REV 04

NOTES
In addition to JKR Standard Specification for Roadworks (including Bridge
Structures) JKR/SPJ/1988, this specific Installation Manual and Technical
Specifications for FLOLINE 3-W, TRIPLE WALL PROFILES HDPE PIPE CULVERT
shall be compiled with.

Should there be any variations in context statements or recommendations between

the specifications that affect the quality of work, this manual and technical
specification shall take precedence.

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 REV 04

FLOLINE 3-W PROFILED HDPE PIPES

HANDLING & INSTALLATION GUIDELINES

This Handling & Installation Guidelines provides information on the handling and
installation of FLOLINE 3-W profiled HDPE pipe in non-pressure applications
including most sewers, culverts and sub-drainage systems.

Most of the information contained in this guide is referred from ASTM D 2321 :
Standard Practice for Underground Installation of Thermoplastic Pipe for
Sewers & Other Gravity-Flow Applications, which is a common guideline for the
installation of HDPE corrugated and profiled pipes.

Safety regulations and guidelines must be observed during all phases of construction
including foundation & bedding preparation, excavation, pipe handling, assembly and
backfilling. FLOLINE 3-W pipes are solely intended for the conveyance of fluids.
Access into this product for maintenance, inspection, or other reason should be done
in strict accordance with OSHA recommendations for confined space entry.

1) DELIVERY INSPECTION

The manufacturer makes every effort to ensure order accuracy and quality. As a final
check, the customer should conduct a personal inspection upon delivery to verify that
the correct product and the expected quantity is received. Pipe ends, couplers or
other accessories should be visually inspected for any damage that may have
occurred during shipment. The pipe walls shall be free from visible cracks, holes,
blisters, voids, foreign inclusions or other injurious defects. Other damages such as
cuts, gouges, delamination, bulges, flat area and ovality that may have occurred
during shipment should be visually inspected.

Product markings on pipe, joints, and accessories may vary slightly among
manufacturers. The information commonly found on FLOLINE 3-W pipes:
• Nominal pipe size
• Type / Stiffness Class
• The brandname FLOLINE 3-W
• Length
These markings help make product identification easier for job-site delivery
inspections.

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 REV 04

2) HANDLING & STORAGE

The contractor should set aside an area for products to be stored on site. This area
should be flat, free of large rocks, rough surfaces, and debris. It should also be out of
the way of construction traffic. Pipes and fittings must be stored away from heat
sources.
FLOLINE 3-W pipes can be unloaded by carefully rolling single lengths of
loose pipe from the delivery truck onto a front-end loader, and then onto the ground.
For the smaller pipe sizes, they can be easily loaded/unloaded by one or two person,
one piece at a time.
For larger pipes, the pipe can be lifted using a nylon strap sling or cushioned
cable at the third points by a crane or excavator. For palletized pipes, loading and
unloading of pallets shall be done with a forklift. Pipes should never be dropped on
the ground.

FIGURE 1 - Handling of FLOLINE 3-W Pipes

All pipes shall be stacked on firm ground to support the weight of the pipes
and lifting equipment. Pipes shall not be supported in such a way that will cause
them to be twisted or bowed.

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 REV 04

Stacking height shall be limited to five units; but not exceeding 2 meters and wedged
at approximately third points along the length to prevent movement.

FIGURE 2 - Stacking/Storage of FLOLINE 3-W Pipes

Items such as couplers, fittings, and accessories are packaged in different

ways depending on the product, quantity, and size. They should be unloaded in a
safe manner that will not cause damage.
Any protective covering of gaskets should remain until the pipe is ready for
installation; exposed gasket should be protected from dust and exposure to sunlight.
Extreme heat could affect the ovality or shape of some pipes. It is recommended that
products be rotated during storage to eliminate deflection.

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 REV 04

3) EXCAVATION, LAYING & BACKFILLING

As with all piping systems, FLOLINE 3-W pipes should be installed with the proper
selection of bedding and backfill material. Like all flexible pipes, the SERVICE
STRENGTH of FLOLINE 3-W is a function of both the pipe properties and the
characteristics of the backfill and loading on the pipe. The backfill envelope must
provide structural and drainage characteristics appropriate for the application.
Therefore, it is important that excavation & backfilling activities are carried out
properly to the given guidelines.

3a) TRENCH TERMINOLOGY

The trench is mainly made up of four different zones: Bedding, Haunching,

Initial Backfill and Final Backfill. The trench size depends on the pipe
diameter, backfill material and method of compaction. The trench should be wide
enough to place the pipe and install backfill around it. As a practical
consideration, standard excavator bucket sizes or trench box dimensions may
also factor in the decision.
If, during the course of excavation, the soil properties are not what were
expected as noted in the contract, the organisation responsible for design should
be informed.

For the purpose of guidance and in the absence of unusual conditions, the
following TABLE 1 can be used.

The pipe trench shall be dug to a width approximately 1 pipe diameter on

each side for pipe sizes up to 900mm and 1 meter on each side for pipe
sizes 1200mm and above. TABLE 1 shows the recommended trench width
and cover depths for the various pipe sizes.

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 REV 04

Trench Width Bedding Depth Overlay Depth

Size B (mm)* b (mm) e (mm)
300mm / 12” 900 100 150
450mm / 18” 1350 100 150
600mm / 24” 1800 100 150
750mm / 30” 2250 150 150
900mm / 36” 2700 150 150
1200mm / 48” 3200 150 300
1500mm / 60” 3500 150 300
1800mm / 72” 3800 150 300
2100mm / 84” 4100 200 350
2500mm / 96” 4500 200 350

Note: * Meet both minimum trench width by AASHTO Sec 30 and ASTM D2321.

TABLE 1 : Pipe Trench Parameters

For conditions with poor soils, increasing the minimum trench width to two times
the outside diameter of the pipe is recommended.

FIGURE 3 - Terminology of Buried FLOLINE 3-W Pipe & Trench

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 REV 04

• BEDDING
Uniformity of support and proper alignment of pipe require a trench bottom of
stable soil.
On the bottom of the trench, a 100 to 200mm thick bedding layer, depending on
the size of pipe (refer TABLE 1) shall be prepared, leveled and well compacted
(See Figure 4). The bedding soil shall be free from debris, coarse gravel or rocks.
The use of loose, granular material is recommended for bedding.
A foundation layer is required below the bedding ONLY IF the trench bottom is
not firm or stable to support the installed pipe. Under such conditions, the trench
may be required additional excavation to remove unsuitable materials such as
rock outcrop, very soft soil and replaced with suitable granular material. Trench
bottom may need wooden piles, concrete base or even geofabric migration
barriers to provide sufficient stability and load bearing capacity before the
bedding is laid.

FIGURE 4 - Proper Bedding Layer

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• HAUNCHING & INITIAL BACKFILL

The haunching zone extends from above the bedding layer until the pipe’s
horizontal centerline, covering the semicircular bottom half of the pipe (See
Figure 5). The haunching is the most important zone since it provides the primary
support for soil and traffic loading. Granular material without sharp particles shall
be used as haunching and initial backfill material.
Haunch material may be Class I, II or III, they must be compacted to a minimum
of 90 percent Standard Proctor. Void and haunch areas are to be handfilled when
Class IA materials are used.

FIGURE 5 (i) - Haunching (Compaction Done By Layers)

FIGURE 5 (ii) - Haunching Zone as Primary Support

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Compaction of the haunching material is carried out in layers of 150mm to

300mm using mechanical hand-held compactor. Larger, more angular backfill
materials can be placed in thicker layers than materials with smaller, rounder
particles. This should be done with care to prevent any movement of the pipe.
The side support zones on both sides of the pipe shall be fully filled (no voids)
and well compacted (See Figure 6).

FIGURE 6 - Haunching and Initial Backfill

The initial backfill material shall cover the whole width of the trench. It anchors the
pipe and ensures that loads are distributed as evenly as possible into the
haunching. Compaction procedures for the initial backfill layer should be the
same as for the haunching layer (See Figure 7).
Initial backfill extends a minimum of 150mm to 400mm (according to pipe size)
above the crown of pipe.
Class I, II, III and low plasticity Class, IV A material may be used. In practice, use
of Class IV A fine-grained, inorganic, low to medium plasticity materials (ML and
CL) is discouraged.
High plasticity clays and silts (Class IV B and Class V materials) are not
recommended for initial backfill. Class III materials are suitable only in dry trench
conditions.

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 REV 04

FIGURE 7 - Compaction of Initial Backfill Layer

The final layer of initial backfill shall extend over the pipe crown by 150mm to
400mm, depending on the size of pipe (refer tabulated overlay depth, e, in
TABLE 1). The overlay serves to protect the pipe and distribute loads from final
backfilling.

• FINAL BACKFILL
Most original excavated material can be used for final backfilling (See Figure 3).
The material shall be free from rocks, stumps and debris to avoid possibility of
any damage or concentrated loads during backfilling. However, should the pipe
be subjected to traffic loads, the excavated material must be carefully reviewed
for suitability.

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 REV 04

3b) EMBEDMENT MATERIAL

Under ASTM 2321, the material used for pipe embedment (or backfill envelope)
in a trench can be classified into five classes; depending on the type of soil
material, soil properties, particle size. The different degree of compaction and
density of each class of material will provide different levels of strength to
support the buried HDPE pipe.
Refer to TABLE 1 in APPENDIX A for the ASTM 2321 classification of
embedment material and TABLE 2 for their suitability of use at each different
backfill zones.

Below are minimum recommended embedment density by ASTM and AASHTO,

and however these recommended embedment density cannot be assumed
applicable for all projects. The responsible engineer should establish the
minimum density based on evaluation of specific project conditions.

ASTM recommends a minimum Standard Proctor density (based on average

modulus of soil reaction, E’ of 1000psi)
- 85% Standard Proctor for Class II and better soils
- 90% Standard Proctor for Class III soils
- 95% Stnadard Proctor for Class IV soils

AASHTO Section 30 recommends a minimum of

- 90% for all soil that meet their structural backfill requirements

3c) COMPACTION OF EMBEDMENT MATERIALS

Compaction serves to minimize air voids in the backfill material and increase
embedment density to improve its load carrying capability. Compaction should be
done with care so as not to contact and damage the pipe.
Compaction of the haunching zone should be done preferably by mechanical
hand-held compactor. If Class 1 material (crushed stones) is used without
compaction, the material should be hand-placed and then shoveled into the
haunches to fill it properly.
In the Initial Backfill zone, mechanical tampers (impact or vibratory
types), usually the most effective and practical methods, can ONLY be used
directly over the pipe after the required overlay depth (refer TABLE 1) has been
achieved over the pipe crown.

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 REV 04

Vibratory equipment is preferred for clean coarse-grained wash stone,

gravels and sands of Classes I and II.
Jumping jacks are walk-behind vibratory rollers suitable for most classes
of embedment and backfill materials, are generally used to provide the vibratory,
kneading and impact force needed for soils of fine materials and high plasticity.
During placement and compaction of the embedment side fill, care must
be taken to avoid elongation of the vertical diameter of the pipe in excess of the
manufacturer’s recommendation.

3d) WATER IN TRENCH

Dry trench conditions are a prerequisite for proper placement and embedment of
drainage pipe. Surface water draining towards the trench must be redirected. In
cases where the pipe is buried below the ground water table, the trench would be
waterlogged. The water should be continuously removed while the pipe is being
laid, the embedment placed and compacted, and until sufficient backfill is covered
over the pipe to anchor the pipe to prevent against floatation.

3e) PARALLEL PIPES IN COMMON TRENCH

When two or more pipes are laid parallel to each other in a trench, a minimum
spacing between adjacent pipes is needed to ensure proper soil compaction and
adequate soil support. The recommended spacing for parallel pipes is shown in
TABLE 2 below:

Nominal Diameter, D (in(mm)) Minimum Spacing (in(mm))

≤ 24 (600) 12 (300)

≥ 24 (600) D/2

TABLE 2: Minimum Spacing of Parallel Pipes in a Single Trench

Depending on the type of backfill, the compaction equipment and jointing

methods, these dimensions (TABLE 2) may need to be increased.

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 REV 04

3f) MINIMUM BURIAL DEPTHS

For shallow cover under traffic loading, FLOLINE 3-W pipes must be backfilled
and compacted to a certain minimum burial depth to avoid excessive deflection or
crushing/flattening. The pipe-soil system at the buried depth must be able
withstand the impact load of the vehicle going over the pipe.
Generally, if installed using good and proper backfill material (i.e. a
Backfill Soil Modulus, E’ > 6900kPa) and procedures, a minimum cover of
300mm is sufficient for FLOLINE 3-W pipes subjected to a 25-tonne (AASHTO H-
25) vehicle load.
Minimum burial depths for FLOLINE 3-W pipes can be calculated using
the deflection design formula for flexible pipes given in the DESIGN
CALCULATIONS FOR FLOLINE 3-W HDPE PROFILE PIPES manual. For the
AASHTO H-25 load, the minimum burial depth for FLOLINE 3-W pipes under
various soil & ground conditions is tabulated and shown in APPENDIX B.

3g) MAXIMUM BURIAL DEPTHS

The maximum burial depth is mainly dependent on soil & backfill conditions, as
live loads have negligible effects for depths exceeding 3 meters. Under very good
soil conditions, FLOLINE 3-W pipes can be even buried up to between 20 to 30
meters deep, depending on the pipe’s stiffness class. The limiting factor to
maximum burial depth is not its deflection limit, but the pipe’s resistance to
crushing under heavy soil.
The maximum burial depth for FLOLINE 3-W pipes under various soil &
ground conditions is also tabulated and shown in APPENDIX B.

3h) LOAD FROM CONSTRUCTION VEHICLES

Additional precautions may be required at job-sites where construction traffic in

excess of the design load will be present. Heavy construction vehicles can place
unanticipated loads on the pipe and cause structural problems if the pipe does
not have sufficient cover over it.
The traffic should be routed around the pipe. Otherwise, additional
compacted soil should be mounded over the pipe to create at least the greater
of one pipe diameter or 900mm of cover over the pipe crown for construction
vehicles to cross over.

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 REV 04

4) LAYING AND PIPE JOINTING METHODS

In most cases, pipes need to be joined at site for one of the following reasons;-
• To achieve the required lengths for their application
• To allow for a change in direction
• To allow extensions or repairs
• To allow for inspection & servicing (for large pipes only)

FLOLINE 3-W pipes can be joined by the following methods;

1. FLOLINE Push-In Couplers (for sizes up to 600mm)
2. Clamp-Joint with rubber sleeve or heat shrinkage sleeve (for all sizes)
3. Heat Shrinkage Joint (for all sizes) – To be done by qualified personnel
4. Extrusion Welding (for all sizes) – To be done by qualified personnel
Refer to APPENDIX C for details for installing each type of joint.

Unless otherwise specified, all joints of all drainage pipes are generally required to be
soil tight. Joints that will permit the transport of soil at any time during its service life
must be expected to cause problem related to erosion of invert and springline
support. The integrity of pipe/soil composite structure risks being severely
compromised.

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 REV 04

5) CUTTING PIPE AT SITE

FLOLINE 3-W pipes can be easily cut to length and trimmed using any of the
following tools:
• Jigsaw
• Hacksaw
• Circular Saw
• Grinders

FIGURE 8 - Cutting of FLOLINE 3-W Pipes Using Chainsaw

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 REV 04

6) BENDING OF PIPES

FLOLINE 3-W pipes can accommodate small misalignment by bending. Under

normal conditions, the minimum bending radius should be 200 times the nominal
outside diameter of the pipe (i.e. maximum of approximate 1.5 degrees measured
from the pipe’s neutral axis) to avoid over-stressing the pipe.

TABLE 3 : Minimum Bending Radius for FLOLINE 3-W pipes

Pipe Size
300 450 600 750 900 1200 1500 1800 2100 2500
(mm)
Min. Bending
68 102 136 169 203 270 338 404 468 564
radius (m)

FIGURE 9 - Bending of Pipe

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 REV 04

7) ABOVE GROUND INSTALLATIONS

For applications where FLOLINE 3-W pipes are suspended above ground, they must
be properly and adequately supported to perform satisfactorily. The pipe will sag
excessively over time if the supports are spaced too far from each other. The
maximum span/distance between two supports for each pipe size is given in TABLE
4 below.

TABLE 4: Maximum Support Span for FLOLINE 3-W pipes

Pipe Size
300 450 600 750 900 1200 1500 1800 2100 2500
(mm)
Max. Support
1.8 2.4 2.7 3.0 3.2 3.6 3.6 3.6 3.6 3.6
Span (m)

3
Note : Liquid Density = 1000kg/m
Average Pipe Temperature = 40°C

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 REV 04

APPENDIX A
Embedment and Backfill Materials

19

TABLE 1 : Classes of Embedment and Backfill Materials, as per ASTM D2321
Class Type
Manufactured Aggregates
IA that are open-graded and
clean
Manufactured, Processed
IB Aggregates that are
dense-graded and clean
Coarse-grained soils,
clean
II
Coarse-Grained Soils,
borderline clean to w/fines
REV 04
Soil
Percentage Passing
Symbol Description Atterberg Limits Coefficients
Sieve Sizes
Group
Angular, crushed stone or rock, crushed
gravel, broken coral, crushed slag, 1 ½” (40 mm): 100
None cinders, or shells; large void content, #4 (4.75mm): ≤10
contains little or no fines. #200 (0.075mm): <5
LL: Non-Plastic
PI : Non-Plastic
Class IA materials or stone/sand mixtures 1 ½” (40 mm): 100
with gradations selected to minimize
None #4 (4.75mm): ≤50
migration of adjacent soils; contains little
#200 (0.075 mm): <5
or no fines.
Well-grated gravels and gravel-sand 1 ½” (40 mm): 100
Uniformity (Cu):>4
GW mixtures; little to no fines #4 (4.75mm): <50 of
Curvature (Cc): 1 to 3
material retained on a
Poorly-graded gravels and gravel-sand #200 sieve
Uniformity (Cu): <4
GP mixtures; little or no fines #200 (0.075mm): <5
Curvature (Cc): <1 or >3
Well-graded sands and gravelly sands;
1 ½” (40mm):100 Uniformity (Cu):>6
SW little or no fines
#4 (4.75mm):>50 of Curvature (Cc): 1 to 3
material retained on a
Poorly-graded sands and gravelly sands; LL: Non-Plastic
#200 sieve Uniformity (Cu):<6
SP little or no fines
#200 (0.075 mm): <5 PI : Non-Plastic Curvature (Cc): <1 or >3
Sands, gravels borderline between clean
1 ½” (40 mm):100
and w/fines
#4 (4.75mm): varies
e.g. #200 (0.075mm): 5-12
GW- Same as for GW, GP,
GC, SP- SW, and SP
SM
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 REV 04

Soil
Percentage Passing
Class Type Symbol Description Atterberg Limits Coefficients
Sieve Sizes
Group
Silty gravels, gravel-sand-silt mixtures 1 ½” (40 mm): 100 LL: -
GM
#4 (4.75mm): <50 of PI : <4 or < “A” line
material retained on a
Clayey gravels, gravel-sand-clay mixtures #200 sieve LL: -
GC
#200 (0.075 mm): 12-50 PI:<7 and > “A” line
Coarse-Grained Soils with
III Silty sands, sand-silt mixtures
Fines LL: -
SM 1 ½” (40 mm): 100
PI : >4 or < “A” line
#4 (4.75mm): >50 of
material retained on a
Clayey sands, sand-clay mixtures #200 sieve LL: -
SC
#200 (0.075 mm): 12-50 PI:>7 and > “A” line

Inorganic silts and very fine sands, rock

flour, silty or clayey fine sands, silts with LL: <50
ML
slight plasticity PI : <4 or < “A” line
Fine-Grained Soils
IVA 1 ½” (40 MM): 100
(inorganic) Inorganic clays of low to medium
#4 (4.75mm): 100
plasticity, gravely clays, sandy clays, silty LL: <50
CL #200 (0.075mm): >50
clays, lean clays PI:>7 and > “A” line

Inorganic silts, micaceous or

diatomaceous fine sandy or silty soils, LL:>50
MH
Fine-Grained Soils elastic soils 1 ½” (40 mm): 100 PI : < “A” line
IVB
(inorganic) #4 (4.75mm): 100
Inorganic clays of high plasticity, fat clays #200 (0.075mm): >50 LL : >50
CH
PI : > “A” line
Organic silts and organic silty clays of low LL: <50
OL
plasticity PI : <4 or < “A” line
Organic Soils Organic clays of medium to high plasticity, 1 ½” (40 mm): 100
V OH organic silts #4 (4.75mm): 100 LL: >50
#200 (0.075mm): >50 PI : > “A” line
Peat and other high organic soils
Highly Organic Soils PT

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TABLE 2 : Recommendations for Installation and Use of Soils and Aggregates, per ASTM D2321

Class IA Class IB Class II Class III Class IVA Class IVB

Do not use where Process materials as Where hydraulic Do not use where water Obtain geotechnical
conditions may cause required to obtain gradient exists check conditions in trench may evaluation of proposed
General migration of fines from gradation which will gradation to minimize cause instability. material. May not be Not
Recommendations adjacent soil and loss minimize migration of migration. “Clean” suitable under high earth recommended.
and Restrictions of, pipe support. adjacent materials. groups suitable for fills, surface applied wheel
Suitable for use as a Suitable for use as use as drainage loads, and under heavy
drainage blanket and drainage blanket and blanket and vibratory compactors and
underdrain in rock cuts underdrain. underdrain. tampers. Do not use
where adjacent where water conditions in
material is suitably trench may cause
graded. instability.

Suitable. Also for Suitable. Also for Suitable. Also for Suitable. Also for Suitable only in
replacing over- replacing over- replacing over- replacing over- undisturbed condition and
Foundation excavated and excavated and excavated and excavated and unstable where trench is dry. Not
unstable trench bottom unstable trench unstable trench trench bottom as Remove all loose material recommended.
as restricted above. bottom. Install and bottom as restricted restricted above. Do and provide firm, uniform
Install and compact in compact in 6” above. Install and not use in thicknesses trench bottom before
6” maximum layers. maximum layers. compact in 6” greater than 12” overall. bedding is placed.
maximum layers. Install and compact in
6” maximum layers.

Suitable as restricted Install and compact in Suitable as restricted Suitable only in dry Suitable only in dry trench
above. Install in 6” 6” maximum layers. above. Install and trench conditions. conditions and when Not
Bedding maximum layers. Level final grade by compact in 6” Install and compact in optimum placement and recommended.
Level final grade by hand. Minimum depth maximum layers. 6” maximum layers. compaction are
hand. Minimum depth 4” (6” in rock cuts). Level final grade by Level final grade by maintained. Install and
4” (6” in rock cuts). hand. Minimum hand. Minimum depth compact in 6” maximum
depth 4” (6” in rock 4” (6” in rock cuts). layers. Level final grade
cuts). by hand. Minimum depth
4” (6” in rock cuts).

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 REV 04

Class IA Class IB Class II Class III Class IVA Class IVB

Suitable as restricted Install and compact in Suitable as restricted Suitable as restricted Suitable only in dry trench
above. Install in 6” 6” maximum layers. above. Install and above. Install and conditions and when
Haunching maximum layers. Work in around pipe by compact in 6” compact in 6” maximum optimum placement and
Work in around pipe by hand to provide maximum layers. layers. Work in around compaction are Not
hand to provide uniform support. Work in around pipe pipe by hand to provide maintained. Install and recommended.
uniform support. by hand to provide uniform support. compact in 6” maximum
uniform support. layers. Work in around
pipe by hand to provide
uniform support.

Suitable as restricted Install and compact to Suitable as restricted Suitable as restricted Suitable as restricted
Initial Backfill above. Install to a a minimum of 6” above above. Install and above. Install and above. Install and Not
minimum of 6" above pipe crown. compact to a compact to a minimum compact to a minimum of recommended.
pipe crown. minimum of 6” above of 6” above pipe crown. 6” above pipe crown.
pipe crown.

Place and work by Minimum density 85% Minimum density 85% Minimum density 90% Minimum density 95%
hand to insure all Standard Proctor. Use Standard Proctor. Standard Proctor. Use Standard Proctor. Use
Embedment excavated voids and hand tampers or Use hand tampers or hand tampers or hand tampers or impact Not
Compaction haunch areas are vibratory compactors. vibratory compactors. vibratory compactors. tampers. Maintain recommended.
filled. For high Maintain moisture moisture content near
densities use vibratory content near optimum to optimum to minimize
compactors. minimize compactive compactive effort.
effort.

Final Backfill Compact as required Compact as required Compact as required Compact as required by Suitable as restricted Not
by the Engineer. by the Engineer. by the Engineer. the Engineer. above. Compact as recommended.
required by the Engineer.

Notes:
1. Class IVB and V Materials are unsuitable as embedment. They may be used as final backfill as allowed by the engineer
2. Avoid contact with the pipe when using mechanical compactors. When compacting over pipe crown maintain a minimum of 6” cover when using small mechanical
compactors. When using larger mechanical compactors maintain minimum clearances as required by the Engineer.
3. The minimum densities given in the table are intended as the compaction requirements for obtaining satisfactory embedment stiffness in most installation conditions

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APPENDIX B
Burial Depths and Technical
Specifications

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 REV 04

RECOMMENDED LIMITS FOR BURIAL DEPTH – FLOLINE 3-W C4000

Modulus AASHTO H-25 TRAFFIC

Minimum Degree of of Soil Rigid Pavement* Unpaved Roads**
Material Class 1 Embedment Material (Soil Type)
Compaction2 Reaction Minimum Maximum Minimum Maximum
Burial Burial Burial Burial
E' (kPa)
Depth (m) Depth (m) Depth (m) Depth (m)
Crushed Rocks (Stones & DUMPED 6900 0.3 12.0 1.5 12.0
I
Gravel) SLIGHT - HIGH 20700 0.3 17.0 0.5 17.0
DUMPED 1350 NR NR NR NR
Coarse-grained Soils with Little
SLIGHT 6900 0.3 12.0 1.5 12.0
II or No Fines (Gravel, Coarse
MODERATE 13800 0.3 15.0 0.5 15.0
Sands)
HIGH 20700 0.3 17.0 0.5 17.0
DUMPED 675 NR NR NR NR
Coarse-grained Soils with Fines
SLIGHT 2700 0.6 11.0 3 11.0
III (Silty / Clayey Gravel and
MODERATE 6900 0.3 12.0 1.5 12.0
Coarse Sands or mixture)
HIGH 13800 0.3 15.0 0.5 15.0
DUMPED 338 NR NR NR NR
Fine-grained Soil (LL<50) (Fine
SLIGHT 1350 NR NR NR NR
IV Inorganic Clay / Silts or
MODERATE 2700 0.6 11.0 3 11.0
mixture)
HIGH 6900 0.3 12.0 1.5 12.0
Fine-grained Soil (LL>50)
V ANY 0 NR NR NR NR
(Organic Silts & Clay, Peat)

25
 REV 04

RECOMMENDED LIMITS FOR BURIAL DEPTH – FLOLINE 3-W C2000

Modulus AASHTO H-25 TRAFFIC

Minimum Degree of of Soil Rigid Pavement* Unpaved Roads**
Material Class 1 Embedment Material (Soil Type) Minimum Maximum Minimum Maximum
Compaction2 Reaction
Burial Burial Burial Burial
E' (kPa)
Depth (m) Depth (m) Depth (m) Depth (m)
Crushed Rocks (Stones & DUMPED 6900 0.3 9.0 1.5 9.0
I
Gravel) SLIGHT - HIGH 20700 0.3 14.0 0.5 14.0
DUMPED 1350 NR NR NR NR
Coarse-grained Soils with Little
SLIGHT 6900 0.3 9.0 1.5 9.0
II or No Fines (Gravel, Coarse
MODERATE 13800 0.3 12.0 0.5 12.0
Sands)
HIGH 20700 0.3 14.0 0.5 14.0
DUMPED 675 NR NR NR NR
Coarse-grained Soils with Fines
SLIGHT 2700 2.4 8.0 3 8.0
III (Silty / Clayey Gravel and
MODERATE 6900 0.3 9.0 1.5 9.0
Coarse Sands or mixture)
HIGH 13800 0.3 12.0 0.5 12.0
DUMPED 338 NR NR NR NR
Fine-grained Soil (LL<50) (Fine
SLIGHT 1350 NR NR NR NR
IV Inorganic Clay / Silts or
MODERATE 2700 2.4 8.0 3 8.0
mixture)
HIGH 6900 0.3 9.0 1.5 9.0
Fine-grained Soil (LL>50)
V ANY 0 NR NR NR NR
(Organic Silts & Clay, Peat)

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RECOMMENDED LIMITS FOR BURIAL DEPTH – FLOLINE 3-W C1000

Modulus AASHTO H-25 TRAFFIC

Minimum Degree of of Soil Rigid Pavement* Unpaved Roads**
Material Class 1 Embedment Material (Soil Type) Minimum Maximum Minimum Maximum
Compaction2 Reaction
Burial Burial Burial Burial
E' (kPa)
Depth (m) Depth (m) Depth (m) Depth (m)
Crushed Rocks (Stones & DUMPED 6900 0.3 9.0 1.5 9.0
I
Gravel) SLIGHT - HIGH 20700 0.3 13.0 0.5 13.0
DUMPED 1350 NR NR NR NR
Coarse-grained Soils with Little
SLIGHT 6900 0.3 9.0 1.5 9.0
II or No Fines (Gravel, Coarse
MODERATE 13800 0.3 11.0 0.5 11.0
Sands)
HIGH 20700 0.3 13.0 0.5 13.0
DUMPED 675 NR NR NR NR
Coarse-grained Soils with Fines
SLIGHT 2700 2.4 7.0 3 7.0
III (Silty / Clayey Gravel and
MODERATE 6900 0.3 9.0 1.5 9.0
Coarse Sands or mixture)
HIGH 13800 0.3 11.0 0.5 11.0
DUMPED 338 NR NR NR NR
Fine-grained Soil (LL<50) (Fine
SLIGHT 1350 NR NR NR NR
IV Inorganic Clay / Silts or
MODERATE 2700 2.4 7.0 3 7.0
mixture)
HIGH 6900 0.3 9.0 1.5 9.0
Fine-grained Soil (LL>50)
V ANY 0 NR NR NR NR
(Organic Silts & Clay, Peat)

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NOTES:
1. Refer to TABLE 1 in APPENDIX A for definition
2. Degree of Compaction
• DUMPED refers to uncompacted soil
• SLIGHT refers to soil with maximum 85% Standard Proctor and maximum 40% Relative Density
• MODERATE refers to soil with between 85 – 95% Standard Proctor and between 40 - 70% Relative Density
• HIGH refers to soil with more than 95% Standard Proctor and exceeding 70% Relative Density
( Refer to ASTM 648 and ASTM 2049 for definition of Percent Proctor and relative density)

3. AASHTO H-25 Load represents a 25-ton Highway Semi-Truck with a 18,140kg axle load
4. Paved roads refer to either 12” thick rigid (concrete) or flexible (bituminous) pavements. For rigid pavement, the Burial Depth is measure
from pipe crown to the top of the pavement. For flexible pavement, the Burial Depth is measure from pipe crown to the bottom of the
pavement.
5. Assumed embedment Soil Density of 1900 kg/m3
6. NR – NOT RECOMMENDED FOR USE
7. It is recommended that embedment soil material should always have an E’ value of 6900 kPa and above where possible for all buried
applications

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L e n g th , L

ØOD
ØID
D E T A IL "A "
D E T A IL " A "
( P r o f ile S e c t io n )

FLOLINE 3-W TYPE C4000 PIPES

Nominal Internal Minimum Maximum Approximate Minimum
2
Diameter Designation Diameter, Internal Internal Outer Length Pipe
(mm) ID (mm) Diameter Diameter Diameter Stiffness, PS
1 1 2 3
(mm) (mm) OD (mm) (kg/cm )
300 (12") C4000 300 292 304 338
450 (18") C4000 450 439 457 508
600 (24") C4000 600 585 609 678 To Any 4
Transportable
750 (30") C4000 750 732 760 844 Length (392kPa)

900 (36") C4000 900 877 913 1012

1200 (48”) C4000 1200 1170 1218 1350
1500 (60”) C4000 1500 1462 1522 1690
1800 (72”) C4000 1800 1755 1827 2060
2100 (84”) C4000 2100 2050 2130 2360
2500 (96”) C4000 2500 2437 2537 2760

1 – Pipe diameter specification to DIN 16961

2 – Non Standard length are available subject to transportation and site access
3 – Pipe stiffness are tested to ASTM D2412 at 5% diametrical deflection

Notes: Data may change from time to time.

29
 REV 04

L e n g th , L

ØOD

ØID
D E T A IL " A "
D E T A IL " A "
( P r o f ile S e c t io n )

FLOLINE 3-W TYPE C2000 PIPES

Nominal Internal Minimum Maximum Approximate Minimum
2
Diameter Designation Diameter, Internal Internal Outer Length Pipe
(mm) ID (mm) Diameter Diameter Diameter Stiffness, PS
1 1 2 3
(mm) (mm) OD (mm) (kg/cm )
300 (12") C2000 300 292 304 338
450 (18") C2000 450 439 457 508
600 (24") C2000 600 585 609 678 To Any 2
Transportable
750 (30") C2000 750 732 760 844 Length (196kPa)

900 (36") C2000 900 877 913 1012

1200 (48”) C2000 1200 1170 1218 1350
1500 (60”) C2000 1500 1462 1522 1690
1800 (72”) C2000 1800 1755 1827 2040
2100 (84”) C2000 2100 2050 2130 2360
2500 (96") C2000 2500 2437 2537 2760

1 – Pipe diameter specification to DIN 16961

2 – Non Standard length are available subject to transportation and site access
3 – Pipe stiffness are tested to ASTM D2412 at 5% diametrical deflection

Notes: Data may change from time to time.

30
 REV 04

L e n g th , L

ØOD

ØID
D E T A IL " A "
D E T A IL " A "
( P r o f ile S e c t io n )

FLOLINE 3-W TYPE C1000 PIPES

Nominal Internal Minimum Maximum Approximate Minimum
2
Diameter Designation Diameter, Internal Internal Outer Length Pipe
(mm) ID (mm) Diameter Diameter Diameter Stiffness, PS
1 1 2 3
(mm) (mm) OD (mm) (kg/cm )
300 (12") C1000 300 292 304 328
450 (18") C1000 450 439 457 488
600 (24") C1000 600 585 609 658 To Any 1
Transportable
750 (30") C1000 750 732 760 828 Length (98kPa)

900 (36") C1000 900 877 913 994

1200 (48”) C1000 1200 1170 1218 1312
1500 (60”) C1000 1500 1462 1522 1650
1800 (72”) C1000 1800 1755 1827 1990
2100 (84”) C1000 2100 2050 2130 2340
2500 (96") C1000 2500 2437 2537 2760

1 – Pipe diameter specification to DIN 16961

2 – Non Standard length are available subject to transportation and site access
3 – Pipe stiffness are tested to ASTM D2412 at 5% diametrical deflection

Notes: Data may change from time to time.

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APPENDIX C
Pipe Jointings

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PIPE JOINTING METHODS AND PROCEDURES:

A. Clamp-Joint
Made from either galvanized steel or stainless steel, clamp joints or split couplers
are clamped over the external perimeter of the pipe joint. For large-sized (typically
750mm and larger) and long pipes where push-in or weld jointing is difficult, clamp-
joints are more convenient.
They provide structural support to the joint and seal the joint when they are
lined internally with a layer of flexible rubber sleeve gasket. The sleeve shall wrap
around the joint between two culverts, and the clamp shall be fastened over the
sleeve to ensure proper coupling alignment. For sewer pipe applications, they are
installed over the heat shrinkage sleeve to reinforce the joint (refer to Heat Shrinkage
Joint).
Before a clamp can be installed over the joint, two pipe ends need to be
rotated with both profile ends meeting each other. The clamp-joint is then loosely
slipped over one end of the pipe before the two pipe ends are aligned in place and
mated together. The clamp is positioned over the joint and the bolts and nuts
tightened.

FIGURE 11 – Installation of FLOLINE Clamp-joint

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Installation procedure:

1. Prepare the following items for jointing:

• Galvanized/Stainless Steel Clamp Coupler (3mm thick) attached with Rubber
Sleeve
• Galvanized/Stainless Steel Bolts & Nuts
• Torque Wrench or Ratchet Wrench
2. Clear the soil around the pipe-end to be joined. The exposed pipe–end should be
at least 1 meter long in order for jointing to be done.
3. Ensure that the external face at the pipe-end is clean, smooth and free from any
defects. Sand, oil and other foreign matter should be removed.
4. Slip in the clamp coupler (the tightening bolts on the coupler must be loosened
first). DO NOT USE ANY LUBRICANT.
5. Hoist down & position the second pipe in the trench and align the pipe-ends
together, with a maximum separation gap of 20mm at the joint. Hold the pipe in
position
6. Shift the coupler over the joint such that center of coupler is positioned at the
joint.
7. Start tightening the bolts of the coupler in sequence. The coupler will gradually
grip onto the sleeve and hold the joint. The torque required on all bolts is 50 Nm.
(Refer Figure 12)
8. Drill hole through the pipe following position indicated on the coupler. Tighten the
bolts and nuts to join both the FLOLINE pipes and coupler together. (Refer Figure
11)

FIGURE 12 - FLOLINE Clamp-joint

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Clamp Joint Sizes:

Size and Type 'A' Width (mm) 'B' Nos of Bolts & Nuts

C1000 ,
450 mm 300
C2000 & C4000
C1000 ,
600 mm
C2000 & C4000
450 8 x M16
C1000 ,
750 mm
C2000 & C4000
C1000 ,
900 mm 600
C2000 & C4000
C1000 ,
1200 mm
C2000 & C4000
800 12 x M16
C1000 ,
1500 mm
C2000 & C4000
C1000 ,
1800 mm
C2000 & C4000
1000
C1000 ,
2100 mm 16 x M20
C2000 & C4000
C1000 ,
2500 mm 1200
C2000 & C4000

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B. Extrusion Welding

Extrusion welding is normally used for large diameter pipes (750mm & above).
However, they can also be done on the smaller sizes, but welding can be done at the
joint from outside only. To ensure that welds are homogeneous and well-fused,
all extrusion welding activities must be performed only by skilled personnel.
(Please contact supplier for this services)
Before welding can be done, both ends of the pipe must be chamfered such
that when the pipes are aligned together, the joint area would form a wedge gap all
around the pipe. Using an extruder-gun, hot, molten HDPE material is then injected
and pressed into the wedge to fill the gap and fuse with the pipes. The welding is
done all around the pipe circumference.
The jointing of pipes using this process must be done above ground as it is
not possible to be done in a narrow trench. After the pipes are joined, they are then
rolled in or hoisted into the trench for backfilling and compaction.

FIGURE 13 - Extrusion Welding of FLOLINE Pipes

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C. Heat Shrinkage Joint

The heat shrink sleeve is a radiation cross-linked high density polyethylene sheet
with an internal layer of visco-elastic low-preheat adhesive sealant. The sleeve is
slipped over the pipe joint and when heat is applied, the sleeve contracts to form a
tight fit around the joint covering and
sealing it. This process can be used to join pipes of dissimilar material. The process
is similar to jointing of cables.
The permanently cross-linked outer layer forms a tough barrier against
mechanical damage. Further reinforcement can be achieved by installing a clamp
coupler around it. This method is suitable for use on large diameter pipes.
The jointing procedure should be done by trained personnel only.

FIGURE 14 - Heat Shrinkage Joint of FLOLINE 3-W Pipes

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APPENDIX D
Possible Defects During
Handling and Transportation

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Delivery of FLOLINE 3-W pipes are inspected thoroughly at the factory prior to the
shipment. In some cases, the transporter or representative of the owner may also
have inspected the pipes.
However, all of the FLOLINE 3-W pipes received at site should undergone inspection
for potential damage that may have caused during transportation or handling. Critical
damage may happen to the pipe or fittings which may render it as unsuitable for
usage. During inspection, checks should be conducted for the following potential
defects as follow:-

Any gouges or sharp cuts on either the inside or outside

surface of the pipe which is greater than 10% of the inner or
outer wall thickness, may affect the serviceability of the
Gouges or Cuts pipe. Minor scuffing or scratching does not reduce the
serviceability of FLOLINE 3-W. Gouges or sharp cuts that
are greater than 10% of the inner or outer wall may be
repaired if the extent is limited.

FLOLINE 3-W will deflect slightly under its’ weight when

stored, or will deflect if stored in bundles of several layers.
This deflection or ovalizing of the pipe should not exceed
3%. If the ovality of the pipe exceeds this limit, the pipe
Ovality or
should be isolated and stored with the long dimension in a
Pipe Deflection
vertical position to allow the pipe to relax and return to a
round condition, prior to the installation. Alternatively, the
pipe ends can be aligned with jacks or other equipment prior
to welding.

The outer pipe wall may puncture if the pipe is subjected to

Pipe Wall point loading. Examine the pipe to ensure that point loads
Perforation have not caused perforation of the outer wall. Wall
punctures can be repaired.

The profile closure consists of HDPE plate welded on all

four (4) sides to the profile termination. Check to confirm
Profile Closure
that the closure plate has not been damaged in transit.
Transit damage can be repaired.

Any discrepancies in product quality should be noted on the Bill of Lading (BL) prior
to accepting the goods by signing the BL. Please contact FLOLINE 3-W supplier to
resolve discrepancies in time.

39