; chromic acid; nitric
acid (over 25%); phosphoric acid (over See Figure A.
50%) and sulphuric acid (over 70%).
A
SDR17.6 SDR11
PE100 PE80
Jointing PE to PE by Fusion
PE pipes of different SDRs
CORRECT
Butt-welding
Butt-welding should only be used for jointing pipes of the
same SDR value. (b) Similar materials and/or wall thicknesses may be
jointed by butt-fusion or electrofusion.
Electrofusion
Electrofusion fittings are able to weld pipes having NB. SDR17 may be butt-fused to SDR17.6.
differing wall thicknesses (SDRs). They are available in a
choice of 10bar or 16bar (water) and 5.5bar or 7bar See Figure B.
(gas) rating. Care should be taken to ensure that the
pressure rating of the fittings is equal to or greater than
B SDR11 to SDR11
that of the pipe.
SDR17.6 to SDR17.6/17
SDR applications are marked on individual fittings.
However, for the more unusual SDRs, specific advice
should be sought from our Technical Support Department.
PE100 to PE100
Jointing different types of PE PE80 to PE80
Any medium density PE80 can be joined to any other CORRECT
medium density PE80 either by butt-welding or
electrofusion. Different pipe producers may have
(c) Dissimilar wall thicknesses must not be jointed on-site
alternative suppliers of preferred PE80 grades, but these
using butt-fusion. NB: PE80 should only be butt-fused
are all intended to be joined by identical techniques.
to PE100 (Excel) under closely controlled factory
Similarly different grades of PE100 can be joined together
conditions.
in like fashion. Butt-welding different pipe materials - for
example, PE80 to PE100 - is not recommended on site
See Figure C.
(see below).
C
SDR17.6 to SDR11
PE100 to PE80
INCORRECT
11
GPS
POLYETHYLENE
PRESSURE RATINGS AND FLOW CHARACTERISTICS
Various ISO/CEN working groups have considered the Surge and fatigue in PE80 and PE100
design factors that should be used to determine the
(Excel) pipes
maximum operating pressures of polyethylene water and
gas systems. These factors will account for any additional The two phenomena of surge and fatigue may be treated
loadings or environmental conditions, eg. elevated separately, since they describe different potential effects on
temperature or exceptionaly poor ground conditions. the pipe material. UK IGN 4-37-02, March 1999, can be
summarised as follows with respect to PE pipe systems:
The graph below shows the reduction factor which should

Surge
be applied to the recommended maximum continuous
working pressure at 20C to obtain appropriate working For systems where extreme transient conditions are unlikely,
pressures for elevated temperatures. it may be safely assumed that the peak surge pressure will
never have a value more than twice the rated steady state
1.0 pressure. Occasional surge pressures of up to this value will
0.9
not harm even low toughness PE pipes that have been rated
for the steady state system pressure.
0.8
Factor
0.7 Fatigue
0.6 Fatigue is associated with repeated transient pressure
variations occurring over an extended period of time. The
0.5
fatigue resistance of PE pipes depends on the toughness of
0.4 the material used, as well as on the magnitude of the
10 20 30 40 50 60 pressure variations. Data from numerous laboratory and
Temperature C
field test programmes have resulted in the table below (see
Reduction factor vs Temperature also the Notes) which can be used to re-rate PE pipes
according to material toughness and the predicted frequency
The reduction graph has been calculated to give normal of pressure excursions in the system:
factors of safety after 50 years. It refers only to the
conveyance of fluids to which the pipe material is
completely resistant.
MAXIMUM CONTINUOUS OPERATING PRESSURES AT 20C FOR GPS STANDARD PE PIPES.

SDR17.6(GAS) /
PIPE OD SDR11 SDR17 SDR21 SDR26
* PIPES SPECIFICALLY SIZED
SDR17 (WATER)
FOR INSERTION LINING PE80 PE100 (EXCEL) PE80 PE100 (EXCEL) PE100 (EXCEL) PE100 (EXCEL)
APPLICATIONS
GAS WATER GAS WATER GAS WATER WATER WATER WATER
20mm 5.5 12.5
25mm 5.5 12.5
32mm 5.5 12.5
50mm 5.5 12.5
63mm 5.5 12.5 7.0 16.0 3.0 8.0
90mm 5.5 12.5 7.0 16.0 3.0 8.0 10.0
110mm 12.5 16.0 3.0 8.0 10.0
125mm 5.1 12.5 7.0 16.0 3.0 8.0 10.0
160mm 5.1 12.5 16.0 3.0 8.0 10.0 8.0 6.0
180mm 4.1 12.5 7.0 16.0 3.0 8.0 10.0 8.0 6.0
213mm*
225mm 12.5 16.0 8.0 10.0 8.0 6.0
250mm 4.0 12.5 7.0 16.0 3.0 8.0 10.0 8.0 6.0
268mm*
280mm 12.5 16.0 8.0 10.0 8.0 6.0
315mm 3.4 12.5 7.0 16.0 2.7 8.0 10.0 8.0 6.0
355mm 3.1 12.5 7.0 16.0 2.5 8.0 10.0 8.0 6.0
400mm 12.5 7.0 16.0 2.3 8.0 10.0 8.0 6.0
450mm 12.5 7.0 16.0 2.2 8.0 10.0 8.0 6.0
469mm*
500mm 12.5 7.0 16.0 2.1 8.0 10.0 8.0 6.0
560mm 7.0 16.0 2.0 10.0 8.0 6.0
630mm 7.0 16.0 1.8 10.0 8.0 6.0
710mm 16.0 10.0 8.0 6.0
800mm 10.0 8.0 6.0
900mm 10.0 8.0 6.0
1000mm 10.0 8.0 6.0
- GPS CAN USUALLY OFFER SDRs OTHER THAN THOSE SHOWN IN THE TABLE, E.G. FOR CLOSE FIT LINING APPLICATIONS
- UK GAS OPERATING PRESSURES HAVE HISTORICALLY BEEN LIMITED TO 7 BAR FOR PE100 PIPE - THIS IS THE RESULT OF THE UK RATING SYSTEM FOR CHARGES ON PIPELINES AT HIGHER PRESSURE
- THERE MAY BE A REQUIREMENT TO DE-RATE MITRED BENDS FOR WATER APPLICATIONS - PLEASE CONTACT OUR TECHNICAL SUPPORT DEPARTMENT FOR ADVICE
- PE80 (MDPE) WATER PIPELINES 355MM AND GREATER IN DIAMETER SHOULD BE DERATED IF SIGNIFICANT AMOUNTS OF AIR ARE PRESENT - SEE THE UK WATER INDUSTRY'S IGN 4-32-18 MARCH 2003
- PE80 (MDPE) GAS PIPE PRESSURES MUST BE FURTHER DERATED FOR TEMPERATURES BELOW 0 DEGREES C.
- THE VALUES IN THE ABOVE TABLE DO NOT ADDRESS ANY OTHER SAFETY-RELATED ISSUES ASSOCIATED WITH PIPELINE DESIGN.
12
GPS
POLYETHYLENE
High Frictional Pressure Loss in Low Pressure

Daily number Low Toughness Toughness GPS
of Pressure PE80 & 100 PE80 & 100
Polyethylene Gas Pipelines
Transients Re-rating factor Re-rating factor The flow charts on the following page are based on the
4 1.1 0.5 Low Pressure Flow Equation derived from the General
24 1.5 0.5 Flow Equation as referenced in Section 4.5 of the
48 1.7 0.5 Institution of Gas Engineers and Managers publication:
120 2.0 0.5
240 2.3 0.5 Recommendations on Transmission and Distribution
1200 3.0 0.5 Practice - Distribution Mains (IGE/TD/3: Edition 3: 1992)
For Natural Gas assuming:
Notes General Flow Equation Constant (C) = 7.57 x 10-4
The predicted pressure variation range for the system Average Compressibility Factor (Zavag) = 1
must be multiplied by the factors given in the table in Specific Gravity (s) = 0.6
order to establish the pipe PN necessary to avoid the
Average Gas temperature (Ta) = 15C
risk of fatigue damage.
Standard Temperature (Ts) = 15C
GPS PE80 (MDPE) and PElOO (Excel) pipes are able to
resist a wall stress of 4.6Mpa at 80C for 1,000 hours Standard Pressure (Ps) = 1.013.25bar
in the EN 13479 Notched Pipe Test without any stress (absolute)
crack growth, and therefore need no re-rating for fatigue Low Pressure Flow Equation
irrespective of the frequency of the surge events (as (P1-P2) = Q2 x 1.841 x 106 x f x L
reflected in the final column).
D5
N.B. The pipe PN must always be at least equal to the
where P1 = Upstream pressure bar (absolute)
maximum steady state pressure of the system, and the
pipe must be structurally adequate for the given burial P2 = Downstream pressure bar (absolute)
conditions. Q = Gas flow at base conditions m3/hr
D = Internal pipe diameter mm
Example L = Pipe length m
A PE100 (Excel) system operating at a steady state fspl = Friction factor (spl = smooth pipe law)
pressure of 5bar is expected to experience cyclic transient assuming Pipe Absolute roughness (k)
pressure variations between Obar and 16bar 1200 times
for new pipework = 0.003mm
per day. From the table, a pipe pressure rating PN of at
least 8bar should be specified [i.e. 16 (=the pressure Efficiency factor (e) = 0.97
variation in bar) X 0.5 (=the re-rating factor)]. Friction factor (fspl) = fspl/e2
where 1 = 14.7519 + 3.5657X + 0.0362X2
(fspl)0.5
with X = log1O (Re) - 5
and Re = 25043 x Q (Reynolds Number)
D
The above is considered valid for pressures up to 75mbar.
13
GPS
POLYETHYLENE
Flow Charts for Low Pressure
Polyethylene Gas Pipelines
SDR11
125mm
180mm
250mm
315mm
20mm
25mm
32mm
63mm
90mm
100
Pressure Drop mbar/1000m
10
0.1
0.01 0.1 1 10 100 1000
Demand m 3 / hour
SDR17.6
125mm
180mm
250mm
315mm
90mm
100
Pressure Drop mbar/1000m
10
0.1
0.01 0.1 1 10 100 1000
Demand m 3 / hour
14
GPS
POLYETHYLENE
Pressure Losses and Flows in Polyethylene
Water Pipelines
Flow Calculations for Water Fittings constant

Pressure drop due to friction can be determined for Fitting F
practical purposes using a flow nomogram. The GPS 90 Elbow 0.030
nomogram is based on the Colebrook White formula for 45 Elbow 0.015
water at 10C using a hydraulic roughness factor K for 90 Tee Straight through 0.020
new pipework of 0.003mm. 90 Tee Side branch 0.075
The pressure drop at a given flow rate can be determined 90 Long Radius Bend (4D) 0.020
as follows: 45 Bend Long Radius Bend 0.010
1. Obtain the internal bore diameter of the pipe to be Reducer (d/D= 3/4) 0.007
used by referring to the dimensions tables.
2. Mark this diameter on Scale A.
3. Mark the required flow rate Flow Nomogram
on Scale B.
4. Draw a straight line A B C D
connecting the points on Internal Diameter Flow Rate Flow Velocity Hydraulic Gradient
Scales A and B and extend (mm) L/sec L/min (m/s) m/100m pipe
the line to cross Scales C 15
and D.
5. The velocity of flow in
metres per second is
determined from the 20
intersection with Scale C. 0.01
0.01
1
6. The frictional head loss in 25
0.02
metres per 100 metres of 2 0.05 0.02
pipe can then be read off 30
0.05 3
Scale D. 4 0.03
35 5
0.1 0.1 0.04
Fittings 40 0.05
10
The calculation of pressure drop 0.2 0.15
in fittings is more complex, but 50
0.3
20
0.4 0.2
calculations can be made for 0.1
0.5 30
equivalent lengths of straight 60 40
pipe using the Formula E = Fxd 50 0.3
1
where: 70
0.4 0.2
100
E= equivalent pipe length 80 2
0.5
(metres) 3 0.3
90 200
4
F = fittings constant (See 5 300
0.4
100
below) 400 0.5
d = fitting internal 500
1
diameter (mm)
1000
20 1
To calculate the total pressure 1.5
150 30
drop in the system, the 2000
40 2
equivalent straight pipe lengths 50 3000
for fittings is then added to the 4000 2
200 5000 3
total straight pipe length to 100
3
obtain the total drop. 10000 4
250 200 4
5
300 20000 5
400
300
500 30000
40000
350 50000
1000 10 10
400 m3/min.
100
2000
15
3000 20
500 200
4000 20
5000 300 Approx. values only
Diagram for water at 10C
NOTE: For sizes not covered by the nomogram, please contact Technical Support Department
15
GPS
POLYETHYLENE
PRESSURE TESTING - WATER
Water mains Pressure Test

The traditional testing procedures used for most pipeline On reaching the test pressure, and satisfying the
materials throughout the Water Supply Industry is given in conditions for minimal air entrapment, the pipeline is
BSI CP 312:Part 3:1973:Section 10. isolated and the pressure allowed to decay. The pressure
These procedures, which are generally satisfactory for loading time (t1) to achieve test pressure is used as a
linearly elastic materials, are not suitable, without reference. The natural pressure decay readings at
modified analysis procedures, for visco elastic materials predetermined times (multiples of t1) are recorded.
such as Polyethylene. A correction of t1 is then used to calculate ratios (N), the
Pipe made from such visco elastic exhibit creep and values of which indicated either the soundness of the
stress relaxation. main or the presence of an unacceptable leak.
When a Polyethylene pipeline is sealed off under a test As the pressure decay is of exponential form the use of
pressure there will be a reduction in pressure (pressure logarithms is necessary when comparing readings but the
decay), EVEN in a leak free system, due to the visco use of a pocket calculator is all that is required for on
elastic (creep) response of the material. This pressure site calculations.
decay is non-linear in an unconstrained pipe. PE pipes should be tested in reasonable lengths
appropriate to the pipe diameter, pressurising pump
capacity, and the prevailing site conditions. Pipelines
longer than 1000 metres may require testing in sections.
The pipeline should not initially be subjected to any
pressure when filling from the mains supply or from
Pressure
standing heads, as this may affect the test result.
Polyethylene pipelines must not be pressure tested unless
the wall temperature is kept to below 30C; this includes
open trench situations. To enable a precise analysis of the
Time
pressure test data, pressure transducers with a logging
Typical pressure decay curve for an unrestrained PE pipeline facility and display should be used.
The detailed procedure is as follows:
Note: this represents a slight modification of the
procedure detailed in the first printing of the WRc Manual
A pressure test procedure has been developed by WRc to
for Polyethylene Pipe Systems for Water Supply 1986.
enable interpretation of the effects of creep and stress
relaxation. Take a first reading of pressure P1 at t1, where t1 is equal
to the pressure loading time tL.
For PE pipe systems the test pressures should always be
a maximum of 1.5 times the rated pressure of the lowest Note t1c = t1 corrected = t1 + 0.4tL
rated component and/or 20bar maximum if any Take a second reading of pressure P2, at a decay time of
mechanical fittings are present. With these provisos the approximately 7tL this is time t2.
test pressure should be 1.5 times the pipe rated pressure
Note t2c = t2 corrected = t2 + 0.4tL
when this is up to 10bar, and 1.5 times the mean
log P1 log P2
working pressure of the system for pipes rated at 12.5 Calculate N1 =
bar and above. log t2c log t1c
16
GPS
POLYETHYLENE
For a sound main this ratio N1 should be: Commissioning

a) 0.08 to 0.10 for pipes without constraint (eg. sliplined The commissioning of new or repaired supply and
or not backfilled) distribution mains is normally carried out in the following
b) 0.04 to 0.05 for pipes with compacted backfill. sequence:
Cleaning and/or swabbing of the main
If the values are significantly less than the minimum
Filling and sterilisation
identified, then there is too great a volume of air in the
Flushing and/or neutralisation
pipework. This air will have to be removed before a
Refilling the main
satisfactory test can be performed. Experience shows that
Bacteriological sampling
retesting can be more difficult to carry out because the
Acceptance certification
pipe has already stretched due to creep from the pressure
Introduction and/or returning of the main into service
originally applied.
The sequence for PE should include these basic
It is therefore of extreme importance to ensure that air is
procedures but may be adapted to meet particular
removed prior to testing.
conditions (eg. pre-chlorination of sliplined mains). In all
Take a further reading of pressure P3 at a decay time not cases the procedures must comply with the requirement
less than 15tL. Let this time be t3. of the local Water Undertaking.
Note t3C = t3 corrected = t3 + 0.4tL Service pipes should be tested with the ferrule connected
log P2 log P3 to the main but before the cutter taps into the main.
Calculate N2 =
log t3C log t2C After being tested, all service pipes must be subjected to
a final disinfection process before being introduced into
The ratio for N2 should be
the water supply system. Guidance is given in the Water
a) 0.08 to 0.10 for pipes without soil constraint
UK publication, Principles of water supply hygiene and
b) 0.04 to 0.05 for pipes with compacted backfill. technical guidance notes. The water utility should be
The sensitivity of the test can be increased by extending consulted with regard to their disinfection policy for
the value of t3. service connections.
If at any stage during this pressure test an unacceptable Special attention should be paid to the proper sterilisation
leak is indicated, it is advisable to check all mechanical of those services laid to hospitals and renaldialysis
fittings before visually inspecting the welded joints. Any machines.
defect in the installation revealed by the test should, of For further support concerning specific installations,
course, be rectified and the test repeated. please contact our Technical Support Department.
On completion of a test sequence the remaining pressure
should be released slowly until the pipeline is under its
pre-test conditions.
In the event of a further test being required on the
pipeline, such a test should NOT be attempted before
sufficient time has elapsed for the pipeline to recover from
the previously imposed conditions. This recovery time will
depend upon individual circumstance but a period
equivalent to 5 times the previous test period may be
taken as a guide.
17
GPS
POLYETHYLENE
PRESSURE TESTING - GAS
Pressure testing procedures vary according to utility; it is body). This test pressure should be applied to the highest
advisable that the regulations of the relevant body are point of the pipe and checked with a gauge.
referred to. The following general guidelines are based on Regular re-pressurisation is necessary before the start of
the procedures of the Institute of Gas Engineers. the test period in order to permit creep to take place. Once
All new mains and services should be pressure tested this has elapsed the test period can begin.
before being commissioned. This includes any part of the Pressure and ground temperature should be recorded at
pipeline which has been renewed or altered. It is important regular intervals (e.g. every 15 minutes) during the test
that the same test instrument is used for initial, period.
intermediate and final pressure readings.
The pressure test is passed if there is no pressure loss
Any pressure testing of a polyethylene pipeline has to allow recorded or if there is a constant or declining pressure
for creep. This is the phenomenon whereby a PE pipe will decay rate which does not exceed 5% of the test pressure
relax when pressurised leading to a small increase in per hour.
volume and a decrease in internal pressure.
If the results do not meet the above criteria, it is advisable
There are two types of pressure test; hydrostatic and to extend the test period to allow more data to be
pneumatic. For mains and services which will operate collected.
above 2bar a hydrostatic pressure test should be followed
Following the test, the water must be removed, usually by
by a pneumatic test, for mains and services with an
the use of air propelled pigs. Dry pigs should then be put
operating pressure less than 2bar a pneumatic test only
through the system until the pipe is deemed dry enough by
should be sufficient.
the engineer.
Hydrostatic pressure testing

Pneumatic pressure testing
This is carried out before a pneumatic pressure test. The
This is a leakage test that simulates the system at its
mechanical integrity of a main or service is determined by
maximum operating pressure under gas conditions. When
completely filling the pipeline to be tested with water
conducting this type of test account must be taken of
which is then pressurised.
barometric pressure.
When using this technique the engineer should avoid
For pipes greater than 63mm stand pipes and gauges,
excessive test pressures which may occur due to
should be connected at the ends of the new main and
hydrostatic head at low lying points.
include a pressure relief valve (see figure 1). Air should be
An initial test pressure of 350mbar should be applied prior introduced into the main until the correct test pressure is
to the main test in order to ensure the general integrity of attained.
the system.
If the main is being filled by gravity, thought should be
given to the need to vent air at high points and to allow
water removal at low points. Also, excessively aerated
water should not be used. Wherever possible water should
be introduced into the pipeline at the lowest point.
An uninterrupted, even flow of water should be used to
completely fill the pipe. This should not take place if the
air temperature is 2C or less or likely to drop to such a
level.
Once water has been pumped into the pipe, the
temperature should be allowed to stabilise prior to
pressurising to the test level (refer to relevant governing
18
GPS
POLYETHYLENE
The pressure in the service should be increased to the

relevant value.
The test period should be as recommended by the
relevant governing body. No pressure loss is permissible.
For low pressure services, once a successful test has been
completed, the meter control valve should be closed, the
test apparatus detached and the integrity of the meter
control valve tested. The pressure can then be released
from the electrofusion tapping tee end.
Leakage detection
The pipeline should be dosed with a suitable tracing
agent (eg. sulphur hexafluoride or ethyl mercaptan
usage instructions must be followed carefully) and
pressurised to 350 mbar. The length of the pipe should
then be checked using a suitable detection device. Once
the leak(s) has/have been located, the pipe should be
repaired and all pressure tests repeated.
Temperature effects
Figure 1. Pneumatic pressure testing of gas mains Pressure changes with temperature and any calculations
must consider this. To reduce temperature variations as
Before the start of the test period, the temperature of the
much as possible the pipe trench should be backfilled.
air should be allowed to stabilise.
At the start of the test period a pressure reading should Test equipment availability
be taken followed by another reading at the end. If the For further details of pressure testing, please contact the
period is long, it may be wise to take several readings GPS Technical Support Department.
during the test. In this way, any early indication of
probable test failure avoids the need to run for the full
period.
When completed, air should be vented in a controlled
manner until the main is at atmospheric pressure.
For pipes of a diameter not greater than 63mm, and of
low pressure (not greater than 75 mbar), air is introduced
into the service through the meter control valve, which is
left open whilst the opposite end of the service, at the
electrofusion tapping tee, is securely blanked off. For
medium pressure (greater than 75 mbar not greater than
2bar) and intermediate pressure (greater than 2 bar, but
not greater than 7bar) the test is from the main to the
inlet valve of the service governor.
19
GPS
POLYETHYLENE
SQUEEZE-OFF
The procedure must not be carried out within 3 pipe

diameters of a fitting, a fusion joint or a previous
squeeze-off operation.
The squeeze-off procedure should not normally be used
on pipes larger than 500mm diameter.
After the squeeze-off procedure is complete the pipe must
be
Inspected and re-rounded if necessary
Renewed if there are any signs that the pipe is
damaged ie splitting or cracking
Recorded and marked as having been squeezed-off.
Tests which have been carried out by external test
laboratories have indicated that satisfactory long-term
The flow of the contents in a polyethylene pipe, where a performance can be achieved on previously squeezed-off
repair is required remote from valves or where it would be and re-rounded pipes of various wall thicknesses.
too expensive to empty the pipe line, can be arrested by
N.B. Individual Gas Companies may limit the maximum
using equipment that squeezes the pipe walls together.
diameter of pipe that can be squeezed-off and/or may
This method was developed by the UK Gas Industry in
require the use of stainless steel reinforcement bands
the early 1980s. GPS can supply clamps suitable for
above certain diameters.
pipes from 16mm to 400mm in diameter. Hydraulic jacks
are used to provide the necessary force to compress the
pipe wall for sizes 110mm and above. Manual tools are Operating procedure for 63mm-180mm
used up to and including 90mm. Built in rotatable check hydraulic squeeze-off tools
plates protect the pipe from damage from over 1. Screw upwards the two stop screws to allow
compression. These plates can be exchanged to allow the clearance for the squeeze bars to be separated.
tool to be used with the many sizes of metric and
2. Using the jacking handle turn the oil valve on the
imperial pipe that exist.
hydraulic jack in an anticlockwise direction. This will
The squeeze-off equipment comprises two tangential bars release the oil pressure in the jack and allow the two
to apply pressure to the outside of the pipe. The bars are long return springs to pull up the upper squeeze bar
moved together, manually or hydraulically, squeezing the and cause the jack to compress within itself.
pipe material until a seal is formed where the upper and (Occasional assistance by hand may be needed).
lower walls meet.
3. Check pipe diameter and SDR ratio.
Hydraulic tools have a spring return for the jack and
4. Set the limit plates on the sides of the squeeze off to
locking pins to prevent accidental release of pressure
the appropriate size. (The correct size must be
during operation.
pointing downwards towards the lower squeeze bar).
Where the pipe wall is compressed the polyethylene pipe
5. Put the squeeze-off on the pipe to be squeezed (it
will be severely deformed in the regions of maximum
may be easier to remove the bottom squeeze bar).
compression. PE100 (Excel) polyethylene material will
also discolour due to stress whitening. 6. Using the jacking handle, tighten clockwise the oil
valve on the hydraulic jack (to allow it to be jacked
The pipe will eventually regain its original shape after the
up).
release of the squeeze-off but there will be some
reduction in pressure bearing properties for diameters 7. Using the jacking bar in the hydraulic jack actuating
above 125mm. Re-rounding equipment is available and it lever, pump up the jack and start to squeeze the pipe
is recommended not to force the pipe back to a round together.
shape more quickly than necessary, especially in cold 8. Continue jacking until the limit plates just touch the
weather. bottom bar (they should still be moveable by hand).
The following important points must be followed. Further 9. The pipe is now in a 'squeezed-off' condition.
details are given in DIS 5.3 or the WRc Polyethylene Pipe 10. If the squeeze-off is to be left in this squeezed-off
Systems Manual. condition for a while (for example overnight) it is
Specifically designed equipment fitted with the correct prudent to tighten down the two safety stop screws
check plates should be used to avoid over compression to alleviate any potential hydraulic pressure loss due
of the pipe. to a leak somewhere.
20
GPS
POLYETHYLENE
H E A LT H A N D S A F E T Y
Our polyethylene products have been installed and Fire characteristics

used safely in large volumes over many years. When PE is heated in air, melting will occur at 120-
However, good working practice is vital in ensuring 135C and decomposition will commence at
safety; our products should be handled and approximately 300C. Above this temperature PE will
processed in accordance with the British Plastics pyrolise oxidatively to produce carbon dioxide, carbon
Federation guidelines. All PE80 and PE100 (Excel) monoxide, water and various hydrocarbons. These gases
pipe systems contain trace quantities of process may ignite and provide heat which may accelerate the
residues and may also contain other materials such pyrolysis of more PE in the vicinity. In burning, molten
as pigments, antioxidants and UV stabilisers. droplets of material may be released which could ignite
adjacent inflammable materials. Actual cooling conditions
Chemically unreactive, PE is regarded as being
in a real fire will be influenced by many factors such as
biologically inert, though some pipe materials
location and oxygen availability, which will determine the
contain low levels of additives which may be toxic.
progress and combustion products of the fire.
Combustion of PE may release toxic materials. Avoid
inhalation of smoke or fumes. Also, do not allow PE dust
to accumulate, since there may be a risk in exceptional
Ingestion circumstances of dust explosion, and consider carefully
Ingestion of PE should be avoided. Some pipe materials the sitting of potential heat sources such as electrical
may contain additives which are harmful if swallowed. equipment.
Materials specified for purposes other than carrying water In case of fire with PE80 or PE100 (Excel), any fire
may contain pigments which are not suitable for use with extinguisher may be used. Powder extinguishers are very
potable water. effective in quenching flames. Water sprays are especially
These materials may be hazardous if ingested in large effective in rapid cooling and damping down a fire, but
quantities. are not recommended in the early stages of a fire since
they may help to spread the flames.
Inhalation Other factors will also influence the selection of fire
PE does not release harmful fumes at ambient extinguishers eg. proximity of live electrical equipment.
temperature.
3
The threshold limit value for PE dust is 10mg/m (8-hour-
time-weighted average in the working environment), but
Handling of molten material
During the fusion welding of PE pipe and fittings molten
the generation of such levels when working with PE pipe
PE is formed which, if allowed to contact the skin, will
and/or fittings is extremely unlikely.
adhere strongly and cause severe burns. Such molten
material has a high heat content and will remain hot for
Physical contact
some time. Gloves should be worn where there is any risk
PE is not considered to be a skin irritant. Where PE dust
of skin contact.
is generated by cutting or machining pipe or fittings,
powder particles of PE dust may cause eye irritation by Small quantities of fumes may be given off by molten PE
abrasion. these are more pronounced at higher temperatures and
greater care must be taken where there is a risk of PE
adhering to heated surfaces, such as heating plates used
for welding. Ventilation must be provided to ensure safe
working conditions.
21
GPS
POLYETHYLENE
HANDLING & STORAGE
General Handling
Polyethylene is a resilient material, lightweight and
easy to handle. Nonetheless, care should be taken
not to cause excessive scuffing or gouging of the
surface. In addition to the guidelines set out here, Allow for a certain amount of deflection or slight bending
the handling and storage of PE pipe is covered by of pipe bundles when loading or unloading. Standard six
codes of practice issued by various utilities (eg. the metre bundles may be handled by forklift, but longer
WRc manual for PE pipe systems for water supply lengths should be moved by a side-loader with a
& IGE/TD/5:1992). minimum of four supporting forks or by a crane with
a spreader beam. Individual lengths should be handled
In lifting operations, where either manual or similarly. Off-loading on site will be eased by skid timbers
mechanical effort is involved in moving a load, the and rope slings.
following points are common to all situations and
provide the basis on which the selection of the
appropriate type of lifting equipment can be made:
The weight of the load
The bulk, size or shape of the load
The method of joining the load to the lifting
system
The centre of gravity of the load
The method of security or stabilising the lifting
Handling of long lengths
equipment
Plus the training of personnel involved in lifting
operations
Coils
Loading and off-loading Small coils of pipe strapped on to pallets are easily
Lengths and bundles handled by forklift. Larger coils of 125mm or 180mm
A flat-bed vehicle, free from sharp objects and projections pipe will require lifting individually by forklift.
should be used for transporting pipes. When lifting pipe
bundles by crane, wideband slings should be used; do not Releasing coils
use chains, hooks or hawsers. For lengths greater than six Safety first: Pipe held in coils is under tension and is
metres, load-spreading beams should be inserted at equal strapped accordingly. Coils may be hazardous if released
distances apart. in the incorrect manner particularly if the end of the
pipe is not kept restrained at all times. It is most
important to read and understand the following guidelines
Slings before attempting to release coils.
Support timbers
12 metre pipe bundle
Good lifting practice
22
GPS
POLYETHYLENE
Coils are secured by one of two methods depending on

the pipes diameter:
1. Outer bands with additional strapping of individual
layers. Fittings
Do not remove any of these bands until pipe is Never use hooks to lift fittings. Make sure that the tines
required for use. Remove them carefully, from the on forklift trucks are adequately covered (eg. by scrap PE
outermost layer first, so that only the length of pipe pipe offcuts).
needed immediately is released. Successive layers can
be released by removing banding as the pipe is drawn Storage
away from the coil. Coils of pipe above 32mm Badly stacked pallets, coils or bundles may slip or
diameter should only be dispensed in the field from collapse, causing injury to personnel or damage to the
proprietary trailers. pipe. Pipe-end caps, intended to prevent ingress of
contamination, should be kept in place during storage.
2. Wrapped coils of pipe of 32mm and below have
external layers of filmwrap, enabling the free end of the Lengths
pipe to be taken from inside the coil. Take only Pipe lengths stored individually should be stacked in a
sufficient pipe for immediate use from the coil and on pyramid not more than one metre high, with the bottom
no account remove the outer wrapping until the coil is layer fully restrained by wedges. Where possible, the
almost fully unwound. bottom layer of pipes should be laid on timber battens at
one-metre centres. On site, pipes may be laid out
individually in strings. (Where appropriate, protective
barriers should be placed with adequate warning signs
and lamps.)
Pipe Lengths
1 metre max
Recommended practice for releasing coils from filmwrap

Lateral
restraints
Support 1 metre
Drums Battens
Drums are delivered direct to site on a low loader and the

Storage of loose pipes
pipe is usually dispensed from the drum by pulling off
with a machine such as a JCB. The inner end of the pipe
is restrained at the hub of the drum, and although
drummed pipe has less energy locked into it than coils, Bundles
caution is required when parting the pipe end from the Bundled packs of pipe should be stored on clear,
drum. For safety, we recommend that the end of the pipe level ground, with the battens supported from the
should be tethered to the dispensing machine when it is outside by timbers or concrete blocks. For safety,
unhooked from the drum. This will prevent potentially bundled packs should not be stacked more than
dangerous springing. three metres high.
Support 1m Spacing
Battens
3m Maximum
Recommended practice for off-loading drums
Ground Level
Storage of bundles
23
GPS
POLYETHYLENE
Coils Fittings
Coiled pipe should be stored flat, especially during Electrofusion fittings should be stored under cover in dry
periods of warm weather, and on firm level ground which conditions, preferably on racking. They should be kept in
has suitable protection for the bottom coil. Where space their boxes or packaging until ready for use. Butt fusion
is limited and coils are to be stacked, the height of and spigotted fittings may be stored outdoors, as long as
stacked coils should be such that the stack is stable and they are protected against damage and prolonged direct
the uppermost coil can be safely handled. Under no sunlight. Electrofusion fittings should be retained in their
circumstances should the stack exceed plastic bags until used.
2.5 metres in height.
The use of wooden battens below the bottom coil and as Storage outside
spacers between each layer will facilitate easy access for Black polyethylene material contains pigment to provide
slinging when the need for transportation to the job is excellent protection against degradation due to UV
required, which should only be carried out by a trained radiation.
plant operator. Blue and yellow polyethylene is UV stabilised to resist
degradations in storage only. The maximum recommended
The eye (loop) on a wire sling can be secured by a
storage outside, in Northern Europe, is 12 months.
number of methods:- manually spliced, secured by a
Product stored outside for periods in excess of this should
ferrule or secured by a group of bulldog clips.
be covered with black polyethylene sheeting or stored
Manual splicing reduces the SWL of a wire rope to 90% under cover.
and ferrules to 95%. Bulldog clips reduce the SWL to
85% and is therefore not recommended. The rules on handling and storage
A tag should be attached to each wire sling to show an Never
identifying number and the SWL. Drag or roll individual pipes or bundles.
Batches of coils delivered on pallets must remain secured Throw/drop pipe/fittings from delivery vehicles.
to the pallet and only be broken at the time of use. Use metal slings, hooks or chains when handling.
For details of safe procedure when releasing coils, see Expose pipe/fittings to prolonged sunlight. (Protect with
Releasing Coils under the Loading and off-loading section. opaque sheeting or tarpaulin).
Stack more than three metres or three bundles high.
Place pipes or fittings in contact with lubricating or
hydraulic oils, gasoline, solvents or other aggressive
2.5 metres max. height
materials
(see Chemical Resistance in the Health & Safety
section).
Always
Store pipes on flat, firm ground, able to withstand the
Storage of coils weight of pipe/fittings and lifting apparatus.
Keep pipe/fittings well away from sharp objects, such
Where large diameter coils are to be stored vertically, coils as flints.
must be secured in purpose built racking and facilities for
Use wide non-metallic slings (eg. nylon or
safe lifting, movement and loading must be available.
polypropylene).
Exercise special care when handling pipes in wet or
frosty conditions, since they may become slippery.
Keep protective packaging (battens, shrinkwrap, pallets,
strapping, etc.) intact until pipes/fittings are required for
use.
Keep pipes/fittings away from intense heat, except
when jointing.
Allow for some bending deflection when pipes are
loaded and unloaded. Lifting points should be evenly
Example of racking for vertical storage of large diameter coils spaced.
24
GPS
POLYETHYLENE
PROCEDURES & TECHNIQUES FOR PIPELINE INSTALLATION
A major advantage of PE is that pipe lengths can be butt-

fused or electrofusion jointed to form a continuous string
of pipe and there is rarely need for thrust blocks. This,
together with the material's inherent flexibility, (see
material properties section for bend radii) makes
polyethylene ideally suited to a full range of new and
innovative installation techniques. GPS PE systems
support all methods of installation used today including
chain trenching, moleploughing, size-for-size moling, pipe
bursting and slip-lining. Working practice and techniques
for installing GPS products by a variety of pipelaying
methods are described below.
Conventionally Buried Pipelines

Considerable savings in the costs of imported backfill
(where necessary, see below) reinstatement and waste
spoil disposal can be made if trench width is minimised.
The dimensions of a trenchline opening are normally
governed by the pipe diameter, method of jointing and
site conditions. Normal minimum depth of cover for
mains should be 900mm from ground level to the crown
Polyethylene pipe systems from GPS are designed of the pipe. Trench width should not normally be less
to make installation quicker, easier and more cost- than the outside diameter of the pipe plus 250mm to
effective. Installation is as much a part of the allow for adequate compaction of sidefill unless
costing equation as ease of maintenance and the specialised narrow trenching techniques are used and/or
cost of the pipe system itself. PE's great advantage specially free flowing and self-compacting side materials
in installation is its lightness and flexibility, are employed (see below).
coupled with its durability and totally secure
jointing methods. For all modern pipelaying
techniques, whether in rehabilitation work or the
construction of new pipelines above or below
ground level, PE80 (MDPE) and PE100 (Excel)
systems from GPS usually provide the simplest, Compact in
Normally 900mm layers of
most economic solution. Indeed, rehabilitation minimum backfill 250mm (max.)
techniques have been developed which rely

completely on polyethylene's unique properties. 250mm minimum
initial backfill.
Do not use
heavy compaction 100mm minimum cover
equipment above pipe crown
Fill material to
conform to
IGN 4-08-01
WIS 4-08-02
110mm minimum
bedding
25
GPS
POLYETHYLENE
In many instances it may be acceptable to lay PE pipe

directly on the bottom of the trench - especially where the
soil is uniform, and there are no large flints, stones, or
other large hard objects present. In rocky ground, the
trench should be cut to a depth which will allow for the
necessary thickness of selected bedding material below
the bottom of the pipe. Where the finished top surface
will subsequently be trafficked, and spoil from the
excavation is unlikely to give the degree of ground stability
required, even after a degree of grading and compaction,
granular material should be imported. Gravel or broken
stone graded between 5 & 10mm in size provides suitable
bedding, since it needs little compaction. Coarse sand, a
sand and gravel mix, or gravel smaller than 20mm are excavation method. After lowering the pipe into position,
also all acceptable straight from the quarry. The best the trench can be backfilled and the layers consolidated.
granular material available from most modern quarries is It is important to emphasise that the above requirements
designated 803X, and has been tested and approved by generally only apply when the PE pipe is buried in ground
WRc. This has a maximum particle size of 12mm and that will subsequently be trafficked, with or without a road
very few fines and allows for trench widths only 50- pavement. The stated sidefill and backfill materials are
100mm greater than the pipe irrespective of the required to give a stable top surface - the PE pipe itself will
not be harmed if laid in much poorer surround provided
there are no large sharp stones pressing against it.
Normal sidefill & backfill requirements

For minor roads excavated material can often be returned
to the trench and compacted in layer thicknesses specified
by the Utility Company. Relevant Water Industry
specifications. e.g. WIS 4-08-02, permit much coarser
material for the side and backfill (uti 10% of pipe nominal
size) for PE pipelines than is recommended for the
bedding. However, heavy compaction equipment should not
be used until the fill over the crown of the pipe is at least
300mm.
When GPS PE pipes are laid in fields it is preferable and

most cost effective to use the originally excavated material
all around the pipe provided that there are no large sharp
stones positioned underneath it (see above). Large clay
masses should be kept as dry as possible after excavation
and broken up by rotovating. By using as-dug the drainage
characteristics of the land are not altered, and any slight
future soil movement as the ground re-stabilises is easily
accommodated by the flexible and ductile nature of the PE
pipes. It can rarely be justified to import granular fill in
such cases and there are no particular benefits from using
a geotextile wrap around the fill area.
26
GPS
POLYETHYLENE
Low-Dig and No Dig New Lay Techniques

for Buried Pipelines
Narrow/chain trenching Moleploughing

As previously noted, a major installation advantage of PE This technique was originally developed for laying land
pipe is that lengths can be fused together by butt-welding drainage and adapted for installation of gas and water
to form continuous strings. Since the need for trench pipes in rural areas. It enables pipelines to be laid across
jointing is virtually eliminated, the width of excavations rural landscapes with minimum disruption to agriculture,
can be minimised, resulting in reduced labour cost, less while the ground can also be reinstated virtually to prime
imported backfill and lower reinstatement costs. Modified condition. A new PE pipe string is literally ploughed into
mechanical diggers with narrow buckets are ideal the ground to a prescribed depth and the ground restored
provided that the soil produced by the digging action is immediately to its original condition.
relatively fine. Chain excavators in particular will break up
the original ground finely and permit trench widths only
50 to 100mm greater than the PE pipe outside diameter.
Moleploughing
Impact moling
Impact moling is highly economic in instances such as
Narrow/chain trenching
road crossings, where considerable savings can be made
over traditional open-cut excavation methods. Traffic
control systems are often unnecessary, for example, and
the cost of excavation, backfill and reinstatement is
virtually eliminated. With this installation method,
excavation is only necessary at the starting and finishing
locations of the pipeline - in order to accommodate the
mole and its ancillary equipment. The impact mole drives
a borehole between launch and reception pits, leaving the
ground surface undisturbed. A sacrificial liner is
sometimes attached to the mole and pulled along behind
it. The PE pipe is pulled directly behind the mole or into
the pre-liner if present. Independent studies have
indicated that only thin walled pipes e.g. thinner than
SDR17, are at significant risk from excessive scoring
during impact moling. However, for total security GPS's
Secura-Line can be specified (see also pipe bursting
below).
Sacrificial Liner
Impact moling (not to scale)
27
GPS
POLYETHYLENE
ii) An enlarged hole is bored by one of various means,

which include high - pressure fluid jets for cutting (plus
carbide cutting blades to cope with the more difficult
soils), and drill bits which are driven by mud motors.
iii) The drill head is steered by using a flexible joint close

to the head which is moved by manipulation of the
jets or by thrust force on the end of the drill string. A
transmitter in the head sends signals to the surface,
and these are received by a hand-held locator which
displays both the lateral position and depth of the
head, allowing tracing and guidance of the drill head.
Pipeline
Directional drilling Drilling Rig
This is a pipe installation technique that was originally
developed for oil and gas wells, however it is now Barrel
Reamer
increasingly used for PE pipe. It allows pipelines to be
installed under roads and rivers etc. with minimal Washover
Pipe
excavation work. Basically, it involves drilling a hole under
an obstacle and then pulling the pipeline back through an
enlarged hole from the far side.
The stages are as follows: Drilling Rig
i) A small diameter 'pilot hole' is drilled from one side of

Pipeline
the obstacle to the next by a drill head attached to the
'pilot string' which, in turn, may be connected to a
Washover
'washover' pipe which overdrills the hole and provides Pipe
Barrel Swivel
Reamer Joint
rigidity to the pilot string.
Drilling Rig
iv) When the drill head exits on the far side of the
obstacle, the drill head is removed and a reverse barrel
reamer is attached to the washover pipe followed by
Washover Drill Bit
Pipe
Drill Pipe
the PE pipe string. The reamer is used to increase the
size of the hole to the final size required to enable the
PE pipe string to be pulled back through.
In the case of large diameter pipes, a number of passes

are made using reamers of progressively increasing sizes
before the final pull-through of the PE pipe string is
carried out.
28
GPS
POLYETHYLENE
Rehabilitation and Renovation using Grouting

No-Dig Techniques Where ground water loads are an issue in conventional
Slip-lining slip-lining, annular grouting is usually more economical
In slip-lining a replacement PE pipe string of smaller size than using the heaviest possible grade of PE pipe
is inserted into an existing decommissioned pipeline. guaranteed to give satisfactory resistance to ground water
Although rarely necessary, pressure grouting (see next loads. The resistance of the inserted pipe to grouting
column) of the annular gap can enable the existing pressure will depend on SDR and on cross-sectional
pipeline to be rehabilitated structurally, whilst also circularity - a particularly important consideration for pipe
reinforcing the hoop strength of the new PE pipe. taken off a coil or drum.
Though some reduction in flow capacity is inevitable, this Grouting is irrelevant to close-fit lining systems of course
can be minimised by careful preparation and cleaning of (see below), since the final annular gaps are negligible.
the old pipe so that the largest possible diameter of new The following table is reproduced from the WRc Sewerage
PE pipe can be inserted. In many instances an average Rehabilitation Manual, Vol III.
annular clearance of as little as five per cent of mains
diameter - less still for sizes above 300mm - has proven
adequate where pipelines are reasonably straight and of Permissible external pressures on PE pipes at grout curing
temperatures.
uniform bore. In pressure pipelines the reduction in
carrying capacity can also be compensated for by an Deformation 0% 1% 3% 6%
SDR Permissible External Pressure (kN/m2)
increase in internal pressure. In gravity applications any
33 13 12 10 7
effect of bore reduction is minimised both by the
26 27 25 20 15
exclusion of ground water entering the system and by the 17 96 88 73 59
improved flow characteristics of PE. 11 417 383 317 242
Copyright Water Research Centre 1986
In average conditions welded strings up to 700 metres
long for PE80 and 1000 metres for PE100 (Excel) - can
be pulled into place, irrespective of diameter or SDR and
without excessive axial strain. The maximum
recommended pulling loads at 20C for various sizes of
GPS PE80 and PE100 (Excel) pipe are shown on page
30.
For long strings we recommend a pipe relaxation period of

at least 24 hours before grouting or making permanent
tie-in joints and lateral connections. To further minimise
residual tensile stresses it is also desirable to carefully
nudge in any accessible exposed pipe ends using a digger
bucket. This is especially helpful in warmer weather.
Slip-lining (not to scale)
29
GPS
POLYETHYLENE
Pipe bursting
Size-for-size replacement, or upsizing, of existing iron
pipelines can be achieved with significant savings by the
pipe bursting method. With this technique an existing
Maximum pulling loads at 20C main is cracked open and the borehole simultaneously
expanded by a mole. Modern pipe bursting moles -
Nominal PE80 PE100 (Excel)
especially those with hydraulically expanding segments -
PE Pipe Dia 20C load 20C load
(mm) SDR Max OD (tonnes) (tonnes) can crack and open out an unserviceable pipeline, even if
it has repair collars or concrete surrounds. Risk of
20 8.7 20.3 0.10 N/A
25 11 25.3 0.13 N/A damage to adjacent utility installations is minimised by
32 11 32.3 0.21 N/A using hydraulic moles, helping to maximise the cost
50 11 50.4 0.5 N/A advantages of using the existing 'hole in the ground'. Up
63 11 63.4 0.8 N/A until recently, the usual practice was to use a sacrificial
90 17 90.6 1.1 1.4
polyethylene sleeve which was drawn behind the mole
90 11 90.6 1.7 2.1
110 26 110.6 1.1 1.4 through the cleared borehole and the new PE main could
110 17 110.6 1.7 2.1 then be inserted. Naturally the use of a sacrificial PE
110 11 110.6 2.5 3.1 sleeve or liner increased both time and cost of the
125 26 125.6 1.5 1.8 operation, so GPS developed Secura-Line which is a
125 17 125.6 2.2 2.7
normal PE pipe with an abrasion resistant outer coating.
125 11 125.6 3.2 4.1
160 26 161.0 2.4 3.0 This saves on time because no second insertion has to
160 17 161.0 3.6 4.5 take place.
160 11 161.0 5.3 6.6
180 26 181.2 3.0 3.8
180 17 1812 4.5 5.6
180 11 181.2 6.7 8.4
225 26 226.4 4.7 5.9
225 17 226.4 7.0 8.8
225 11 226.4 11 13
250 26 251.5 5.8 7.3
250 17 251.5 8.7 11
250 11 251.5 13 16
315 26 316.8 9 12
315 17 316.8 14 17 Pipe bursting (not to scale)
315 11 316.8 21 26
355 26 357.1 12 15 Close-fit insertion systems
355 17 357.1 18 22 Close-fit systems offer two major advantages. They never
355 11 357.1 26 33 require grouting (see above) and, in most cases, even
400 26 402.3 15 19 though there is a slight reduction in pipe diameter, the
400 17 402.3 22 28
exceptional hydraulic smoothness of GPS pipe actually
400 11 402.3 33 42
450 26 452.6 19 24 enables flow capacity to be increased. The following
450 17 452.6 28 35 figure illustrates the point graphically. Quite clearly,
450 11 452.6 42 53 PE100 (Excel) pipe is the best choice where maximum
500 26 502.9 23 29 flow capacity is required for a given pressure rating.
500 17 502.9 35 43
500 11 502.9 52 65
560 26 563.2 29 36 If the old main is structurally unsound, close-fit PE linings
560 17 563.2 44 55 can be SDR17/17.6 or SDR11, depending on ground
560 11 563.2 65 81 cover and pressure requirements. For pipelines that are
630 26 633.7 37 46 strong but leaking, PE lining thickness down to SDR33 or
630 17 633.7 55 69
less should be considered. With a 50-year minimum life
630 11 633.7 82 103
710 26 714.0 47 59 and exceptional gap-bridging performance, thin-walled PE
710 17 714.0 70 88 linings provide a cost-effective sealing membrane that is
800 26 804.6 59 74 totally reliable.
800 17 804.6 89 111
900 26 905.0 75 94
Rolldown
900 17 905.0 113 141
1000 26 1005.0 93 116 One of the first close-fit methods to be developed, was
1000 17 1005.0 139 174 conceived and patented by the former Stewarts and
Lloyds Plastics and is now operated by Subterra Ltd. In
OD = Outside Diameter this system pre-welded strings of PE pipe are reduced in
SDR = Standard Dimensional Ratio
diameter by approximately ten per cent - with very little
extension - by pushing them through rollers. The reduced
diameter pipe string is then inserted, often as a separate
operation, into the old pipeline and re-expanded by water
pressure to take up a close fit.
30
GPS
POLYETHYLENE
70
Lining SDR
60
50 42
40 33
Flow Improvement (%)

30 26
17.6
20
11
10
130 140
0
80 90 100 110 120
10
20
30
Hazen Williams Roughness
40 Coefficient of Original Mains
Subline Flow capacity improvements for close-fit PE80 or PE100 (Excel)

Also developed in conjunction with Subterra, in this lined mains, irrespective of head loss or mains size. (Assumes
technique welded up strings of liner pipe ranging in Hazen Williams Roughness Coefficient 'C' of Lining = 150 and
diameter from 8inch right up to 40inch, are deformed in 1% fit deficit)
the field into a "C" cross sectional shape by jacking them
through a mechanical plough and trough. The C shape is External loading
retained by friction-welded plastic straps until these are If a pipeline to be rehabilitated by any of the above
intentionally snapped by internal water pressure after the methods is deeply buried or passes under a river, the
Subline string has been winched into the old mains. The buckling loads produced by external ground water should
liner SDR is generally chosen to ensure that the reverted be considered. Account should also be taken of PE ovality
liner is pushed out into a tight fit against the host bore by and whether grouting will be carried out. Long term safe
the normal operational pressure of the mains. external heads can vary between approximately 60 metres
of water for a grouted installation using fully circular
Sleeved Subcoil SDR11 PE80 pipe, down to about two metres for an
GPS uniquely manufactures and supplies this product to ungrouted and loose SDR26 lining with six per cent
Subterra and its licensees at 3, 4, 5 and 6inch mains ovality. These examples assume that the old mains is
application sizes. Liner pipes at SDR26 and thinner are structurally sound and that the PE lining OD is
factory deformed into a C shape, held by means of a thin significantly less than the mains bore. If host pipe
externally applied PE sleeve, and then wound onto strength is doubtful, ground and water calculations must
compact drums in lengths of up to more than take into account probable soil support and grout stiffness
1,000metres. The sleeve provides for reliable long term (if used) and the known condition of the existing main.
shape retention, and also protects the liner pipe when it is
pulled off the drum and into a deficient mains. As for its
bigger brother Subline, the Sleeved Subcoil liner pipe SDR
is chosen to render a tight fit in the host pipe when the Embankment installation
sleeve is intentionally split by installation or operational Where pipes are to be installed above existing ground
pressure. Also in common with Subline, the very compact level and then covered, they should not be laid until the
C shape of Subcoil allows it to negotiate significant bends mound of made up ground has been built up and
in the host mains. compacted to one metre above where the crown of the
pipe is to be. A trench should then be cut into the mound
and the pipes laid in the conventional way.
Above-ground supported installation

For exposed supported above ground pipework proper
anchorage is essential. The structure and anchorages
must resist or accommodate thermal stresses or
movement over the ambient temperature range to which
the pipe system will be subjected. Above-ground PE
During Insertion After insertion systems should preferably be installed at or near
maximum operating temperature. In this way the pipe will
Swagelining be thermally expanded when clamps or supports are
Works by pulling a pre-welded string through a reducing bolted into position (see page 9 for support spacings).
die and into the old pipeline in one operation. Re- Tensile stresses will develop as the pipeline cools, but any
expansion to a close-fit diameter occurs naturally within a sagging will be minimised when it returns to installation
few hours of the winching load being released. temperature.
31
GPS
POLYETHYLENE
ELECTROFUSION JOINTING PRINCIPLES
The DuraFuse system comprises a complete range Electrofusion Principles

of PE electrofusion fittings (couplers, elbows, tees,
Hot and cold zones, sometimes called melt and freeze
tapping tees and branching saddles) for use with
zones, are formed after energising the coil. The length of
PE long spigot fittings and pipe in either PE80
these zones is particularly important. Each zone ensures
(MDPE) or PE100 (see material compatibility
that fusion is controlled to a precise length of the socket
section).
of the fitting and that the melt pressure is also controlled
throughout the entire jointing process. The precisely
controlled pitch and positioning of the coil in relation to
DuraFuse Technology and the inner surface of the socket ensures uniform heat
Product Design distribution. DuraFuse electrofusion fittings are supplied
for mainly 39.5V operation although some sizes and
All DuraFuse electrofusion fittings employ the same
materials are available for 79V operation.
basic principle. The socket of the fitting incorporates
an electrical heating coil. An electrofusion control unit
(ECU) supplies the electrical energy necessary to heat
the coil. When the coil is energised the material Cold Hot Cold Hot Cold
adjacent to it melts and forms an expanding pool

which comes into contact with the surface of the pipe.
The continued introduction of heat energy causes the
pipe surface also to melt and a mixing of pipe melt
and fitting melt takes place; this is vital to produce a
good weld. Following the termination of the heat
cycle, the fitting and pipe are left to cool and the
melted material solidifies to form a sound joint. High Electrofusion Control Units
integrity, consistently reproducible electrofusion joints
will only be achieved if the following criteria are met: GPS manufactures, under the Calder brand name,
electrofusion control units to meet all conceivable needs.
Heating coils are as close to the joint surfaces as In addition, a comprehensive range of accessories is also
possible. offered.
Electrofusion control units are designed to operate from
Wire position is accurately controlled during an electrical mains or field generator supply having an
manufacture and during the subsequent fusion output of 110V and a rating of generally 3 to 3.5kVA for
process. 39.5V fittings and 6 to 7kVA for 79V fittings.
Electrofusion control units can also be obtained combined
Heat distribution is uniform over the length of the with an integral generator.
hot zone. All ECUs manufactured after 1st January 1996 for sale
into Europe comply with the Electro-Magnetic
Melt pressure and temperature are both accurately Compatibility Directive and are CE marked.
controlled. All units have been designed for arduous site conditions.
They are equipped with combined carrying and protective
Coils are protected from damage prior to, during and frames.
after fusion.
The design and unique manufacturing technique of the

DuraFuse electrofusion system ensures positive
compliance with all these criteria.
32
GPS
POLYETHYLENE
Bar Coded Electrofusion Fittings

Technology is now available which eliminates the need to
enter the fusion time manually. Special control units can
be supplied with the ability to read a bar code where
fixed to an electrofusion fitting. These machines have a
'light pen' attached which the operator uses to input the
data contained within the bar code. Bar code control units
also have data logging facilities to ensure traceability of
Temperature/Fusion time compensation
welding parameters. An output socket allows the DuraFuse products are designed to work on a fixed fusion
downloading of this information onto a computer database time for temperatures between -5C and +23C. Where
or printer to obtain a complete record of the joints which the time is being entered manually then temperature
have been made. This information can be downloaded compensation is not normally necessary within these
daily, or upon completion of the project. The units will parameters. The bar code system will automatically adjust
store up to 200 operations. The ECU will display a the fusion time by small amounts to compensate for
description of the fitting which includes three digits to variations in ambient temperatures. Additional data
denote size and this should be read and checked by the relating to extremes of temperature can be obtained from
operator before proceeding. the GPS Technical Support Department.
26 Digit Bar Code Traceability for Spigot Fittings

DuraFuse Black PE100 (Excel) and PE80 (MDPE) fittings are fitted with traceability bar codes, these bar codes can be read by
any bar code Electrofusion Control Unit fitted with a traceability option. The traceability bar code contains specific information
regarding the manufacture of the product such as: the name of the fitting manufacturer, the type of fitting, the size of the
fitting, the production batch number, the manufacturing plant where the product was made, the product SDR rating, the
product raw material, the material status (virgin etc)., the material MRS PE80/PE100 (Excel) and the material melt flow index.
26 Digit Traceability Bar code Identification Black PE fittings only - Example
3 4 5 1 0 3 0 6 3 1 2 3 4 5 6 0 1 7 0 6 0 1 0 2 1 6
Manufacturer Diameter Production Batch GPS PE Compound PE Type Check

(DuraFuse) in mm Number Site Digit
0601 - (Autofina) 2 - PE80
Finathene 3 - PE100
3802B
0504 - (Solvay)
Eltex
Tub 121
Shape Code
01 - Straight Pipe
Material Status
02 - Coiled Pipe
03 - Coupler 0 - Virgin
04 - Tapping Saddle
SDR Rating
05 - Branching Saddle
06 - 90 Elbow Melt Flow Rate
0 - >SDR 33
07 - 45 Elbow 1 - SDR 33 1 - <5g/10min
08 - Other Elbows 2 - SDR 26 2 - 5-7g/10min
09 - Tee 3 - SDR 21 3 - 7-10g/10min
10 - Endcap 4 - SDR 17.6 4 - 10-15g/10min
11 - Reducer 5 - SDR 17 5 - 15-20g/10min
12 - Swept Bend 6 - SDR 13.6 6 - 20-25g/10min
13 - Stub Flange 7 - SDR 11 7 - 25-32g/10min
28 - PE/Brass Transition Fittings 8 - SDR 9 8 - 32-40g/10min
29 - Excess Flow Valve 9 - <SDR 9 9 - 40g/10min
33
GPS
POLYETHYLENE
Electrofusion Sequence
The sectional drawings show the jointing sequence from
energising the coil until completion of fusion. The whole
cycle is electronically monitored by the electrofusion
control unit (ECU).
1
Indicator Coils Top of
Holes Coupler Terminal
Pipe Pipe
Pipe positioned in coupler prior to energising coil.
2 5
Coil energised. Heat transfers to pipe wall and pipe material starts to melt.
3 6 Freeze Freeze
Material surrounding coils starts to melt. Melt solidifies at the start of the cold zones, thereby
sealing the melt zone. Further input of energy causes
increase in melt pressure.
4 7
Area of melt extends leading to expansion Melt pressure reaches optimum value at end of energising
towards pipe surface. cycle. Emergence of the melt at the indicator holes shows
that fusion is complete.
34
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POLYETHYLENE
DURAFUSE ELECTROFUSION JOINTING PROCEDURES
Jointing using electrofusion is simple, quick and

efficient. Successful joints can be consistently
reproduced after very simple training. Similar
procedures are used for all electrofusion systems
with respect to preparation and assembly. Some
fittings require the fusion time to be entered into
the ECU manually and are therefore described as
manual. Some fittings incorporate auto-recognition
aids and the ECUs are therefore described as
automatic. The majority of fittings require a 39.5V Transition Fittings
supply but some larger couplers are designed to GPS transition fittings, available from 25mm x 3/4" to
accept 79V supply. 63mm x 2", are made by anchoring a short polyethylene
The instructions that follow describe the DuraFuse pup onto a machined brass component. The black PE80
electrofusion fittings used to joint adjacent lengths spigot is designed to be a light interference fit inside
of pipe and Long Spigot fittings. Procedures DuraFuse electrofusion fittings. Transition fittings are only
described must be read in conjunction with any supplied as electrofusion assemblies.
Code of Practice affecting a particular industry, for The brass component should be fully tightened, using a
example: spanner, before the fusion cycle is started. PTFE tape
should be used to seal the threads.
British Gas Code of Practice and IGE/TD/3 It is possible to make minor adjustments to the threaded
WIS 4-32-08 Issue 3 April 2002 component after fusion. Adjustment should be restricted
to 1/4 turn as excessive movement may damage
WRc Manual for PE pipe systems for water
component parts within the brass transition.
supply applications, 3rd Edition 2002.
Recommended Torque Values for Transition Fitting Installation
Equipment Fitting Recommended torque (Nm)
Generator (11OV for the UK and 220V for Europe). 25 x 3/4 50
Generally 3.5kVA output for 39.5V fittings and 6 to 32 x 1 60
40 x 11/4 80
7kVA for 79V fittings.
50 x 11/2 90
Electrofusion control unit (ECU). 63 x 11/2 90
63 x 2 105
Clamping equipment.
Pipe scraping preparation tool capable of removing 0.2
to 0.4mm from the outer surface of the pipe.
Ancillary equipment such as marker pen, solvent wipe
and clean cloth/paper towel.
Pipe cutter/saw.
A shelter to protect the pipe, fittings and ancillary
equipment against adverse weather conditions and
contamination.
35
GPS
POLYETHYLENE
Procedure
1. Cut the pipe square and remove burrs.
2. Wipe loose dirt from pipe ends.
3. Without removing the protective wrap, place the
centre of the electrofusion fitting alongside the pipe
end and mark the pipe around the circumference,
approximately 15mm beyond the extremity of the
socket depth, using a felt tip pen.
4. Using the pipe end preparation tool, remove the
entire surface of the pipe over the marked area,
preferably as a continuous ribbon or strip. Note: The
use of mechanical end preparation tools is preferred
as hand scraping requires great care and can be
time-consuming especially on larger diameter pipes.
It is essential that material is removed by scraping or
peeling; scratching or abrading is not sufficient.
5. Remove the fitting from its packaging and check that
the bore of the fitting is clean and dry.
6. For water applications clean the scraped area of the
pipes and the fitting surface with Isopropanol wipes.
For gas applications, the scraped area of the pipe
should not be wiped. Once wiped or scraped do not
touch the cleaned ends of the pipe or the inside of
the coupler with your hands or rags.
7. Insert the pipe ends into the fitting so that they are in
contact with the centre stop.
8. For all socket electrofusion fittings (couplers,
reducers, elbows and tees) clamps must be used.
The clamps must be adjusted to suit the particular
size and type of fitting being welded so the pipes
cannot move during the fusion cycle. If possible,
rotate the fitting to check that the pipe ends are
correctly aligned.
9. Remove the terminal protection caps from the
terminal shrouds.
10. Connect the ECU output leads to the fitting terminals.
Note: It does not matter which lead is connected to
each terminal. (The connections are not live and
neutral).
11. Check that there is sufficient fuel in the generator to
complete the joint. Start the generator and check for
correct operation.
12. Operate the ECU according to the instructions, which
should have been thoroughly read and understood
prior to any welding operations. The ECU will either
have some form of automatic operating system or
require manual operation. Whichever system the ECU
uses, all DuraFuse fittings are marked with both
fusion and cool times in seconds plus the necessary
input voltage.
36
GPS
POLYETHYLENE
13. If the fitting has melt indicators check that they have 6. Using a felt tip pen, draw a mark on each end of the
risen. The molten material should have risen to a pipe to be inserted which will be used to indicate
point just above or just below, the surface of the where the mouth of each socket of the coupler should
fitting. (DuraFuse PE100 (Excel) fittings size 63mm be positioned prior to fusion.
and below do not have melt indicators. Couplers 7. Check the jointing areas are clean and dry, use
355mm and 400mm have heat sensitive labels to isopropanol wipes if necessary.
indicate that sufficient heat has been generated).
8. Care should be taken to ensure any of the residual
14. The joint must be left in the clamps for the cooling water in the mains is not allowed to come into
time specified on the fitting, although the terminal contact with the electrofusion area. It may not be
leads may be removed carefully without disturbing possible to maintain a clean dry area, in such cases
the joint. the couplings should be mechanical such as
Push-Fast fittings.
If the fusion cycle terminates before completion of the
9. Place the repair couplers over the exposed length of
count-down, check for faults as indicated by the ECU the installed main and slide these away from each
display. other to allow the new pipe to be inserted between
Check that there is adequate fuel in the generator the exposed ends.
Once the fault has been rectified the welding process can
10. Insert the new pipe and align.
be recommenced, but the timer has to be reset to zero.
If using a transformed supply, make sure that the supply 11. Slide the couplers towards each other as shown in
lead to the ECU is not of excessive length. the diagrams ensuring that the socket mouths line up
NEVER extend the length of the leads from the ECU to with the marks on the pipe.
the fitting. 12. Carry out the normal jointing procedure as described
Do not pressurise the system until the joints have cooled in the previous section.
to ambient temperatures.
Electrofusion Jointing of Coiled Pipe

i) Up to 63mm diameter. Clamps must be used which
align and restrain the pipes.
ii) Greater than 63mm diameter. To electrofuse coiled
pipe with a diameter greater than 63mm, the pipe
must be rerounded.
Repair
The pipe stops incorporated in the DuraFuse couplers are
shearable and have been provided for the specific purpose
of using the fittings for making repairs or breaking into
existing pipelines.
The procedure, shown diagrammatically in fig.1: is as
follows:
1. Cut out the damaged section of pipe and ensure the
pipe is cut square.
2. Measure the distance (L) between the exposed pipe
ends and cut the pipe length to be inserted equal to
the measured distance less 10mm.
3. Clean the pipe ends for a distance slightly greater
than the overall length of the coupler.
4. Scrape the pipe ends, as previously described, but for
the overall length of the coupler.
5. Remove the pipe stops in the coupler. This can be
most satisfactorily achieved by placing one end of a
thoroughly cleaned short length of pipe into the
coupler and striking the other end onto a hard
surface. The pipe stops can also be removed using a
sharp knife, but care must be taken not to damage
the bore of the fitting.
Figure 1.
37
GPS
POLYETHYLENE
JOINTING PROCEDURES FOR FRIALEN LARGE DIAMETER

ELECTROFUSION COUPLERS
The installation of large diameter electrofusion FRIALEN 400, 450, 500, 560 and
fittings (400mm and above) is a specialist activity. 630mm Coupler Installation Procedure
To ensure full control over the quality of
For site representation or to arrange product installation
electrofusion jointing it is important that the
training, please contact our Technical Support
following procedures are adhered to. Large
Department.
diameter couplers must only be installed by
contractors/operatives who have successfully
Essential Equipment:
achieved the standards required on the GPS
training course. Successful candidates will possess 1) 7kVA Minimum petrol generator
a Frialen ECU operator control card and a 2) FRIALEN electrofusion control box
completion certificate. 3) Mechanical pipe scraper FWSG630
Friamat Electrofusion Control Units are supplied in 4) Re-rounding clamp
the closed operating mode ensuring that they can 5) Alcohol wipes
only be activated by the trained operator's control
6) Packing tape
card.
7) Hand scraper
8) Marker pen
9) Rubber/nylon hammer
10) Outside diameter tape
Additional Equipment:
1) Feeler gauge
2) 90 Set square
EQUIPMENT CAN BE
HIRED FROM FRIATECS
(GPS) APPROVED HIRE
CENTRES:-
HIRE CENTRE -
TEL: 01462 457591
38
GPS
POLYETHYLENE
in in g C e r t ific at e?
Tra Preparing the pipe
a v e y o u go t y ou r s?
H 1. Check the pipe for any abrasions or impact damage
that may provide a detrimental effect to the
p ho n e: 0 14 8 0 4 42620 performance of the coupler.
Tele 2. Ensure that the pipe end is cut square. It may be

useful to use a setsquare to be certain - the pipe
should not be out of square. Use your outside
FRIALEN Large Diameter Electrofusion diameter tape to measure the pipe dimension. The
Couplers Jointing Procedure pipe diameter should be greater than the nominal
(minimum) diameter specified. By determining the
Electrofusion Coupler Electrical Check outside diameter of the pipe it will aid you when
1. Check that the coupler is OK by running the fusion trying to access how much of the pipe material needs
cycle for 10-12 seconds. Before starting this process to be scraped off from the outside diameter of the
start the generator and leave to settle for pipe.
approximately 1 minute. Ensure that the FRIALEN 3. The FRIALEN Mechanical Scraper takes off
ECU is switched OFF before connecting the power approximately 0.25mm of the pipe surface per
supply lead to the generator, then connect it to the rotation. Note - this equates to 0.5mm reduction of
generator and switch ON. the pipe diameter.
2. Before starting it will be necessary to first swipe your 4. Once you have established how much material is
user card I.D. card and log on to the ECU. There are required to be removed you can now mark the pipe
two bar code labels on each FRIALEN fitting. There end for the couplers insertion depth.
may be two single bar code labels, one white and
one yellow, or two white (see below), one with one 5. Before scraping takes place clean the surface of the
bar code and one with two bar codes. Connect the pipe to remove as much grease, oil or surface dirt as
leads of the electrofusion control unit to one side of possible.
the coupler. Once connected swipe the WHITE bar 6. Use your hand scraper to create a chamfer on the
code on the fitting that has a yellow and a white bar leading edge of the pipe and remove all swarf from
code label. Where the fitting has two white bar code the pipe. This will provide a smooth leading edge to
labels swipe the Fusion bar code on the Double bar assist with the installation of the coupler.
code label (see diagram below) on the fitting and
7. Mark the pipe end for the couplers insertion depth (12
press START on the ECU. Once 10-12 seconds have
Coupler Iength plus 5mm). Use wavy lines to help
elapsed press the Stop button. (This procedure
identify the area that needs to be scraped. If the
checks the heating element).
coupler is to be used for a repair, the whole length of
3. If the coupler cuts out during this 10-12 seconds the coupler should be scraped.
check the ECU for error messages and rectify
8. Check that the scraper blade is in good condition.
accordingly after turning off and disconnecting the
Worn blades must be replaced. Scrape the surface of
ECU from the generator. The most probable cause is
the pipe to remove any dirt and the oxidised layer the
a faulty generator or dirty connections/terminals.
required number of times, but before the final scrape,
Should the coupler prove to be faulty then mark the
try the coupler on the pipe and check the fit and
coupler and return to supplier.
establish any pinch points.
9. Scrape off any remaining line markings using hand
scrapper (groves and scratches should not be present
on the area to be fused) and then use the alcohol
wipes to clean the outside surface of the pipe. Use
separate wipes to clean the inside of the coupler. All
traces of the cleaner should be allowed to evaporate
completely prior to the fusion process continuing.
10. DO NOT TOUCH THE CLEANED ENDS OF THE
PIPE OR THE INSIDE OF THE COUPLER WITH
YOUR HANDS OR RAGS.
11. Protect the end against the ingress of dirt, dust or
water.
39
GPS
POLYETHYLENE
Final Preparation Electrofusion Process
1. We have now completed the final preparation before 1. Now connect up the Frialen ECU as previously
starting the fusion process. Fusion should now be described. Connect the terminal leads to the coupler
conducted immediately after scraping. and swipe the yellow bar code this initiates the
preheat cycle of the coupler. Confirm the details on the
2. Measure 12 coupler length on the end of each of the Frialen ECU display and press Start button. Once
pipe ends to be joined and using your marker pen completed allow the electrofused side to warm (heat
mark this onto the pipe. Now set the hydraulic soak) for a minimum of 12 minutes and a maximum of
14 minutes, this will allow the pipe enough time to
re-rounding clamp to the pipe behind the mark.
expand inside the coupler. It may be necessary to
3. Place coupler on to the end of the pipe and establish preheat more than once. Up to a maximum of three
where pipe ovality may interfere with placing the times is permissible (depending on wall
coupler onto the pipe. It may be necessary to mark thickness/SDR).
the pipe end and hand scrape the affected area.
2. Each preheat cycle should bridge a gap of
4. Deburr both the inner and outer end edges of the approximately 1mm between the pipe and coupler.
pipe using the hand scraper before proceeding. You
3. Once you are satisfied that you have taken adequate
are now ready to install the coupler onto the pipe.
precaution to eliminate any gaps, you can now proceed
Frialen couplers are designed to be an interference fit
with fusion process. To begin fusion return to the first
and it may be necessary to tap the coupler with care
side and reconnect leads to the terminal and swipe the
onto the pipe using a nylon or rubber mallet. Care
White Bar Code. Confirm the details press Start on
must be taken not to allow the coupler to tilt on the
control box display and press Green Start button.
pipe during this final phase. Knock the coupler on
using the rerounding clamp as a stop. Note - The 4. Repeat steps 1 to 4 for the other side. Precaution must
maximum air gap between the pipe and the be made to prevent any movement bending or pulling
electrofusion fitting should be no more than 2mm. If on the coupler to avoid tension on the joint during the
in doubt, this should be checked with a feeler fusion cycle.
gauge. Particular care should be taken if a feeler
gauge is used as these can be a source of 5. It is also important not to disturb the joint during its
contamination to the previously cleaned surfaces and fusion or cooling period.
can damage the wires of the electrofusion fitting.
Note: Frialen Safety Couplers have fusion indicators
5. Control localised gaps by using packing tape to close next to the terminals, which fill up to the shoulder
the annual gap between the pipe and coupler, this when the fusion process has taken place. One way to
will help keep any warmth inside the coupler, thus observe this is to insert a match in the indicator hole
aiding the preheat process to close any gaps caused before commencing fusion.
by ovality or pipe tolerances.
Datalogging/Fusion Completion
6. Before starting the fusion process ensure, that both
the pipe and the coupler are adequately supported 1 Download joint data from the electrofusion control unit
to stop any 'sagging' during the fusion process and for trace ability.
avoid any tension on the coupler.
2 Swipe l.D card - log off.
Please Note: Additional Points to Remember
1. Handle couplers and fittings with care. Do not drop

or throw.
2. Always store in a clean dry place. Never outside.
3. All fittings Must be pre-heated to the main
electrofusion weld. Take care to adhere to the
minimum and maximum times between pre-heat
and final electrofusion.
4. Always ensure that the generator has sufficient fuel
and does not run out during fusion as this could
lead to a failed joint.
5. The weld indicators do not always fully protrude
from the fitting; this does not indicate a weld
failure.
40
GPS
POLYETHYLENE
JOINTING PROCEDURES FOR DURAFUSE TAPPING TEES & BRANCHING SADDLES
The DuraFuse system includes a range of stack-loading/ Tapping tees - jointing procedure using the
top-loading tapping tees and branching saddles designed
to fit pipes with outside diameters up to 400mm. (See strap type loading tool
also Friatec section). 1. Remove the tapping tee from the polyethylene
wrapping, leaving the cardboard protector in position
secured by the red terminal protectors.
Stack-loading saddles
2. Place the fitting on the mains pipe in the position in
These fittings are designed for use with either the strap which it is to be welded, with the cardboard protector
type, or the pedestal type stack-loading tools. Both tools still in position. Mark the outline of the unit on the
perform the same function of clamping the saddle to the pipe using a felt tip pen.
pipe with a predetermined force.
3. Remove the fitting and place somewhere clean and
Tapping tees can be electrofusion welded to a live main, dry. Thoroughly scrape the pipe within the marked
the specially designed cutter being used to make a hole in area to completely remove the surface layer.
the pipe once the service connection has been made.
4. Rotate the handwheel of the top-loading tool until the
stop is reached.
5. Remove the threaded cap from the top of the tee and
check that the cutter head is flush with or slightly
proud of the threaded stack.
6. Remove the red terminal protectors and remove the
cardboard protector from the underside of the fitting.
7. Place the fitting on top of the prepared area on the
main pipe.
8. Press the nose of the loading tool into the aperture in
the top of the tapping tee cutter and push fully home.
9. Holding the loading tool and the tee in position with
one hand, push the straps under the main pipe and
up through the slots in the tool. Ensure that the
straps are not twisted or kinked. Clamp the straps in
place using the lever locks. It is not necessary, at this
stage, to pre-tension the straps to a taut condition.
10. Still holding the tool and tee with the one hand,
rotate the handwheel of the loading tool in a
clockwise direction until the central indicator is flush
with the top face of the handwheel.
The clamping assembly is now at the required loading
pressure for fusion to commence.
41
GPS
POLYETHYLENE
Tapping tees - jointing procedure when

using a pedestal type stack loading tool
1. Remove the tapping tee from the polyethylene
wrapping, leaving the cardboard protector in position
secured by the red terminal protectors.
2. Place the fitting on the mains pipe in the position in
which it is to be welded, with the cardboard protector
still in position. Mark the outline of the cardboard
protector on the pipe using a felt tip pen.
3. Remove the fitting and place somewhere clean and
dry. Thoroughly scrape the pipe within the marked
area to completely remove the surface layer.
4. Release the wing nut on the pedestal stack loading
tool.
5. Remove the red terminal protectors from the tapping
tee and remove the cardboard protector.
6. Remove the threaded cap and check that the cutter
head is flush or slightly proud of the threaded stack.
7. Press the nose of the top loading tool into the cutter
head.
Service connections -
8. Place the grooved base plate underneath pipe and
tapping into a water main
lower the tapping tee onto the scraped pipe surface.
Tapping into the water main should not be carried out
9. Tighten the wing nut.
until at least 30 minutes have elapsed following the end
10. Screw the handwheel in a clockwise direction until of the cooling cycle. After this time period the tapping
the central indicator is flush with the top face of the procedure is as follows:
spring carrier.
1. Insert the tapping key into the recess in the top of the
The clamping assembly is now at the required loading
metal cutter and turn in a clockwise direction.
pressure for fusion to commence.
Continue until the pipe wall is completely cut through
1. Connect the leads from the ECU to the terminals of (indicated by a reduction in the force necessary to
the tapping tee. Start the generator and key in the turn the key).
correct fusion time, as shown on the fitting.
2. Retract the cutter by turning the key in an anti-
2. Check the loading pressure is correct by ensuring that clockwise direction until the top of the cutter is flush
the central indicator is still flush with the top face of with the top of the threaded stack, showing that the
the spring carrier. cutter is clear of the branch.
3. Press the fusion start button. The coupon of material cut from the pipe wall will be
4. On completion of the cycle remove the leads and retained in the end of the cutter.
allow the joint to cool for the required time, as shown
Check that the 'O' ring seal is in place in the cap and
on the fitting, before removing the tool.
screw it down hand tight onto the threaded stack of
To remove the tool, unscrew the handwheel anti- the tee.
clockwise until all the pressure is released and withdraw
Note: Thread Followers - The torque may be high when
the tool from the top of the tapping tee.
cutting through the wall of large diameter pipes. Thread
Replace the threaded cap ensuring that the 'O' ring followers are available to enable the load to be spread
seal is in position. over a greater number of threads, minimising the risk of
stripping the moulded threads inside the stack of the
Service connections - tapping tee.
tapping tee to service pipe
The service connections between the tapping tee and the Jointing Procedures for DuraFuse
service pipes are made using either service couplers or Branching Saddles
service reducers in conjunction with a miniclamp-type The procedure for branching saddles is very similar to the
pipe clamp. procedure previously outlined except that a hole cutter
The procedure for making a service connection is as will be required to cut a hole in the pipe wall prior to
described for the electrofusion couplers. fusing on the saddle. It is also necessary to use an
Any hydrostatic pressure test should be carried out on the adaptor plate to replace the 'nose' of the stack-loading
service pipe before the hole is cut through the wall of the tools in order to clamp the fitting onto the pipe surface
mains pipe using the integral cutter. during the fusion cycle.
42
GPS
POLYETHYLENE
Jointing procedure for using DuraFuse Installation procedure for Type B

Underclamp Tapping tees Underclamp Tapping tee
DuraFuse underclamp tapping tees are supplied complete Remove tapping tee form bag polythene bag wrapping.
with 2 types of underclamps as shown below. Place the fitting on the mains pipe in the position in
which it is to be welded. Mark the outline of the fitting
DuraFuse tapping tees can be electrofusion welded to a on to the pipe using a felt tip pen
live main, the specially designed cutter being used to Remove the fitting and place in a clean, dry place.
make the hole in the pipe once the service has been Thoroughly scrape the marked area to completely
connected and tested. remove the surface layer.
Place the fitting back on top of the prepared area of the
main pipe.
Place the strap underclamp piece, without screws, onto
one of the tapping tee wings. The strap piece will only
fit in one particular orientation to ensure the correct
loading is applied.
Thread the strap under the pipe and place the strap
underclamp piece, with screws, onto the tapping tee
wing at the other side of the tapping tee. Whilst holding
the tapping tee in position screw the screws up until
they are fully tightened and the 2 bars of the strap
underclamp piece are pulled together.
The tapping tee is now at the required pressure for
electrofusion to commence.
Electrofusion procedure.
Connect the electrofusion control unit (ECU) leads to

the tapping tee. Start the generator and key the correct
fusion time into the ECU. The fusion time is moulded
onto the fitting.
Press the fusion start button
On completion remove the ECU leads and allow the
fitting to cool for the stated time. The cooling time is
moulded onto the fitting.
The underclamp pieces can be either left in place or
removed.
See page 42 for instructions on tapping into a main or

service pipe.
Installation procedure for Type A
Underclamp Tapping tee
Remove tapping tee form bag polythene bag wrapping.

Place the fitting on the mains pipe in the position in
which it is to be welded. Mark the outline of the fitting
on to the pipe using a felt tip pen
Remove the fitting and place in a clean, dry place.
Thoroughly scrape the marked area to completely
remove the surface layer.
Place the fitting back on top of the prepared area of the
main pipe. Fit the underclamp piece in to place under
the fitting body and push into place whilst holding the
fitting from the top. The underclamp piece should be
fully pushed on to the fitting wings. A mallet should be
used to carefully tap the underclamp piece in to place if
it cannot be fully pushed by hand.
The tapping tee is now at the required pressure for
electrofusion to commence.
43
GPS
POLYETHYLENE
B U T T- F U S I O N J O I N T I N G P R I N C I P L E S
General
Butt-fusion is a jointing method which allows on-site
jointing of pipes from 90mm to 1000mm. It is a
thermofusion process which involves the simultaneous
heating of the ends of two components which are to be
joined, until a melt state is attained at each contact
surface. The two surfaces are then brought together under
controlled pressure for a specific fusion/cooling time and
Note: The Site Fusion Jointing Specification WIS 4-32-08
homogeneous fusion takes place.
Issue 3, April 2002 emphasises the importance for the
The resultant joint is fully resistant to end thrust and has butt-fusion machine to be able to control properly the
identical performance under pressure to the pipe. reduced secondary ram pressures that are now required
for 'dual pressure' butt-fusion jointing.
This method of jointing requires an electrically heated
plate to raise the temperature of the pipe ends to the For SDR11 pipes of sizes 250mm, 280mm and 315mm
required fusion temperature. It is used for both PE80 and and for all pipe (SDRs 11, 17, 17.6, 26) of size 355mm
PE100 (Excel) grades of material for pipes of size 90mm and above, i.e. all pipes with a wall thickness greater
and above of the same Standard Dimension Ratio (SDR). than approximately 20mm, the butt-fusion pressures
should be reduced to 1/6 of its initial value after 10
Butt-fusion machines are available in manual, semi-
seconds and therefore fully automatic butt-fusion
automatic and fully automatic configurations. The
machines are preferred.
machine sizes start at 90mm and can weld up to
1000mm OD pipe. For manual machines a data plate, coloured blue for
water and yellow for gas should be permanently
attached to the machine.
For automatic machines the jointing data will be
programmed in accordance to the SDR rating of the
pipe and/or fittings to be jointed.
(These conditions are tabulated in the section following
the description of butt-fusion jointing procedures).
When jointing pipes using butt-fusion techniques, the
heater plate temperatures are the same for both PE80
and PE100 (Excel) - 225C to 240C (average in the
case of low ambient temperatures) as given in
WIS 4-32-08 Issue 3, April 2002.
A UK water industry guidance note was published by
Bodycote PDL in February 2003 that allows an extra one
minute soak time for PE100 pipe sizes above 500mm
SDR11. This is designed to ensure that fully ductile welds
are always obtained under all field conditions to comply
with onerous UK requirements in this respect.
44
GPS
POLYETHYLENE
The GPS System Jointing Method

Depending on the design and make, butt-fusion machines Pre-welding checks
may or may not be capable of accepting moulded fittings,
Before commencing a welding operation check that:
as manufactured, for direct welding to pipes. GPS
therefore offers two ranges of fittings for butt-fusion There is sufficient fuel for the generator to complete
systems to provide the greatest flexibility: the joint and that it is functioning correctly before it is
connected to the machine.
Long Spigot fittings
The trimming tool and hydraulic pump are in working
These unpupped fittings are long enough to be gripped for
order.
butt or electrofusion by most types of machines/clamps.
The heater plate is clean and residues from previous
'Pupped' fittings welds have been removed.
Pupped fittings are fabricated by butt-fusing, in the
A tent is available to provide shelter during welding.
factory, 0.5m lengths of pipe (pups) to each leg of a
spigot fitting. The pup can be gripped by clamps of the The machine is complete and undamaged.
butt-fusion machine. The GPS butt-fusion system
The pipes and/or fittings to be jointed are of the same
comprises, therefore:
size, SDR and material.
Straight polyethylene pipe.
The operator knows the correct welding parameters
Long Spigot fittings. for the machine and pipe being welded.
Pupped fittings. The heater plate is at the correct temperature.

(Connect the heater plate to the power supply and
Accessories.
retain it for at least 20 minutes inside the thermally
insulated guard).
Equipment The heater plate may be
washed when cold at the start
Generator to supply the heater plate, trimmer and
of the jointing session, with
hydraulic pump.
copious quantities of clean
Butt-fusion machine fitted with the correct size clamp water to remove dirt deposits.
shells, trimmer, heater plate, hydraulic pump and Only clean, lint free materials
timer. may be used to clean the
plate. To remove grease and
Pipe support rollers.
oily films the plate may be
Welding tent. wiped with lint free material
Cleaning material, lint-free cotton cloth or paper dampened by a suitable
towel. solvent, eg. Isopropanol.
External/internal debeading tool. Dummy Welds

Bead gauge. Even though washing may
remove large deposits of dirt,
Digital thermometer with surface probe to check very fine particles of dust may
heater plate. still remain on the heater
Pipe end covers. plate. To remove such dust it
is necessary to make a
Baseboard. dummy joint at the start of each jointing session,
Pipe cutters. whenever the plate has been allowed to cool below
180C, or at a change of pipe size. Two dummy joints
Air temperature thermometer. must be made if the pipe size is greater than 180mm.
Indelible marker pen. A dummy joint can be made using pipe off-cuts of the
Timer. same size, SDR and material as the pipe being installed.
It is not necessary to actually make a joint. The procedure
can be discontinued after the full heat cycle has been
completed.
45
GPS
POLYETHYLENE
Manual Welding Procedure 12. 0pen and then close the clamps and note the drag
pressure needed to move the pipes together using the
1. Place the pipes in the clamps with the ends against hydraulic system. Drag pressure is the minimum
the trimming tool and with the pipe markings gauge pressure required to overcome the sliding
aligned. frictional drag on the rams due to the operation of the
2. Align and level the components using the support machine and the weight of the pipes/fittings being
rollers. jointed. Note: the drag pressure (in bar) must be
assessed accurately prior to making each fusion joint
3. Tighten the pipe clamps to grip and re-round the
and must be added to the basic ram pressure values
pipes.
shown on the machine. (When fully automatic
4. Cover the free ends of the pipes to prevent cooling of machines are used this operation will normally be
the plate by internal draughts. carried out automatically).
5. Switch on the trimming tool and bring the clamps 13. Remove the heater plate from its protective cover.
slowly together so that the pipe ends are moved Check that it is clean and up to temperature.
against the trimming tool until continuous shavings
14. Place the heater plate in
are cut from each surface.
the machine and close
6. Keep the trimming tool turning whilst separating the the clamps so that the
clamps to avoid steps on the trimmed surfaces. surfaces to be joined are
touching the plate. Using
7. Remove the trimming
the hydraulic system
tool taking care not to
apply the pressure
touch the trimmed ends.
previously determined.
8. Remove loose shavings
15. Maintain the applied
from the machine and
pressure until the pipe or
component ends. Do not
fitting ends begins to
touch the prepared
melt and a uniform bead
surfaces.
of 2-3mm is formed on
9. Check that both surfaces each.
are completely planed. If
16. After the initial bead up,
they are not then repeat
the pressure in the
the trimming process.
hydraulic system should
10. Bring the clamps be released so that the
together and check that pressure gauge registers
there is no visible gap between zero and the drag pressure so as to control
between the trimmed the bead growth during the heat soak time. Check
faces. that the pipe does not slip in the clamps. The pipe or
fitting ends must
11. The maximum permitted
maintain contact with
outside diameter
the heater plates.
mismatch is: 1.0mm for
pipe sizes 90mm to 17. When the heat soak time
315mm & 2.0mm for is completed, open the
pipe sizes 316mm to clamps and remove the
800mm. If the mismatch heater plate ensuring
is greater than these that the plate does not
values then the pipe touch the melted
must be realigned and surfaces.
re-trimmed.
46
GPS
POLYETHYLENE
18. Immediately close the clamps (within 8 to 10 The rules for butt-fusion
seconds of removing the plate) and bring the melted
surfaces together at the previously determined NEVER
pressure. Attempt to weld together pipes of different SDR (wall
19. Maintain the thickness).
required pressure Touch trimmed pipe ends.
for the minimum
Leave trimming swarf inside pipe or on welding
cooling time as
machine.
indicated in the
table. Allow equipment to get wet or dusty.
20. After this time the Use non-approved machinery.
assembly can be
Remove a weld from the machine before cooling time
removed from the
has elapsed.
machine but
should not be Allow untrained personnel to use welding equipment.
handled for a
Cut corners in any part of the welding procedure.
further period
equal to the Weld pipes of different material on-site.
above cooling
Use a generator of inadequate capacity.
time.
Machines can be hired from MCA Hire Services (Luton),
21. Examine the joint
who can be contacted on telephone 01582 414140.
for cleanliness
and uniformity Training Courses
and check that the bead width is within the specified
It is essential that all installers of polyethylene pipe
limits.
systems have received thorough training. GPS offers one
22. Remove the external bead and if required the internal day product familiarisation courses which are designed to
beads using suitable debeading tools. provide a basic knowledge of practices and on-site
training. Training leading to a NVQ (National Vocational
23. The beads and joint should be numbered/coded using
Qualification) can be done at a number of institutions.
an indelible marker pen.
Two organisations that are used by major water
24. The beads should be twisted at several positions. If companies in the UK are Water Training International
the bead is seen to split at any point then the joint (WTI) and Whitwell. WTI can be contacted at their head
should be cut out from the pipeline and the joint office in Hampshire, telephone 01734 813011. Whitwell
remade. If a similar defect reoccurs, all further in Leicestershire, can be contacted on telephone 01780
jointing must cease until the equipment has been 460323.
thoroughly cleaned, examined and new trial joints
In addition, GPS offers a specialist training course on the
made and shown to be satisfactory.
installation of FRIALEN Large Diameter Couplers. For
further information, please contact our Technical Services
Department.
Butt-fusion Jointing Parameters for Gas

Single pressure butt-fusion jointing conditions for PE80 - as employed historically by Transco in the UK.
Initial Heat Heat Max Plate Cooling Time Final

Pipe Bead Soak Soak Removal Under Out of Bead Width
Size Size Pressure Time Time Pressure m/c mm
90 2mm 0 bar 90 sec 8 sec 10 min 10 min 8-12
NB. These are being reviewed in 2004.
47
GPS
POLYETHYLENE
Butt-fusion Jointing Parameters for Water (WIS 4-32-08 issue 3 April 2002)
Heater Plate Surface Temperature: 225C to 240C.
Table 1 Single pressure butt-fusion jointing conditions for PE80 and PE100 (Excel)
Fusion Cooling Typical
Initial Min and Cooling time for final
Wall Bead up bead soak Max plate cooling Cooling time out coiled overall
Outside thickness interface size Soak interface removal interface time in of pipe in bead width
diameter SDR (minimum) stress (approx) time stress time stress clamps clamps clamps min max
mm mm MPa mm seconds MPa seconds MPa minutes minutes minutes mm mm
90 26 3.5 0.15 2 95 0 10 0.15 10 5 15 8 15
90 17.6 5.1 0.15 2 110 0 10 0.15 10 5 15 8 15
90 11 8.2 0.15 2 140 0 10 0.15 10 5 15 9 16
110 26 4.2 0.15 2 100 0 10 0.15 10 5 15 8 15
110 17.6 6.3 0.15 2 125 0 10 0.15 10 5 15 9 16
110 11 10.0 0.15 2 160 0 10 0.15 10 5 15 10 17
125 26 4.8 0.15 2 110 0 10 0.15 10 5 15 8 15
125 17.6 7.1 0.15 2 130 0 10 0.15 10 5 15 9 16
125 11 11.4 0.15 2 175 0 10 0.15 10 5 15 10 17
160 26 6.2 0.15 2 120 0 10 0.15 10 5 15 9 16
160 17.6 9.1 0.15 2 150 0 10 0.15 10 5 15 9 16
160 11 14.6 0.15 2 205 0 10 0.15 10 5 15 11 18
180 26 6.9 0.15 2 130 0 10 0.15 10 5 15 9 16
180 17.6 10.2 0.15 2 160 0 10 0.15 10 5 15 10 17
180 11 16.4 0.15 2 225 0 10 0.15 10 5 15 11 18
225 26 8.6 0.15 2 145 0 10 0.15 10 5 9 16
225 17.6 12.8 0.15 2 190 0 10 0.15 10 5 10 17
225 11 20.5 0.15 2 265 0 10 0.15 10 5 12 19
250 26 9.6 0.15 2 155 0 10 0.15 10 5 9 16
250 17.6 14.2 0.15 2 200 0 10 0.15 10 5 10 17
280 26 10.7 0.15 3 170 0 10 0.15 10 5 13 22
280 17.6 15.9 0.15 3 220 0 10 0.15 10 5 14 23
315 26 12.1 0.15 3 180 0 10 0.15 10 5 13 22
315 17.6 17.9 0.15 3 240 0 10 0.15 10 5 14 23
Tolerance 0.02 3 0.02
Table 2 Dual pressure butt-fusion jointing conditions for PE80 and PE100 (Excel)
Fusion Cooling Typical
Initial Min interface interface Cooling Cooling final
Wall Bead up bead soak Max plate stress stress time time out overall
Outside thickness interface size Soak interface removal (1st 10 (after 10 in of bead width
diameter SDR (minimum) stress (approx) time stress time secs) secs) clamps clamps min max
mm mm MPa mm seconds MPa seconds MPa MPa minutes minutes mm mm
250 11 22.7 0.15 2 285 0 10 0.15 0.025 15 7.5 15 24
280 11 25.4 0.15 3 315 0 10 0.15 0.025 15 7.5 16 25
315 11 28.6 0.15 3 345 0 10 0.15 0.025 15 7.5 17 26
355 26 13.6 0.15 3 195 0 10 0.15 0.025 10 5 13 22
355 17.6 20.1 0.15 3 260 0 10 0.15 0.025 15 7.5 15 24
355 11 32.3 0.15 3 385 0 10 0.15 0.025 15 7.5 18 27
400 26 15.3 0.15 3 215 0 10 0.15 0.025 10 5 14 23
400 17.6 22.7 0.15 3 285 0 10 0.15 0.025 15 7.5 15 24
400 11 36.4 0.15 3 425 0 10 0.15 0.025 20 10 18 27
450 26 17.2 0.15 3 235 0 10 0.15 0.025 10 5 14 23
450 17.6 25.6 0.15 3 315 0 10 0.15 0.025 15 7.5 16 25
450 11 41.0 0.15 3 470 0 10 0.15 0.025 20 10 19 28
500 26 19.1 0.15 3 250 0 10 0.15 0.025 10 5 15 24
500 17.6 28.3 0.15 3 345 0 10 0.15 0.025 15 7.5 16 25
500 11 45.5 0.15 3 515 0 10 0.15 0.025 20 10 20 29
560 26 21.4 0.15 3 275 0 10 0.15 0.025 15 7.5 15 24
560 17.6 31.7 0.15 3 380 0 10 0.15 0.025 15 7.5 17 26
560 11 50.8 0.15 3 570 0 10 0.15 0.025 20 10 22 31
630 26 24.1 0.15 3 300 0 10 0.15 0.025 15 7.5 16 25
630 17.6 35.7 0.15 3 420 0 10 0.15 0.025 15 7.5 18 27
630 11 57.2 0.15 3 635 0 10 0.15 0.025 25 12.5 23 32
710 26 27.2 0.15 3 335 0 10 0.15 0.025 15 7.5 16 25
710 17.6 40.2 0.15 3 465 0 10 0.15 0.025 20 10 19 28
800 26 30.6 0.15 3 370 0 10 0.15 0.025 15 7.5 17 26
800 17.6 45.3 0.15 3 515 0 10 0.15 0.025 20 10 20 29
900 26 34.6 0.15 3 405 0 10 0.15 0.025 20 10 18 27
900 17.6 50.9 0.15 3 570 0 10 0.15 0.025 20 10 22 31
1000 26 38.4 0.15 3 445 0 10 0.15 0.025 20 10 19 28
1000 17.6 56.6 0.15 3 630 0 10 0.15 0.025 25 12.5 23 32
Tolerance 0.02 3 0.02 0.01
NB All jointing pressures must be calculated by using the effective ram area of the machine in relation to the cross-sectional area of the
pipe wall. Effective ram area varies with manufacturer and models. Effective ram area should be marked on each model.
48
GPS
POLYETHYLENE
F R I AT O P A S S E M B LY A N D O P E R AT I N G I N S T R U C T I O N S
Assembly and Operating Instructions for

Friatop Top Loading Clamping Unit when
used on Frialen Multi Branch Saddles
(250 - 630mm)
Assembling the FRIATOP clamping unit on

250-560mm pipe
1. The adaptor is fitted into the clamping unit before 5. Thread the loose end of the tensioning belt into the
this is tensioned and forms the connection with the rollers on the twist grip. Pull the belt taut by turning
FRIALEN component. It has various steps, the twist grip clockwise.
depending on the type of saddle fitting being fused 6. Check that the clamping unit is in the untensioned
on. If a FRIALEN-SPA-TL is being fused on, the state (no air pressure at the valve) and then connect
screw cap of the fitting is located directly into the the air pump to the valve. In the unpressurised state
unit without the adaptor. The same applies to the the tensioning figures (1 or 2) are visible in the
VSC-TL. window on the rim of the housing.
2. The preparation of the area being fused (scraping, 7. If necessary make a final correction to the seating of
cleaning) is carried out in a similar manner to the the saddle on the pipe.
descriptions given in the assembly instructions for 8. Pump up the clamping unit. (The pressure gauge on
FRIALEN safety fittings. the pump should indicate between 3 and 4bar). The
3. Place the saddle component onto the pipe. expansion of the cylinder will press the saddle onto
4. Fit the adaptor and the clamping unit onto the saddle the pipe. The gap between the pipe and the saddle
component. The different steps in the adaptor fit the must be completely closed by the pressure applied.
various types of saddle component. Lay the A visual check must be made by the user!
tensioning belt around the pipe (do not twist it!) 9. In the pressurised state the tension number is read
off in the window next to the handle and marked for
safety on the piece of pipe. This will give a check on
any fall off in pressure during fusion. If this drop in
pressure is no greater than one scale graduation then
the fusion has been carried out in accordance with
the standard. If the pressure drop is greater than this
the fusion process must be broken off and the reason
investigated. Afterwards, and when the proper
cooling time has elapsed, a second fusion can be
carried out.
49
GPS
POLYETHYLENE
Assembling the FRIATOP clamping unit for Removing the FRIATOP clamping unit
SA-TL on 630mm pipe After the fusion has finished, always maintain the joint
1. The adaptor is fitted into the clamping unit before pressure in accordance with point 8 on page 41 for a 10
this is tensioned and forms the connection with the minute cooling period.
FRIALEN component. The required steps vary,
After this, the pressure can be taken off by venting the
depending on the type of saddle fitting to be fused. If
unit to air and the unit dismantled.
a FRIALEN-SPA-TL is being fused, the screw cap of
the fitting is located directly into the unit without the Before drilling through please allow to cool down for the
adaptor. The same applies to the VSC-TL. times listed below:
2. The preparation of the area being fused (scraping, Cooling times d250 - d630mm = 60min
cleaning) is carried out in a similar manner to the
description given in the assembly instructions for
FRIALEN Safety fittings.
3. Place the saddle component onto the pipe.
4. The different steps in the adaptor fit the various types WARNING!
of saddle component. Lay the tensioning belt around If the cooling down time is not adhered to the saddle
the pipe (do not twist it). can come away from the pipe in the area of the fused
5. Thread the loose end of the tensioning ring belt into joint. A permanently safe fused joint cannot be
the rollers on the twist grip. Remove the slack in the guaranteed.
belt by turning the twist grip clockwise.
6. Check that the clamping unit is in the untensioned Warranty
state (no air pressure at the valve) and then connect
the air pump to the valve. In the unpressurised state, The warranty is six months. It will not apply if there are
the tensioning figures (1 or 2) are visible in the signs of force being used or of usage which is not in
window on the rim of the housing. accordance with the operating instructions.
7. If necessary make a final correction to the seating of

the saddle on the pipe. Functional safety
The FRIATOP clamping unit has been checked for safe
FRIALEN fusion operation before being shipped. The equipment requires
very little maintenance. We recommend a half yearly
Connect the fusion cable from the fusion unit to the check on all functional parts. The unit should be
contacts on the saddle and start the fusion process. protected from dirt.
During the fusion process the tension number should be
checked.
Assembly and Operating Instructions for
Friatop Top Loading Clamping Unit when
used on Frialen Multi Tapping Tees (250 -
315mm)
WARNING! FRIALEN Multi Saddle Components are used with pipes
from SDR 17 to SDR 11 from 250mm diameter. They are
For general safety reasons always stay at a distance of held in place during fusion by the FRIATOP clamping
one metre from the point of fusion during the fusion device.
process.
FL615339 Pressure Tapping Fitting - Top Loading
250mm - 315mm diameter.
FRIALEN FL615339 Pressure Tapping Fittings are
suitable for fitting as branch connectors onto non-
pressurised or pressurised pipelines.
N.B. For technical reasons FRIALEN Pressure Tapping
Fittings cannot be used with SDR7 pipes.
50
GPS
POLYETHYLENE
1. Mark out the area of the fusion zone on the pipe (and 4. Carrying out the fusion
the side outlet spigot) and remove the oxide skin by
When using FRIALEN Pressure Tapping Fittings onto
scraping. The fusion zone is the area of pipe covered
pipes carrying a fluid or gas the following maximum
by the saddle; for a side outlet, it is the insertion
permissible operating pressures must not be
depth on the smooth pipe spigot. The oxide skin in
exceeded during the fusion process and until cooling
the area of the fusion zone, which has formed on the
down is complete.
surface of the HD-PE pipes during storage, must be
totally removed before assembly. Maximum permissible working pressure in bar
N.B. if the oxide skin is not completely removed this Pipe Material PE80 PE100 (Excel)
can lead to an unsatisfactory fused joint, which may SDR 17.6/17 11 17 11
leak. Gas pipe 1 4 4 10
Water pipe 8 12.5 10 16
A single unbroken removal of the surface is adequate
(min. 0.1mm). This should leave an uneven surface
with no flat spots or ridges of material. N.B. Only use fusion control units which are
designed and authorised by their manufacturer to
N.B.- Filing or using an emery cloth is not
process FRIALEN Safety Fittings. The fusion
acceptable as this can lead to impurities being
parameters are contained in a bar code which is
embedded in the surface. As a check that the
affixed to the FRIALEN Safety Fitting. The
removal of material from the surface is unbroken and
parameters are entered into the fusion control unit
covers the full area, we recommend the use of
using the reader wand.
marked lines to check. If during the scraping process
areas of the surface are not scraped (e.g. if the pipe The fusion control units automatically monitor the
is oval) these must be reworked. Protect the cleaned progress of the fusion process and regulate the
up zone from dirt, soap, grease, water running back electrical energy input to within specified limits.
and unfavourable weather (e.g. from effects of
The fitting fusion indicator only gives an indication
moisture, the formation of frost).
that fusion has taken place. The proper progress of
2. The surfaces of the pipe being fused and the internal the fusion process, however, is only shown by the
surfaces of the FRIALEN FL615339 Pressure fusion control unit.
Tapping Fitting must be absolutely clean, dry and free
N.B. For the sake of general safety always maintain
from grease. Immediately before assembly, and after
a distance of one metre from the fusion point during
scraping, clean these surfaces with a suitable
the fusion process.
cleaning fluid, using only absorbent non-fibrous, non-
coloured paper. We recommend the use of special PE 5. Drilling and applying the test and working pressure.
cleaning fluid. The waiting times below must be adhered to:
N.B. When using alcohol based cleaners the alcohol
content must be a minimum of 96%. The cleaner Cooling down time for FRIALEN
must have evaporated completely before using. Multi Saddle components
Diameter Before pressurising Before
Now, using a marker pen, redraw the line to show in mm Through the outlet drilling (CT)
the perimeter of the fusion zone on the pipe since 250-500 50 mins 60 mins
previous markings will have been removed by
scraping and cleaning. Take care to ensure that the The cooling CT given on the components are the
fusion zone remains clean whilst doing this. cooling times before drilling.
3. Assembly N.B. If the waiting times are not complied with,
Place the saddle onto the prepared surface of the there is a risk of an unsatisfactory fused joint, which
pipe. may leak. Before drilling, the general installation
guidelines must be observed.
Fit the clamping device as directed in the operating
instructions for Friatop.
N.B. On FRIALEN Pressure Tapping Fittings the
drill setting made at the factory must not be altered
before fusing.
After the fusion process has finished always maintain
the jointing pressure for a 10 minute cooling period.
51
GPS
POLYETHYLENE
FLANGE CONNECTIONS
Connecting PE to iron flanges

It is not possible to join polyethylene pipe to pipe made
from other materials by fusion welding. In the case of
mains pipe sizes it is necessary to use PE flange
adaptors, including SlimFlange, or specialist fabricated
metal fittings eg. from Crane-Viking Johnson or Crane-
WASK, that grip the pipe.
Since polyethylene systems are end-load bearing,
precautions must be taken where connection is made to
pipe of another material, to prevent pull-out of any non
end-load bearing joints in that pipe line. The transition
may need to be externally harnessed or anchor/thrust
blocked.
In larger pipe sizes there can be a discrepancy (in bore
size and bolting) when jointing polyethylene pipe to iron
pipe, as PE pipe has much thicker walls. When
considering multi-material piping systems it is important
to remember that PE pipe is always sized by its OD,
whereas iron pipe is sized by its nominal bore, referred to SlimFlange
as its DN (Diametre Nominal). This unique design of PE flange is available for PE sizes
For example, a 450mm OD PE100 (Excel) SDR17 pipe from 250mm to 560mm and permits actual or near bore
(with a bore of 400mm) can be jointed to a 450mm size-for-size jointing of a PE pipe to the flange of an iron
PN16 valve using a traditional 450mm x 450mm PE pipe or fitting. This huge benefit is achieved by
flange adaptor (see figure (i)). But this means that the incorporating a stainless steel hoop in the PE flange face
bore size between the two components changes from to provide a reinforcing effect and this allows the PE stub
400mm (PE) to 450mm (iron). shoulder height to be reduced dramatically. Unlike
traditional PE flanges, SlimFlange eliminates the need to
upsize the connected valve or other metal component or
to down size the PE pipe (see figure ii).
Figure (i) 450mm PE100 (Excel) Pipe and conventional PE

flange adaptor bolted to a DN450 valve.
Figure (ii) 450mm PE100 (Excel) Pipe and SlimFlange PE
flange adaptor bolted to a DN400 valve.
52
GPS
POLYETHYLENE
Mechanical Joints:
Recommended procedure for bolting up
Flange adaptor incorporating a polyethylene reducer
flange adaptors
For the sizes where a SlimFlange cannot be offered (ie.
315mm SDR11 and 630mm and above), a possible Flanged joints should be made using a single full face or
alternative is a fabricated fitting incorporating a reduced Corrugasket rubber gasket or for more critical
size PE flange. Note there is a temporary reduction in applications at above 10 bar, steel reinforced gaskets
bore with this fitting and also it may be desirable to (details on request) of the correct size. All four mating
incorporate a metal reinforcing plate between the PE surfaces must be undamaged, clean and free from
flange and the metal flange to help stabilise the assembly. contamination.
Please consult our Technical Support Department before A jointing compound should not be used.
specifying one of these combination flanges.
Wherever possible, flange joints should be made before
other joints are completed. Pipework configuration shall
be such that mating faces are aligned and butted squarely
to each other with a maximum separation of 5-10mm
prior to bolting up, irrespective of pipe diameter.
Only clean undamaged nuts and bolts of the correct size
should be employed, with standard thick (Form A)
washers at both ends, also of the correct size.
Care must be taken to ensure that the gasket is centred
Figure (iii) 450mm x 400 PN16 combination flange adaptor properly between the two flanges before tightening
commences. The nuts and bolts must be tightened as
uniformly as possible using a torque wrench, in diagonally
Steel flange converter opposite sequence, progressively from a finger tight start.
Where the PE and iron sizes cannot be accomodated by a For example:
SlimFlange a better solution is to employ a two-way steel Fingertight 5% of final torque 20% of final torque
converter plate. In the diagram below a converter plate is 50% of final torque 75% of final torque 100% of
drilled/studded to allow a direct connection between a final torque.
630mm PE x 600 PN16 flange adaptor and a DN500
PN16 ductile iron flange. For PE diameters above 180mm, it is recommended that
two operators work simultaneously on diametrically
opposite bolts where possible. To guarantee subsequent
leak tightness, final torquing up should be repeated after
the assembly has been allowed to relax for an hour or so.
Evenness of tightening is as important as final torque
values - see the table below. The torques shown are for
SDR11 and SDR17 pipe, in both PE80 and PE100
(Excel).
Typical bolting torques for flanges

Figure (iv) 630mm x 600 PN16 flange adaptor with (PE to PE or PE to metal flanges)
600 PN16 x 500 PN16 steel flange converter
Standard Flanges SlimFlanges
Nominal Nominal Torque Nominal Torque
PE size Iron size Bolting (Nm) Iron size Bolting (Nm)
(mm) (mm) 10% (mm) 10%
63 50 M16x4 35 n/a
Connecting PE to other pipe materials 90 80 M16x8 35 n/a
PE can be jointed to other pipe materials (e.g. PVC-U, 125 100 M16x8 35 n/a
180 150 M20x8 60 n/a
asbestos cement) in the same manner as outlined above
200 200 M20x12 80 n/a
for iron. If further assistance is required, please contact 225 200 M20x12 80 n/a
our Technical Support Department. 250 250 M24x12 100 200 M20x12 60
280 250 M24x12 100 n/a
315 300 M24x12 120 250 *M20x12 70
355 350 M24x16 150 300 M24x12 120
400 400 M27x16 200 350 M24x16 150
450 450 M27x20 250 400 M27x16 200
500 500 M30x20 300 450 M27x20 250
560 600 M33x20 350 500 M30x20 300
*non standard bolt size

53
GPS
POLYETHYLENE
PROTECTA-LINE JOINTING PROCEDURES
Protecta-Line is a complete PE pipe system solution for

drinking water supply through contaminated land. It is a
three layer PE composite barrier pipe which includes an
aluminium layer on the outside of a standard PE pipe to
prevent the ingress of any contaminants into the water
supply.
Protecta-Line pipelines can be jointed using any of the
following methods:
Protecta-Line Mechanical Compression fittings (25-
63mm) Protecta-Line Standards and Approvals
Protecta-Line Fluid Compression fittings (63-180mm) GPS Protecta-Line pipe can clearly be identified as
multi-layered pipe by means of brown stripes on the
Electrofusion fittings (90mm-180mm)
outer skin - to comply with NJUG requirements.
Butt-fusion (90mm-180mm)
GPS Protecta-Line is a WRAS Approved system
Where electrofusion and butt fusion methods are to be
GPS Protecta-Line is manufactured from a DWI
employed, this should first be cleared with the local water
(Regulation 31(4)(a)) approved material.
utility. In both cases local wrapping with aluminium and
Denso tape is recommended (available from GPS). Core PE pipe to WIS 4-32-17
54
GPS
POLYETHYLENE
Mechanical Compression Fittings Assembly Instructions

1. Cut the pipe square. Unscrew the fittings and
remove the nut and the white split ring. Slide
these components onto the Protecta-Line pipe,
nut first, ensuring the taper on the split ring
faces towards the nut.
2. Tap the insert into the end of the Protecta-Line

pipe with a mallet. Ensure the sealing ring is
correctly positioned on the insert.
3. Slide the split ring along the Protecta-Line pipe

until it is up against the insert. Snap the nut
over the split ring.
4. Screw the nut onto the central section of the

fitting body. Continue to tighten the nut until the
thread on the central section is no longer visible.
55
GPS
POLYETHYLENE
Fluid Compression Fittings - Coupler Assembly Instructions

1. Take the two pipe sections to be joined and inspect the
ends for any obstruction, removing any large burrs or
lips on the pipe ends. Check the pipe ends are
reasonably square.
2. Using the marking gauge and a suitable marker pen,
mark the appropriate dimension x (see chart) from the
ends of the pipes to be joined.
Marking distances:
Pipe sizes x mm
63 47
90 64
110 71
125 81 STEP ONE
160 95 mark pipe x mm from end of pipe
180 110
3. Push the Protecta-Line Fluid Compression insert into

one end of the pipe, making sure that the pipe end is
firmly against the shoulder of the insert.
4. Slide the Protecta-Line Fluid Compression outer shell
over the same pipe end that has the insert installed.
Make sure that the shell is far enough up the pipe so
that the insert is visible.
5. Push the second pipe over the visible end of the insert
and make sure that both pipe ends are against each
side of the insert shoulder. STEP TWO
6. Slide the Protecta-Line Fluid Compression outer shell ensure mark lines up with end of sleeve
back over the assembly until the two marks on each
end of the pipe are visible at each end of the outer
shell. This will indicate that the pipe ends are still
against the insert shoulder and that the outer shell is
positioned in the centre of the joint.
7. The joint is now ready for pressurising.
STEP THREE
ensure mark lines up with end of sleeve
56
GPS
POLYETHYLENE
Repairs
Pressurising the joint If for any reason the nipple needs to be removed, the
1. A calibrated hydraulic pump must be used for all pressure in the fitting must be released first by using
pressurisation of the Protecta-Line Fluid Compression the pressure release tool.
Fitting range. The pump must be filled with Protecta- Check that the marks on the pipe still line up with the
Line vegetable oil pressure fluid. end of the fitting.
2. Remove the slide-on nipple connector from its parking The joint is now complete.
nipple on the hydraulic pump. Slide the nipple
connector over the nipple on the Protecta-Line Fluid Pipe Size X 2Y Min L
Compression fitting. Please note that the nipple 63 47 108 400
connector is a slide fit over the nipple, not a push fit. 90 64 142 536
3. Gently raise and lower the pump handle, watching the 110 71 158 596
pressure gauge. As the pressure gauge reaches 260bar, 125 81 176 672
the pressure breaker valve will activate and the pump 160 95 206 788
handle will fall freely with no resistance. This indicates 180 110 236 912
that the required pressure has been achieved. Wait 10
seconds and repeat the pumping action until the pump Remove damaged section L as required
handle breaks again. Wait
Mark pipe ends left in ground X mm from ends using
10 seconds and repeat again. The pressure gauge
the repair gauge and marker pen
should now show a steady reading of approximately
260bar. The joint is now made. Cut length of new pipe L - 2Y long and mark X mm
from end.
4. The pressure must be released before removing the
For minimum length L see table. Note Y = insert liner
slide-on fitting connector from the Protecta-Line Fluid
spigot length + shoulder
Compression shell: lift the manual relief valve for 2
seconds then slide off the fitting connector from the Slide repair shells over new pipe and place inserts into
Protecta-Line Fluid Compression fitting. ends with the shorter end of the insert protruding
Place new pipe section in line with the existing pipe
and move inserts to new position with collar against
WARNING!
existing pipe ends
Pressure within the fitting may be released while
removing the connector, causing a momentary Slide shells into position so that marks previously made
discharge of fluid. line up with the ends of the shells
SAFETY EYE PROTECTION MUST BE WORN. The joints are now ready to be pressurised
57
GPS
POLYETHYLENE
Procedures for Using Electrofusion

Fittings on Protecta-Line Pipelines
Electrofusion Fittings Procedure for using the Protecta-Line Surprep Scraper is

as follows:
Standard electrofusion procedures must be adhered to, 1. Measure the insertion depth of the electrofusion fitting
but please note the following additional points: to be used. Place a mark on both pipes to show the
position where the edge of the fitting will be.
Scraping
2. Clamp the pipe to be
It is essential that the Protecta-
prepared taking care to avoid
Line pipe is properly prepared
damage to the pipes outer
prior to electrofusion jointing. It
covering.
is necessary first to remove the
outer polyethylene coating and
3. Separate the mandrel from
aluminium barrier.
the body of the Protecta-Line
The Protecta-Line Surprep
Surprep Scraper.
Scraper must be used for pipe
end preparation as this
4. Hold the expanding plug and
equipment not only removes the
rotate the mandrel anti-
outer layers, but prepares the
clockwise until the plug is a
core pipe for electrofusion
light interference fit in the pipe
jointing at the same time.
bore.
NB: Two sizes of Protecta-Line

5. Push into pipe until edge of
Surprep Scraper are available,
plug is level with edge of pipe.
one designed to fit 90mm to
Expand plug further using the
110mm pipe and the other to fit
10mm ring spanner.
125mm to 180mm pipe.
Do not over-tighten in order to
avoid pipe distortion.
Safety
It is potentially dangerous to carry out electrofusion
6. Slide the body of the Protecta-Line Surprep Scraper
jointing where the aluminium barrier layer is still in place.
onto the mandrel, depress the release button and
Clamping position the cutter close to the edge of the pipe.
All electrofusion joint assemblies must be held in clamps
throughout the fusion and cooling periods. 7. Note: Protecta-Line Surprep Scraper cuts in an anti-
clockwise direction, beginning at the end of the pipe.
Note
Electrofusion jointing is not be used for Protecta-Line 8. Rotate the knob on the top of the tool post through
pipes of 25mm, 32mm and 63mm. 90, against the spring tension, such that the cutter is
in its raised position.
9. Loosen the body thumbscrew and position the cutter

shoe on the edge of the pipe. Tighten the
thumbscrew.
10.Rotate the knob on top of the post through 90 so

that spring pressure is applied to the cutter.
11.Rotate the tool anti-clockwise in a smooth continuous

motion to remove the outer layers in a continuous
strip. Stop cutting when the socket depth mark is
reached.
58
GPS
POLYETHYLENE
Thumbscrew
90
Tool Surprep body

post
Cutter
Mandrel release button
Expanding plug
Ring spanner
12.Rotate the knob on top of the tool post so that the Butt fusion
spring pressure is released.
Where this is allowed by the local Utility it is important
13.Use the hand scraper to remove the peeled strip from that the outer PE and aluminium skins are removed far
the pipe. enough back, using the Protecta-Line Surprep tool, to
Caution do not attempt to break the peeled strip by prevent the aluminium from coming into contact with the
pulling with bare hands, it has a sharp edge! butt fusion machine trimming or heater plates.
Furthermore, the skins should be removed far enough
14.Inspect the prepared surface to ensure: back to permit normal debeading of the completed joint
i) All of the metallic layer has been removed. for quality control purposes.
ii) All of the adhesive which bonds the metallic layer Care should be taken not to damage the outer skins of
to the blue core has been removed. Protecta-Line pipe when clamping it in the butt fusion
machine. In the case of some machines this may
15.If, for any reason, the prepared surface is not a necessitate gently radiusing the edges of the jaw shut
uniform blue colour all over, use the hand scraper to lines.
complete the preparation process.
Never attempt a second pass with the Protecta-Line

Surprep Scraper.
Important Information
Some Water Utilities have a technical requirement that
only full barrier fittings are used with Protecta-Line pipe.
Where a Water Utility stipulates this, GPS recommends
the use of Protecta-Line Fluid Compression Fittings for
sizes above 63mm (Protecta-Line mechanical compression
fittings for sizes up to 63mm also provide for a full
barrier).
Where Electrofusion or butt fusion is acceptable to the
Utility (in sizes 90mm to 180mm), GPS recommends
subsequent wrapping with aluminium foil and a Denso
type tape.
59
GPS
POLYETHYLENE
Wrapping Procedure for

Electrofusion and Butt-fusion
When additional protection is requested, it is

recommended that Protecta-Line aluminium tape is
wrapped around all butt-fusion and electrofusion joints.
To limit the risk of subsequent damage by third parties, it
is further recommended that the aluminium tape
wrapping is protected with a layer of Denso tape or
equivalent waterproof tape.
The following procedure should be followed:
3. Additional protection can be afforded by further

wrapping the aluminium wrapped joint area with
Denso or other equivalent waterproof tape. (Specific
product advice should be requested if products other
than those referenced are to be used Telephone: +44
(0)1480 442620)
1. Following the jointing of Protecta-Line pipe with

electrofusion fittings or butt-welding, the complete joint
area should be wrapped with Protecta-Line adhesive
aluminium tape. In the case of electrofusion, the
terminal pins should first be sawn off.
2. After completing the jointing procedure the whole joint

surface should be dry and clean. Care should be taken
to ensure that when wrapping electrofusion joints with
the adhesive aluminium foil the extremities of the joint Testing & Commissioning of
are wrapped using a 100% overlap and the main body Protecta-Line Pipelines
area with a 50% overlap.
The sequence of events for Protecta-Line includes the

basic procedures (on page 17) taking the extra care
appropriate for a contaminated environment as set out by
the Local Water Undertaking.
As for normal PE pipes these standards will normally
require, as a minimum, the adequate flushing of the
services and the testing of all pipes and joints to the
maximum head to which the system is to be subjected.
60
GPS
POLYETHYLENE
SECURA-LINE JOINTING PROCEDURES
The GPS Secura-Peel Pipe Preparation tool should be Preparation method for installation of Tapping Tees and
employed to remove the polypropylene coating from Branching Saddles.
Secura-Line pipe prior to joints being made. 1. Remove the fitting from its bag, leaving the cardboard
protector in position. Place the fitting on top of the
pipe in the desired position.
Basic principles of skin removal
2. Mark north, south, east and west positions around the
Secura-Peel comprises a guidance platform/body, cutter
fitting on the pipe, using a felt tip pen.
and head. The cutter features an anvil to limit the depth
of cut and avoid damage to Secura-Lines core pipe. The 3. Remove the fitting and extend the lines to draw a
tool is supplied with full operating and maintainance square on the pipe where the fitting will be joined.
instructions, but the basic principles are set out below. It 4. Using the Secura-Peel tool, push the cutter head into
is easiest in the first instance to use a pushing action to the pipe skin.
penetrate the pipe skin, and a pulling action for cutting. 5. Once the PP skin has been pierced, pull the tool (by
The guidance platform is omnidirectional (works in all holding the platform) towards you along the full length
directions), but the cutter may be readily rotated to of the line marked.
facilitate a change in direction of cut, without lifting from 6. At the end of the line, rotate the tool to the right (by
the pipe however, always rotate the cutter and handle in holding the platform) always working clockwise around
a clockwise direction to maintain position of the cutter the marked area.
under the skin.
7. Repeat along all marked lines.
Preparation method for pipe ends prior to jointing
8. Upon completion, remove the polypropylene skin. Do
1. Hold the fitting against pipe end and mark the Secura- not touch the exposed surface with your hands or with
Line skin at a distance from the pipe end equal to the any rags.
length of the fusion zone plus 10mm.
9. Continue the jointing procedure in the normal way.
2. Align the pointed side of the handle in a
circumferential direction and press the blade into the
Secura-Line skin where marked. Pull the tool around
the pipe circumference keeping the cutting distance
from the end of the pipe constant.
3. When the cutter meets up with its starting position
turn through 90 degrees and push or pull to the end of
the pipe.
4. Lift, peel back and discard skin without touching the
pipe surface underneath.
5. Do not touch the exposed surface with your hands or
with any rags.
6. Continue the jointing procedure in the normal way as
for standard PE pipes.
61
GPS
POLYETHYLENE
PUSHFAST SYSTEM PROCEDURES
General The System

The Water Industry has traditionally used spigot and socket The basic element of the Push-Fast system is the specially
joints for buried mains, the pressure tight seal being designed patented socket. Standard 6m lengths of pipe
affected by a rubber ring seal contained within the socket. are supplied with a factory welded socket on one end.
Such methods are employed for ductile iron and PVC-U A range of complementary fittings is available with plain,
pipework. socketed or flanged ends, based on Long Spigot fittings.
Notwithstanding the reliable methods of welding
polyethylene pipe and fittings, the need still exists for a Jointing Procedure
pipework system which offers the advantages of It is important to remember that the performance of the
polyethylene material but which still employs conventional Push-Fast joint depends on the efficiency of the seal
spigot and socket jointing techniques. between the elastromeric sealing ring, the pipe and the
Recognising this need, GPS offers the Push-Fast System in socket. Damage to the pipe or fitting or the presence of
blue and black PE80 (MDPE) and PE100 (Excel) materials dirt or grit will adversely affect the performance of the
and in PE sizes from 90mm to 250mm. Unlike most of the joint.
conventional spigot and socket systems Push-Fast Factory fitted protective packaging should be left in
incorporates a grip ring. Made from a hard thermoplastic position until the components are ready for use.
material the grip ring enables the Push-Fast joint under Joints between pipes and fittings are made using the
most circumstances to withstand the end-loads induced, following procedure:
initially by the test pressure, and subsequently by the
1. Remove protectors from spigots and sockets and
continuous working pressure, up to a maximum of 16bar.
inspect for damage. Particular attention should be
This largely eliminates the need for thrust blocks, while still
given to any scoring of the spigot. Scored spigots must
allowing simple low force jointing. This system is covered by
be cut back to an undamaged section.
a GPS patent. Please consult our technical support
department for advice when Push-Fast is to be installed
above ground or might be pressure tested before back
filling, especially where there are changes in direction or
when pressures above 10 bar are likely for diameters above
180mm.
2. Push-Fast pipes are supplied with a factory machined

chamfer. Any site cut pipes should be cut square and
similarly chamfered.
Section through Push-Fast assembled joint showing grab ring in

taper and elastromeric seal.
Approvals
The Push-Fast system has undergone extensive testing and
trials to prove the long-term performance, and has Yarsley
Testguard Product Conformity certification.
Testing to WRc 4-32-03 and 4-32-04 has shown that the
performance requirements of these documents are fully met.
Tests for angular deflection and performance under variable 3. Inspect the elastromeric sealing ring, and the
pressure conditions have also been successfully completed. respective locating grooves for any damage and replace
Many UK Water Authorities, Water Companies and Regional if necessary. If dirt or grit is present, the seal must be
Councils use the Push-Fast System including: removed and the seal groove and socket thoroughly
Lothian Regional Council cleaned of all foreign matter before refitting the
Thames Water components.
Rickmansworth Water Company 4. Similarly inspect the grip ring and groove. Clean as
Welsh Water necessary to remove any foreign matters but do not
Southern Water remove the grip ring from the socket groove.
York Water Company
Mid-Kent Water
62
GPS
POLYETHYLENE
5. When all components are clean, care must be taken to 9. Under no circumstances must joints be pushed home
ensure that they remain clean by replacing protectors using mechanical equipment, ie. a digger bucket.
or plastic bags over the ends unless jointing is to be
carried out immediately.
6. The spigot ends of any site cut pipes should be marked
with the insertion depth, using a felt tip pen, as
follows:
Pipe size Insertion depth
mm mm
90 152
110 131
125 143
160 194
180 202 Repairs/Alterations
225 230 The most satisfactory and safest method of effecting
250 250 alterations or repairs to a Push-Fast system is to follow
the procedure previously described using the GPS
7. Apply the GPS Push-Fast lubricant, spray or gel, to the DuraFuse electrofusion techniques.
spigot, and to the grip ring and the elastromeric A repair or slip coupler is included in the Push-Fast range,
sealing ring in the socket. however, the design of the coupler is such that it will not
Typical usage of lubricant is as follows: withstand end thrust loadings. This may therefore cause
complications where a system has initially been installed
No. of joints per 400g spray
without the provision of anchors or thrust blocks.
Size or 500g tub of gel
90 100 In addition, repair or slip couplers must not be used to
110 80 repair long runs of polyethylene pipes as the joint is
125 60 unlikely to accommodate the axial movement that may
160 30 occur.
180 30 There is also the possibility that the pipe outer surface
225 25 may have been damaged or scored to the extent that
250 20 positive sealing cannot be achieved.
However, having checked that the above situations do not
or will not arise, the following procedure should be
followed:
1. Cut out the damaged section over a sufficient length to
ensure that the remaining pipe surface is not damaged
but in any event to a minimum of 600mm.
2. Ensure the pipe ends are square and chamfer the
ends.
3. Clean the outer surfaces of pipe on each exposed end
of the main being repaired for at lest the equivalent
length of the slip coupler.
8. Align the pipe and fitting and enter the spigot into the 4. Using a felt tip pen, mark each pipe end to half the
mouth of the socket. Apply sufficient force to the end depth of the coupler.
of the pipe/fitting remote from the joint so that the 5. Lubricate these two ends and push a slip coupler over
spigot enters the socket up to the marked insertion each end until the pipe ends touch the second
depth. Smaller sizes should be entered using hand elastromeric sealing ring.
applied force, whereas assistance of a crowbar 6. Cut a new length of pipe to fit between the ends of the
purchasing on a wooden block may be necessary for repair coupler. Again check that the ends of this pipe
the larger sizes. are also cut square and are chamfered.
7. Lubricate the ends of the new pipe and place in
position.
8. Pull the slip couplers back over the new length of pipe
until the insertion depth marks are just visible.
Push-Fast fittings are not available in service sizes.
DuraFuse electrofusion fittings have to be used as do
DuraFuse electrofusion tapping tees to achieve service
connections to the main.
63
GPS
POLYETHYLENE
DUCK FOOT BEND KITS
Assembly Instructions
1. Secure a concrete 4. Cut the length of the

base into the ground pupped stub flange
and fit 4 x M16 bolts as required. Note
at 180 x 160mm that the total height
centres. (Bolts not (h) should include
included in kit) the Fire Hydrant
height. Scrape the
m
0m
h
16
stub flange pipe end
180 and place in the top
mm
of the electrofusion
tee. Electrofuse the
tee, securing the
base and stub into
place.
2. Fix and bolt the Duck
Foot Bend base piece
Flow out
to the concrete base.
Note that the
orientation of the
Flow in
base should be such
that the incoming 5. Electrofuse the
flow meets the face coupler, reducer or
of the Duck Foot spigot reducer into
Bend base. place and electrofuse
to the incoming pipe.
3. Remove the lower

pipe stop from the Flow out
electrofusion tee and Incoming
pipe
push firmly onto the
base. As for part 2,
the orientation of the
electrofusion equal 6. Connect the hydrant
tee should be such to the stub flange
that the incoming assembly following
flow meets the face Flow the stub flange
in bolting procedure.
of the Duck Foot
Bend base.
64
GPS
POLYETHYLENE
FAX BACK
If you would like to receive further information regarding other GPS products, please
photocopy this page, tick the information you require and fax back to us on +44 (0)1543 273 232
Polyethylene Pipe Large Diameter Tees PushFast
DuraFuse SlimFlange Duck Foot Bends

Electrofusion Fittings
Fabricated Products Sleeved Subcoil Calder Electrical

and Mechanical
Jointing Equipment
Spigot Fittings Secura-Line Protecta-Line
Name ...............................................................................................................................................................................
Company name..................................................................................................................................................................
Address.............................................................................................................................................................................
.................................................................................................. Postcode .......................................................................
Tel .............................................................................................. Fax ...............................................................................
Email................................................................................................................................................................................
Fax: +44 (0)1543 273 232

GPS reserve the right to modify products without prior notice.
Reproduction of any of the images in this brochure is not permitted without the written consent of GPS.
For information, please contact Marketing Communications via enquiries@gpsuk.com or Tel: +44 (0)1543 273213
Whilst every effort is taken to ensure the accuracy of information contained within the brochure, the details are offered in good
faith and GPS accepts no liability for matters arising as a result of errors or omissions. Should this information conflict with your
normal engineering advise, please contact our technical support department on +44 (0)1480 442620.
A PDF version of this brochure is available from our website.
Distributor
GPS
UK Enquiries Export Enquiries
St Peters Road Walsall Road
Huntingdon Cannock
Cambridgeshire Staffordshire
PE PIPE SYSTEMS PE29 7DA WS11 9NS
email: enquiries@gpsuk.com Tel: +44 (0)1480 52121 Tel: +44 (0)1543 279909
web: www.gpsuk.com Fax: +44 (0)1480 458829 Fax: +44 (0)1543 279450
G0009/1 September 2004

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G0009/1

World leaders in the design, manufacture, marketing and sales of high

website: www.gpsuk.com email: enquiries@gpsuk.com

GPS offers complete piping systems manufactured

Pipes are extruded in two basic materials - PE80 (MDPE)

In addition to the DuraFuse range, GPS also offers a range

Certificate No. E 51385 Certificate No. FM 34819

GPS operates a quality assurance system in

WATER STANDARDS GAS STANDARDS

BS EN ISO 15494:2003 Specifications for polyethylene Transco PL2

Material designation Certifying symbols and standards

Standard Dimension Ratio (SDR) System voltage (if applicable)

SDR fusion range (max/min) Pressure rating

Nominal size (mm)

GPS Pipe Marking

GPS 180mm SDR11 PE100 S 14143004 H

Nominal pipe outside diameter (OD) in mm

International Standard week

Shift period: day = 1

MATERIAL PROPERTIES & COMPATIBILITY

PRESSURE RATINGS AND FLOW CHARACTERISTICS

The graph below shows the reduction factor which should

MAXIMUM CONTINUOUS OPERATING PRESSURES AT 20C FOR GPS STANDARD PE PIPES.

High Frictional Pressure Loss in Low Pressure

Flow Calculations for Water Fittings constant

PRESSURE TESTING - WATER

Water mains Pressure Test

For a sound main this ratio N1 should be: Commissioning

PRESSURE TESTING - GAS

Hydrostatic pressure testing

The pressure in the service should be increased to the

The procedure must not be carried out within 3 pipe

Our polyethylene products have been installed and Fire characteristics

HANDLING & STORAGE

12 metre pipe bundle

Good lifting practice

Coils are secured by one of two methods depending on

Recommended practice for releasing coils from filmwrap

Drums are delivered direct to site on a low loader and the

Recommended practice for off-loading drums

PROCEDURES & TECHNIQUES FOR PIPELINE INSTALLATION

A major advantage of PE is that pipe lengths can be butt-

Conventionally Buried Pipelines

techniques have been developed which rely

In many instances it may be acceptable to lay PE pipe

Normal sidefill & backfill requirements

When GPS PE pipes are laid in fields it is preferable and

Low-Dig and No Dig New Lay Techniques

Narrow/chain trenching Moleploughing

Impact moling (not to scale)

ii) An enlarged hole is bored by one of various means,

iii) The drill head is steered by using a flexible joint close

The stages are as follows: Drilling Rig

i) A small diameter 'pilot hole' is drilled from one side of

In the case of large diameter pipes, a number of passes

Rehabilitation and Renovation using Grouting

For long strings we recommend a pipe relaxation period of

Slip-lining (not to scale)

Flow Improvement (%)

Subline Flow capacity improvements for close-fit PE80 or PE100 (Excel)

Above-ground supported installation

ELECTROFUSION JOINTING PRINCIPLES

The DuraFuse system comprises a complete range Electrofusion Principles

adjacent to it melts and forms an expanding pool