AV K VALVES MANUFA C T U R I N G M A L AY S I A S D N B H D

AV K R e p a i r C l a m p s

Te c h n i c a l B r o c h u r e
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Whenever a leakage in a water mains occurs due to a crack, it is essential

that the repair is done quickly and efficiently so that the consumers and
surroundings experience a minimum of disturbance.

As most cracks occur without any prior notification it is of greatest importance

that the repair products are available ex-stock either at the waterworks,
the contractor or as minimum at the wholesaler. To make this possible the
repair products must have multi functionality, flexibility and wide tolerances.

Furthermore the key demands when conducting repairs are easy and fast
installation and reliable functionality.

For all these specific purposes and demands AVK offers a comprehensive
range of products specially designed for all sorts of cracks in the most
common pipe materials.

FST

FS-10

FS-20

Ty p i c a l p i p e c r a c k s
PVC Pipes have for many years been used for potable water
pipelines as well as for sewage.
The material has proved to be very stable because of the low
weight and relatively high pressure class. If a crack appears it might
be caused by earth settlements or increased traffic load.
A typical crack will be unstructured and can move in both
longitudinal and circumferential direction.
The best way to repair a cracked PVC pipe is to cut out and
replace by a new piece connected with couplings. In this way the
stress in the pipe will be neutralised and new cracks prevented.
If for some reason there is no possibility to use couplings, the AVK
stainless steel repair clamps can be used.
Ductile Iron has been in use for 30 - 35 years. It is more resistant
to impact and settlement forces.
The most common failure mode is longitudinal cracking caused
by cathodic attack i.e. a puncture in the pipe coating which will
create a location for an electric cell from stray currents picked up
from overhead power cables, adjacent railways or from alcaline soil.
The longitudinal cracking can be quite dramatic - the pipe can
virtually unzip. Common corrective action is to drill a small hole
at both ends of the crack to prevent it from travelling further, and
then mount a repair clamp on the pipe.
Typical longitudinal crack in a pipe typicaly caused by earth settlement or increased
traffic load.
3
In the northern part of Europe PE is one of the most used materials
for water networks. Normally there are very few leak problems and
very often the leaks are due to external damages such as digging.
When repairing PE Pipe Systems the part to be repaired is cut out
and replaced by a new piece of pipe, which is directly welded into
the PE Pipe System by using socket fusion welding.
With minor damages Repair Clamps of stainless steel can be
used due to the fact that no stress relieve is required for PE pipes.
The application of Ductile Repair Clamps is seldom seen but can
however be used in line with Stainless Steel Repair Clamps.
Cast Iron was widely used in water and gas systems in the past
and today forms 90 - 95 % of all ferrow pipe failures.
The most common leakage is circumferential cracking caused by:
A: Differing soil types causing earth settlement.
B: Increased road traffic resulting in settlements and cracking.
Cast Iron pipes can be repared with ductile repair couplings since
stress relief is essential.
Asbestos Cement is used mainly in water systems. Failure mode
is similar to Cast Iron Pipes, a circumferential crack caused by
earth settlements or increased road traffic.
Pipe dimensions are only reliable at the pipe ends. It is therefore
essential to use e.g. a sliding caliper to determine the suitability
of Repair Fitting as to tolerances. Also here AVK Ductile Repair
Clamps are to be preferable.
Easy and fast neutralization of the crack is essential in order to minimize distur-
bance for consumer. Here AVK repair clamp is mounted.
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Ty p i c a l p i p e c r a c k s
Cracks in AC, steel, cast
iron or PVC
Pipe ends angled
Holes in AC, steel or cast
iron
Damage caused by service
crane or breaking-off of
branching section
Breaks in AC and cast iron
pipes
Corrosion leaks
Pipes do not join up
Pipe ends do not lie in the
same plane
Cast iron pipes:
- Cracks typically appear circumferentially on the pipe
- The cracks are most often caused by stress in the pipe
- The pipe should be stress relieved before repair
- With minor earth settlements part of the pipe is cut out and
replaced by a new piece of pipe and couplings
Ductile iron pipes:
- Direct pipe cracks, where the pipe cracks in two, appear very
seldom
- Most often leaks appear in connection with wrong pipe fitting,
resulting in galvanic corrosion
- Longitudinal cracks are stopped by drilling the pipe at both ends
of the crack
PVC-pipes:
- The pipe is typically deteriorated because of ozone and
UV-radiation
- Crack zone longitudinal and circumferential of the pipe
- The pipe should be releived from stress before repair
Asbestos cement pipes:
- Pipe cracks typically appear circumferentially because of stress in
the pipe
- Often the crack zone is in the middle of the pipe, where the
external diameter fluctuates the most
- The tolerance area of the repair clamp is important
- Stress relief is required
PE-pipes:
- Cracks most often appear because of mechanical impact on the
pipe
- Repair of big PE cracks is done by cutting out the damaged
piece and inserting a new piece by means of socket fusion
welding
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Stainless Steel Repair Clamps
-Series 729S/D

The AVK Rewag Series 729 is a widely used clamp when dealing
with leaky pipes or complete ruptures in the pipe system. The
clamp construction ensures a cost effective and reliable solution
for quick repairs of pipes in any pipe material. The clamps can be
used for permanent repair of punctures, longitudinal and
circumferential cracks.

The functional principle of the repair clamp rests on a stainless

steel, pre-rolled plate, which is clamped round the pipe and
fastened with lugs and nuts. The clamp has a rubber lining. The
tensile force applied by the clamp fastening is converted to a radial FS-20

pressure on the rubber lining.

AVK offers stainless steel clamps in following variants:

• Single band standard. To be used exclusively as repair clamp. FST

This type is recommended for cost effective repair on primarily

FS-10
pipes where small tolerances are required. Diameter range from
48 mm to 360 mm.
• Double band, standard. To be used exclusively as repair clamp. Main areas of use are for water, gas and sewage covering a

This type is recommended for cost effective repairs on pipes temperature range from -30 Co to +110 Co.

where bigger tolerances are required. Diameter range from 88

The single and double band repair clamps can be supplied in
mm to 650 mm. An advantage of the double band repair clamp
lengths from 100-600 mm with an interval of 100 mm.
is a high degree of a tight equally distributed sealing pressure
due to the double band. The repair clamp is made of stainless steel AISI 304 with teflon
• Double band standard with flange outlet. To be used exclusi- coated stainless steel A2 bolts, bolts and washers. Gasket is
vely as hot tapping saddle. This type is recommended for cost made of EPDM rubber as standard.
efficient hot tappings with flange outlet in various common used
diameters. Sealing diameter range from 88mm to 650 mm.

Making the repair

Mounting instructions for AVK Repair Clamps

1. Excavate pipe allowing sufficient clearance to fit The Repair Clamp.

2. Clean area of pipe where the fitting is to be installed.

3. Measure and check diameter of pipe against tolerance of fitting.

4. Ensure that proper tools are used, i.e. spanner.

5. Open the clamp and place it on the pipe next to the leak.

6. Hook the clamp together and slide it over the leak.

7. Tighten the bolts/nuts in a cross diagonal sequence.

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Complete In Service Repair Box

AVK Complete In Service Repair Box is a "first aid kit" for the maintenance team
within any water work and pipeline contractors.
Based on 6 elements (A-B-C-D-E-F) instant repair on site can be undertaken for a
sealing range from outside pipe diamenter 81 mm to 768 mm combining the elements.
The Complete In Service Repair Clamp comes in standard width 300 mm.

Suitable for pipes made in steel, cast iron, brass, asbestos-cement and plastic pipes.
Use: For water and sewage. Temperature: -/- 30°C up to 110°C
Options: Several lengths and measures. Use of several materials for
clamps and rubber sealing. Clamp can be supplied with fingers or
bolts welded with an interval of 50 mm.
Quality: SIRIM certificate
Materials: Clamp Stainless steel, AISI 304
Rubber sealing EPDM
Bolts Stainless steel, A2, teflon coated
Nuts and washers Stainless steel, A4
Protection cap Plastic

A B C D E F Total Range Range
320 mm 380 mm 440 mm 540 mm 640 mm 285 mm min. max.

285 285 82 89
320 320 91 93
380 380 132 142
440 440 132 142
540 540 162 172
320 285 605 183 207
640 640 143 203
380 285 665 202 227
320 380 700 213 233
320 440 760 232 252
440 285 725 221 242
380 440 820 251 271
320 540 860 264 284
380 540 920 283 304
320 640 960 296 316
440 540 980 302 322
380 640 1020 315 335
440 640 1080 334 354
320 380 440 1140 353 383
320 380 540 1240 385 415
320 440 540 1300 404 434
320 380 640 1340 417 447
380 440 540 1360 423 453
320 440 640 1400 436 466
380 440 640 1460 455 485
320 540 640 1500 468 498
380 540 640 1560 487 517
440 540 640 1620 506 536
320 380 440 540 1680 525 565
320 380 440 640 1780 557 597
320 380 540 640 1880 589 629
440 540 640 285 1905 597 637
380 440 540 640 2000 627 667
320 380 440 640 285 2065 648 698
320 380 540 640 285 2165 679 729
440 540 640 285 2285 718 768
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User guide for
AV K R e p a i r e q u i p m e n t

O u t s i d e D i a m e t e r o f C o m m o n l y u s e d p i p e s i n M a laysia

DN D.I. MS uPVC ABS AC HDPE

Nominal BS4772/ JKR (old) JKR MS1419/ MS 712 DIN8061
Sizing BS EN (new)/ BS5391 /8062
mm 545 BS 534
40 56,0 48,3 48,3 55,9 50,0
50 66,0 60,3 60,3 60,3 69,1 63,0
65 82,0 76,1 82,3 75,0
80 98,0 88,9 88,9 88,9 95,5 90,0
100 118,0 121,9 114,3 114,3 114,3 121,9 110,0
125 144,0 139,7 140,2 149,9 140,0
150 170,0 177,3 168,3 168,3 168,3 177,3 160,0
175 193,7 204,7 200,0
200 222,0 232,2 219,1 219,1 219,1 232,2 225,0
225 244,5 259,1 250,0
250 274,0 286,0 273,0 273,0 286,0
280,0
300 326,0 345,4 323,9 323,9 345,4 315,0
350 378,0 399,3 355,6 355,6 399,3 355,0
375 426,2 426,2
400 429,0 453,1 406,4 406,4 453,1 400,0
450 480,0 506,9 457,0 457,0 506,9 450,0
500 532,0 560,3 508,0 508,0 560,3 500,0
525 587,2
550 650,0 559,0 613,7
600 635,0 667,0 610,0 610,0 667,0 630,0
650 692,0 660,0
700 738,0 754,0 711,0
750 804,0 762,0
800 842,0 854,0 813,0
850 904,0 864,0
900 945,0 954,0 914,0

AV K R e p a i r C l a m p S e a l i n g R a n g e

FS-10 FS-20 FST Repair kit
Range mm Range mm Range mm Range mm

48 - 52 120 - 131 190 - 210 382 - 402 190 - 210 382 - 402 82 - 89
54 - 58 125 - 135 195 - 217 396 - 420 195 - 217 396 - 420 91 - 98
60 - 67 132 - 142 210 - 230 410 - 430 210 - 230 410 - 430 113 - 123
67 - 74 135 - 145 216 - 238 420 - 440 216 - 238 420 - 440 132 - 143
70 - 77 145 - 155 225 - 246 435 - 455 225 - 246 435 - 455 165 - 175
73 - 80 151 - 161 230 - 250 450 - 470 230 - 250 450 - 470 193 - 203
76 - 83 159 - 170 240 - 260 468 - 488 240 - 260 468 - 488
82 - 89 165 - 175 250 - 270 485 - 505 250 - 270 485 - 505
87 - 94 167 - 177 269 - 289 490 - 510 269 - 289 490 - 510
91 - 98 170 - 180 273 - 293 500 - 520 273 - 293 500 - 520
95 - 102 174 - 184 282 - 302 510 - 530 282 - 302 510 - 530
98 - 108 176 - 186 295 - 315 520 - 540 295 - 315 520 - 540
102 - 112 180 - 190 315 - 335 550 - 570 315 - 335 550 - 570
106 - 116 186 - 196 322 - 344 570 - 590 322 - 344 570 - 590
108 - 118 196 - 203 337 - 358 590 - 610 337 - 358 590 - 610
113 - 123 347 - 367 516 - 536 347 - 367 516 - 536
118 - 128 365 - 385 532 - 552 365 - 385 532 - 552

 Non standard sizing available on request.

 T h e AV K R a n g e s o f R e p a i r C l a m p s

The philosophy behind the existing product programme

is to cover the need of our customers in the most efficient
and comprehensive way without compromising quality
and price.

We steadily improve and develop our product programme in

order to offer state-of-the-art products and services. The AVK
repair programme for every possible repair and renovating situation
that demands for prompt and effective handling.

AVK Rewag repair fittings

Series 729 S/D
Single or double band repair
fitting. Light weight and cost
effective solution for long
lasting repair of pipe
systems.
FST For hot tapping the double
FS-20 band repair fitting comes
with flange.
FS-10

AVK Valves Manufacturing

Malaysia Sdn Bhd
Lot No. 1, Jalan Sg. Chadong 8
Batu 5 1/2 Mile, Jalan Kapar
MY-42100 Klang
Selangor Darul Ehsan
Malaysia
Tel: +603 3291 8270
Fax: +603 3291 4257
e-mail: avkmalaysia@avkvalves.com.my
www.avkvalves.com

41729XAB_NEA/2007-10-11