Butt Welding

I~ Y ~ ~ ~ ~ I ~ , ~ ~ I ~ L / Y ~ ~ ~ ~ E M M W L L Y ~ , % E ~ ~ L E ~ ~ ~ S ~ E
Butt welding is a method of connecting pipes by heating up the two ends of PE pipes then joining them under a specific pressure.

B fis7a- /~~b)Becofis*IIR
Process Flowchart: The Procedure for Butt Welding

OPreparation OCleaning the scraped surface Q ~ e m b v aof

l the heating plate
QPipe setting @Heating plate setup @Press to weld
@Scraping the pipe surface @Heating the pipe edge OCooHng

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.Management for welding

Measure the height and width of the bead with a vernier caliper after welding to confirm they are all in the designated value.
Record the welding operation and result for data management.
Commit the leak test onto the welded part.
I$&T~&
-----=#---
Butt Welding Procedure

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Heating the pipe edge

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) $ ~ ~ I L , B % B B I + ~ ! TProcedure
~ ~ for Installing Mechanical Fittings
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I.
----____,
WRE -
-/'
-

Structural compos~t~on
4@hl@&%3BE
Three windows for
confirming insertion
w
$3titwb g!IDlJYZr 8ZW&I%
Cap nut Claw ring Male thread unit

1. Cutting the pipe

Use a pipe cutter to cut the pipe at a right angle.
. Ifyou windohave
not cut the pipe at a right angle to the ppe' s aual direction.
to cut ~tagain to get a r~ght-anglecut.
Cavlrm
. Eosure lhal the cut surface of the pipe is free of burrs.
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2. Attaching the cap nut and Claw ring

Check the direction of the cap nuts and the order of ~nsertionthrough
the pipe.: first the cap nut, then the Claw ring.
. Make sure the dlreclion of the cap u correct and do not lorget to Insert the splil rlng.
Caution

A
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&S

3. Connecting the pipe

Insert the pipe in a straight line right to the back of the fitting.
- Insert the plpe unttl it makes contact with the back of the f~tt~ng.
Cautlon

.t~~el;asrL\~c.araLur<ItsL~
4. Confirming insertion

-
1 Make sure that the ~ i has ~ been
e inserted all the wav to the back of
the fitting, using the window to check.
Complete insertion IS requ~redfor correct operation.
Caution

5. Screwing the cap nut

Tighten the cap temporarily by hand.
Then, apply wrenches to the unit and cap nut and tighten it up.
Be sure to use two wrenches, turnlng the cap nut and t~ghtenlng~tw~thstandard torque
If I, is msubc~entlyt~ghtened.1WIII leak water.
Caution
Be careful that the unlt doesn' t rotate together wlth the cap nut
 AIPOLV BROADPIP
Aipoly Broadpipe Technical Data
8 PEl00 @*$&BPhysical properties of PE 100
m4s/Jm
m?5
Tests ltem Test Method Unit I 'WJVtW
Standard value I IE8-
Notes 1

@B( Fzn$-9B!s,
Hardness (Durometer)

BSBh ( 9hll. 1
Impact strength (Charpy)

m
Linear expansion coefficient

W Specific heat capacity

L
Heat conductivity

Melting point

$1
3 Softening temperature tvicat)

2 I Flammability
3 E@8E%YIFbYERU#+aB8E%#(SDRll)
Performance Standards for High-density Polyethylene Pipes and Joints

JwwAZ l?X$2DJWWAZ110O~clr5
JWWA Z 108.JWWi4 Z 1 10

WE, t . l O M P a x l 6 5 ~
B0F; 1.10MPax 165hrs
Ba"0,I 400MPa 1OC)O Rf@

3 3E?1R%rff3 Pressure and Temperature Limits

EwSBE?lB88, Equation for calculating pressure and temperature limits

at (Naday
P= ~ - t (Naday' s equation)

P : E2 MPa . P : Pressure. MPa

t : gQ crn t : Pipe thickness, cm
a : 3IWll6F;n MPa a : Tensile circumferential stress, MPa
D : €3943 crn D : Outer pipe diameter, cm
XWP@=1.25tT5. XSafety factor=l.25
 ~ ( YU-I~) ; ~
Hazen5Willarnsc~-w.D ~ I J F L X )D63
Hazen-Williams Equation(0D of 63 and bigger)
Q=0.27853 C a d2-63.10.54

*%RPi(SDR21) F h rate table ISDR 21 Ylif : 12 /ssc) Unit. L/sec

EMa&I(O/OO)-.Hydraulic gradient 1 (%) %%.+ormula +M;t(w )...OD(& WC?@ (arm).ND(n)

B Z#BM Support Intervals
.EAftBBE @m%rncn@~a%fanr~7;eaimm
(% 1 ;S@E35Z, % 2 %BZ 50".%$LtWD3R&tar3Zd)
Maximum support intervals A summary ot maximum support intervals for pipes is given as follows.

Horizon,al piping 4.1

~ A E Q W7kTES 4.5 4.8 5.2 5.7 6.1 6.6
Indoor
piping*^ Vertical piping 8.2 9.0 9.6 10.4 11.4 72.1 13.2

efies 7kVE@piping
*2
4.1 4.5 4.8 5.2 5.7 6.1 6.6
Outdoor
pipingw2 8.2 9.0 9.6 10.4 11.4 12.2 13.2

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Minimum bending radius by size A summary of min~mumbending radius for pipes is given as follows.

%ggfklZd;bf$J#g
Thermal longitudinal expansion
ABB9Z@ho
iWk#&fi91Fl/'/@E~L'~I2,f &cT)bRl~d;->T@&I$@kSfibDP,
Sfidt?hh/
L h \ L , S t t l E ~ F f d ~ @ f b f ~ d ; b @ ~ ~ ABi5WcT)kib&l2Blf
d<Zb%
When high-density polyethylene pipe is l a ~ dunderground, fr~ctionwith the earth will prevent expansion,
so no problem arises. However, exposed piplng can undergo great expansion due to temperature fluctuations,
so a certain amount of deflection cannot be avoided.
Bt'BEfi9 I 3 L / Y fcn'Zb@lWL&bR1iI~iCP~%Lbb0
The amount of expansion of hlgh-density polyethylene pipe due to
temperature fluctuations is calculated according to the following equation.
AL=a .A e . L AL=a . A e - L
I;,: AL: M m
, Here, AL: Amount of expansion
L :EBEt L: Length of pipe
A B : W S tiW2olXWT5) A 0: Temperature difference
a : W W 13x10a/9= (mth 20C as base temperature)
a: Coefficient of longitudinal
expansion 1 3 X 1 0 ' / C
9 MgE't!k Chemical Resistance
8%&3YL3b2Baa@zGMm%E5x
~ ~ ~ ~ eaE$x&&#
l ~ m *
Q: fgh 0 : w x : ~q m : ~IZSLI~J%%T~,
The material compr~singhigh-densrty polyethylene pipe exhibits these main chemical resistance properties.
(This table is based on IS0 10358. The behavior shown may vary If a#.;nt)ew ~4lWhld b !BW@FM-~
Su-mmary: 9: great 0: good x : poor K : Pipe odor changes.
3 ~~ZK'.J-~CI-FIWY~P%BE~P%
Strength Characteristics of embedded Aipoly Broadpipe
7439-f a-Fl T O E , fF P I L B ~ L R .fiGZ1:&6B8~G%FPfif7htGL~&5l:f
~~~I~, tII8 40cm PA:AlDB322T,kE
E D % E I L l l z ~ l 40cm o 53~D4%1z13,
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PATIC, 40cm PlRl:@3Lf=S%DB3BE~R%%QZL3~
When Aipoly Broadpipe is embedded in the ground, n o problems should arise from the external forces exerted by
the ground or by vehicle wheels if embedded at a depth of 40 cm or deeper, so long as there is n o concentrated stress
from rocks or anything similar. If it is embedded less deep than 40 cm, it needs to be protected against external forces.
The followings are the results of calculations for the strength in cases involving pipe embedded at a depth of 4 0 c m or deeper.

1 . Calculation m e t h o d
We have calculated the bending stress using the formyla given in
"Waterworks Installation Guidelines and Explanations,
published by the Japan Water Works Association.
We have calculated safety factors as well.

M : BB l c m YrlO€-%>t-(kgf-cm) M : Moment per 1 cm of pipe length (kgf-cm)

K : €-%>EBB :K=M/wR(f NSf 7% 120" O t Q K=0.138) K : Moment coefficient: K = M/wR (with an effective support angle of 120', K=0.138)
W : Pa 1cm Y YO PVl:&iQRS(kgf/cm) W : Linear load according to Pv per 1 cm of pipe length (kgf/cm)
Pv: @&bl:B\b\b\bPttPSr;iJOf Q <PI+P;>(MP~) Pv : Earth Pressure PI + PZexerted on embedded pipe vertically (MPa)
R : BRq%\%B(cm) R=(D-t)/2 R : Pipe thickness center radius (cm) R=(D-t)/2
D : aSO%@(cm) D : Outer diameter of pipe (cm)
Ph: @WaSWO7kVfE(MPa) Ph : Horizontal ground pressure exerted on sides of embedded pipe (MPa)
o : BE3bO%&ftBlfRE;h (MPa) u : Bending stress incurred by embedded pipe (MPa)
Z : $S 1cm %rlOggiEl@ir(cm3/cm) Z : Section modulus per 1 cm of pipe length (cm3/cm)
t :RORt(cm) t : Pipe thickness (cm)
6 : W!?f!fOfibb(cm) 6 : Deflection of embedded pipe (cm)
Fr : @&@LPakiPrR1=.k~Ti#b5lB Fr : Coefficient chosen according to support angle of embedded pipe foundation
(BNSiPrB 120" O t P F1=0.089) (with an effective support angle of 120', F1=0.089)
Fd: k O B r e ! f a f O H B B Fd: Retardation coefficient for amount of ground deformity
E' : @EL& O f (MPa) E1=6.9MPa E' : Coefficient of passive earth pressure of backfilled earth (MPa), E' = 6.9 MP;r
E : ftBlf%B% E=1000MPa E : Bending elasticity, E = 1000 MPa
I : gW lcrn ItzYOCgiB 2 ;~€-%>l.(cm4/cm)l=t3/12 I : Section secondary moment per 1 cm of plpe length (cm4/cm), I = t3/l 2

1 -1 *E%*
e S @ D W M B I C H L \ b fE f f % l t T l E l I ~ & 5 .

1-1 Distribution of earth pressure 1 - 2 B e n d i n g stress

Earth pressure used to calculate the strength The bending moment M incurred in the pipe by the Spangler
of pipes is in accordance with the diagram below. earth pressure distribution chart is given by equation (1).
h=P1 f P 2

d ( l )I= The following:

o = M/Z, Z=t2/6, Ph=E'/R (6/2),

pv Spangler earth pressure

Sin8 distribution diagram E f % h l B T i 3 t d(2) IZtdZL
~ ~ ~ ~ % ~ f t B (2) I l ( '2 1W
P J~~ IY t- D
~ B Z ~ IC&9
) Wbn5XLb.
.-can be substituted into equation (1) to give equation (2). The bending stress
incurred by a buried pipe can be obtained using equation (2) (Spangler' s equation).

Pv : Earth Pressure exerted on embedded pipe in plumb direction

P I : Vertical pressure exerted by backfilled earth 3%#R@-flJERl ,R21:Zz Tables 1 and 2 give examples of calculation results.
P2 : Wheel pressure (verticalearth pressure exerted by live loads)
Ph : Horizontal ground pressure exerted on sides of buried pipe
8 : One-half of support angle 1 - 3 S a f e t y factor
R : Pipe thickness center radius The safety factor is obtained using equation (3).

S=Ob/o
(-1
S:3?4+
The sum of the vertical earth pressure (PI) exerted by ab:Il~tr(MPa)
backfilled earth plus wheel pressure (P2) is the vertical
earth pressure (Pv) exerted on a buried pipe. 74iJ3J-fn-FlY4;9=20MPa
-.(3)
S: Safety factor (negative)
u b : Bending strength (MPa),
Aipoly Broadpipe = 2 0 MPa
 2. Calculation results
Examples of calculation results are shown below.
( * 1 ) lndlcates calculations of the passage b f one 25-ton truck.
( * 2) ind~catescalculations of the simultaneous passage of two 25-ton trucks.
The support angle IS assumed to be 120'. '

As shown by the above calculat~onresults, hrgh-density polyethylene plpe has been confirmed
to possess sufficient safety characteristics for w~thstandingexternal loads. It IS necessary to carry out flex~blllty
factor calculations and confirm that they fall w~thinacceptable limlts.
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Criteria of judgment in Water Pressure Testing ( ~ a n u f a c t u r e rrecommendation)

I Increase the water pressure in the pipe line up to 0.75 MPa and leave it for 5 minutes. I

~ A W H W ~7J ~k, E ~ 0 . 7 5 ~ ~ a ~ ~ ~ T 5
After 5 minutes passed, apply pressure again up to 0.75 MPa

Decrease the pressure to 0.5 MPa soon after applying the pressure up to 075 MPa,
and leave it for a while.

Measure the water pressure after 1 hour passed.

1 Leave: it longer and check the water pressure

after 24 hours D ~ S S B ~

rass 1
 Cautions Regarding Construction
3 f ]lJ Transportation

A Cautions
- When unloading pipes and joints from the truck, do not subject the impacts to the products by tossing them around.
+When transporting products by truck, place cushioning material to avoid direct contact with hoists or corners of the bed.
+When carrying a pipe, be sure to lift and carry the entire pipe rather than dragging or sliding along the ground.

3W P Storage
;S6EEiKJ1Pb% High-density polyethylene pipe
7

As for storage, please conform to the Items below to avoid any discoloration or deterioration of the products.
*As a rule, pipes should be stored indoors in the packaging as they were shipped from supplier. When storing outd?ors
on-site, cover them with a tarp or something similar to avoid direct sunlight, and take consideration with regard to
ventilation. Be sure to attach terminal caps to the pipe ends to prevent deterioration, which may be caused by direct sunlight.
+When storing pipes, select a flat area and place them on wooden sleepers about 1 m apart to avoid any unevenness.
Avoid stacking them crosswise on each other.
+ Fittings should be stored indoors. If stored outdoors on-site, they should be covered with a tarp in the cardb~ard
packaging as they were shipped from the supplier.
*Both pipes and fittings should be stored without any chance of contact with detergents, solvents, or grease,
and away from fire (bonfires, welding torches, and industrial lighting).
1)
B E l Piping

Be sure to avoid getting any water on the EF weld section during welding. If water is present, use a pump to remove it,
or raise the weld section of pipe so that the welding can be performed without any contact with water.
+If you are unable to eliminate water when welding with pre-installed pipe, use mechanical fittings to connect.
+If it is raining, use a tent or something similar to provide shelter from the rain and ensure
that the weld section does not get wet.
+The indicator bulge may appear even if sand or grease has contaminated the welding surface,
so the indicator alone cannot be used to determine a proper weld. Be sure to implement the correct procedure
(proper washing, cutting, and fixing) in addition to checking the controller to confirm normal completion.
+Do not backfill or carry a pipe until its cool-down has been completed.

5m T ? . ~ l $ ~ ~ l f ~ @ Allowable
k ~ R f i bending angle and variation at 5m length

Minimum bending radius

B ~ W W Stra~ght
i plpes only 5.5 6.8 7.5 8.5 9.5 11.0 12.0 13.5 15.0
Includlngjoints 13.5 17.0 19.0 21.0 24.0 27.0 30.0 34.0 37.5

+Bending straight pipe should be done within the range shown above.
+Do not use any adhesive tapes directly onto pipes and fittings. Adhesives may negatively affect pipes.
+If the pipe is encased in concrete or mortar, ensure that the temperature does not exceed 60°C during th8 curing.
$ % Embedding
fi3dLL\%kkklf Desirable finish

fidL<aL\%kkblf Undesirable finish

+A sand footing should be provided around the pipe, with a? least 10 crn of sand between the bottom of the trench
and the bottom of the pipe, and a! least 10 cm of sand on top of the pipe. During this process,
ensure that no hard objects like stones or wooden sleepers are in direct contact with the pipe.
+Backfilling should be performed after the pipe is embedded, using sand or high-quality soil to perform the backfill,
adequately packing it around the pipe and using rarnmers or pile-drivers to harden it until the ground level gets down
to 1 Ocm above the pipe. Then continue to backfill pressing the ground regularly.
+In case of backfilling during the piping process, attach caps to'pipe ends
in order to prevent the incoming of water or sand.
+You must absolutely avoid backfilling without first welding the ends of EF joints.
If you have no choice but to backfill prior to welding, provide sufficient protection to prevent water and sand
or dirt from getting in, and take care not to apply excessive pressure when backfilling.

I %E31fTL\t:f?St;L\T&BW(nP31PiT. 'the "caution" symbol indicates items on which you should exercise caution.

I I-
ll @
The 'prohibition" symbol indicates things you should not do.

The "obligatory" symbol indicates things you must do.