cladding& fitting

8/7/2019 cladding& fitting

1/56

FLEXIBLE CLOSED CELL

PIPE COVERING

M.W.BARVE LECTURE NOTES


2/56

FIELD AND FACTORY-APPLIED

NON-METAL JACKETING

1 PRE-FORMED PIPE INSULATION2 VAPOUR BARRIER ADHESIVE

(NOT REQUIRED WITH SELF-SEAL LAP)3 STAPLES COATES WITH VAPOUR BARRIER COATING

(NOT REQUIRED WITH SELF-SEAL LAP)4 INSULATION FASTENING

(NOT REQUIRED WITH FACTORY APPLIED JACKET)

5 BUTT STRIP SECURED WITH VAPOUR BARRIER ADHESIVE OR SESEAL



3/56

FIELD-APPLIED

METAL JACKET

1 PRE-FORMED PIPE INSULATION2 INSULATION FASTENING3 JACKET OVERLAPPED (POSITION TO SHED WATER)4 JACKET FASTENING OR5 JACKET FASTENING



4/56

STANDARD SPLIT RING

HANGERS

1 PRE-FORMED PIPE INSULATION

2 INSULATION FACTORY JACKET

3 BUTT STRIP

4 INSULATION NEATLY UT TO ACCOMMODATE

HANGER

5 INSULATION ON HANGER ROD


file:///C|/Documents%20and%20Settings/Administrator/Desktop/INSULATION%20&%20CLADDING%20-figers.pdf


5/56

CLEVIS HANGER

HIGH DENSITY INSERTS

1 PRE-FORMED PIPE INSULATION2 HINGH DENSITY INSULATION

(EXTEND 50mm BEYOND ENDS OF SHIELD)3 FACTORY APPLIED VAPOUR BARRIER

4 FINISH JACKET (METAL SHOWN)5 METAL SHIELD (SUPPLIED BY OTHERS)




6/56

PIPE SHOE

ON ROLLER SUPPORT

1 PRE-FORMED PIPE INSULATION2 INSULATION FASTENING IF NOT FACTORY

JACKET3 FINISH JACKET (METAL SHOWN)4 PIPE SHOE SUPPLIED AND INSTALLED BY

OTHERS5 INSULATION IN PIPE SHOE CAVITY




7/56

TRACED PIPING

1. TUBING TRACER (BY OTHERS)2. PRE-FORMED PIPE INSULATION (FACTORY JACKET)3. HEAT TRANSFER COMPOUND (OPTIONAL)4. HEAT TRANSFER COMPOUND CHANNEL

(OPTIONAL)5. BANDING SECURING CHANNEL TO PIPE6. MULTIPLE TUBING TRACER (BY OTHERS)7. ELECTRIC CABLE OR TAPE TRACER (BY OTHERS)




8/56


9/56

PRE-FORMED ELBOW INSULATION

1. PRE-FORMED PIPE INSULATION (SHOWN WITH METALJACKET)

2. PRE-FORMED FITTING COVER

3. BANDING OR SCRES TO SECURE FITTING COVER



10/56

MITRED INSULATION ELBOW

OVERSIZE APPLICATION

1. PRE-FORMED INSULATION2. MITRED SEGMENTS OF PIPE INSULATION3. FINISH JACKET4. WIRE OR BANDING5. FITTING COVER

(METAL CORE TYPE SHOWN)6. FASTENING (SCREWS OR POP REVETS)



11/56

PVC / GLASS FIBRE ELBOW

INSULATION SYSTEM

1 PRE-FORMED PIPE INSULATION WITH FACTORY JACKET

2 COLLAR OF OVER-SIZED PIPE INSULATION

3 FLEXIBLE INSULATION INSERT

4 PVC FITTING COVER SECURED WITH SERRATED

FASTENERS

5 VAPOUR BARRIER END CAP

6 PVC FITTING COVER

7 VAPOUR BARRIER TAPE OR ADHESIVE



12/56

FIELD OR FACTORY FABRICATED

VALVE INSULATION

1 PRE-FORMED PIPE INSULATION WITH METAL JACKET

2 COLLAR OF PIPE INSULATION SIZED TO CLEARFLANGES

3 COLLAR OF PIPE INSULATION SIZED TO CLEARVALVE BODY

4 COLLAR OF PIPE INSULATION SIZED TO COVERBONNET (OPTIONAL)

5 COVER OF RIGID INSULATION OF BONNETINSULATED

6 INSULATION ADHESIVE AT JOINTS7 FLEXIBLE INSULATION FILL (OPTIONAL)8 CAULKING ON OUTDOOR INSTALLATIONS

9 METAL JACKET MATERIAL COVER



13/56

PVC / GLASS FIBRE

VALVE INSULATION

1 PRE-FORMED PIPE INSULATION2 OVER-SIZED PIPE INSULATION COLLAR3 FLEXIBLE INSULATION INSERT4 PVC COVER (SEAM SECURED WITH SERRATED TACKS,

ADHESIVE OR TAPE)5 END COVER

6 CAULKING TO SEAL



14/56

IN-LINE FLANGE INSULATION

BUILT-UP AND BEVELLED

1 PRE-FORMED PIPE INSULATION WITH FACTORY JACKET2 PRE-FORMED PIPE INSULATION WITH METAL JACKET3 COLLAR OF OVER-SIZED PIPE INSULATION4 SLEEVE OF OVER-SIZED PIPE INSULATION5 FLEXIBLE INSULATION (OPTIONAL)6 FABRICATED COVER7 CAULKING8 PIPE INSULATION (BEVELLED)9 BARRIER COATING INDOORS / WEATHER COATING

OUTDOORS



15/56


16/56

FLEXIBLE DUCT INSULATION

ON RECTANGULAR DUCTS INDOORS

1 FLEXIBLE DUCT INSULATION WITH VAPOUR BARRIER

2 JOINTS LAPPED AND STAPLED; SEAL WITH VAPOUR

BARRIER ADHESIVE OR VAPOUR BARRIERE TAPE

3 MECHANICAL FASTENERS

4 VAPOUR BARRIER TAPE ON BREAKS & PENETRATIONS

OF VAPOUR BARRIER

2* & 4* VAPOUR BARRIER TAPE OR SEAL NOT REQUIRED ON

HOT DUCTS



17/56

RIGID DUCT INSULATION ON RECTANGULAR

EXPOSED DUCTS INDOORS

1 RIGID DUCT INSULATION


3 VAPOUR BARRIER TAPE ON JOINTS, BREAKS AND

PENETRATIONS

4 CANVAS FINISH JACKET APPLIED WITH LAGGING

ADHESIVE

5 METAL CORNER BEAD



18/56

HIGH TEMPERATURE

BLOCK OR BOARD

INSULATION

BREECHINGS,

FLUES AND KITCHEN

EXHAUST DUCTS

1 RIGID BLOCK INSULATION (JOINTS STAGGERED)2 METAL MESH OVER STIFFENERS (BY OTHERS)3 STIFFENER OR FLANGED CONNECTION4 MECHANICAL FASTENERS OR BANDING TO SECURE

INSULATION5 METAL JACKET FINISH

6 RIGID BOARD INSULATION7 METAL CORNER BEAD8 REINFORCEDMESH EMBEDDED IN INSULATION CEMENT

AND CANVAS FINISH JACKET APPLIED WITH LAGGINGADHESIVE



19/56

VESSEL BOTTOM HEAD,

LEG, SKIRT INSULATION

AND SECUREMENT

1 VESSEL, INSULATION AND JACKET2 FIREPROOFING (BY OTHERS, IF REQUIRED)3 MECHANICAL FASTENERS4 TIE WIRES5 REINFORCING WIRE MESH & INSULATING CEMENT

6 INSULATION SUPPORT RING (BY OTHERS)



20/56

PIPE AND TUVE EXCHANGERS ENCASED

1 PIPE INSULATION SECURED WITH BANDING2 BLOCK INSULATION SECURED WITH BANDING3 FINISH JACKET (METAL SHOWN SECURED WITH

BANDING)4 SHEET METAL SCREWS5 BEVEL INSULATION AND FINISH WITH COATING6 BLOCK INSULATION AND FINISH WITH COATING



21/56

LARGE DIAMETER

VERTICAL VESSELS

BLOCK AND BLANKET

INSULATION

1 SUPPORT RING FORHEAD INSULATION

2 BLOCK OR BLANKETINSULATION

3 MECHANICALFASTENERS OR

4 BANDING TO SCUREINSULATION

5 SUPPORT RING (BYOTHERS)

6 METAL JACKET7 SHEET METAL SCREWS8 BANDING9 BLOCK INSULATION

MITRED TO FIT10 FABRICATED HEAD COVER11 METAL FLASHING12 BOTTOM HEAD INSULATION13 VESSEL SKIRT



22/56

LARGE DIAMETER HORIZONTAL VESSELS

INSULATION SUPPORT AND SECUREMENT

1 RIGID INSULATION

2 BANDING SUPPORT BARS

3 BANDING

4 FINISH JACKET SECURED WITH BANDING OR

SCREWS

5 HEAD COVER



23/56

FLEXIBLE CLOSEDCELL SHEETS

1 INSULATION ADHESIVE (CONTACT TYPE)2 FLEXIBLE CLOSED CELL INSULATION (CUT TO FIT

TIGHTLY)3 JOINTS SEALED WITH CONTACT TYPE ADHESIVE4 LEGS & PROTRUSIONS INSULATED (OPTIONAL)

5 PROTECTIVE COATING WHERE REQUIRED



24/56

EXTREME TEMPERATURE VESSELS

BLOCK INSULATION

1 FLEXIBLE INSULATION2 INSULATION JOINTS STAGGERED3 FINISH JACKET (METAL SHOWN)4 BANDING5 INSULATION ATTACHMENT FOR HEAD

6 FABRICATED HEAD COVER7 CLOSED CELL INSULATION FOR FIRST 300mm



25/56

SMALL DIAMETER VESSELS / EXHAUST

PIPE COVERING

1 INSULATION SUPPORT RING (BY OTHERS)2 PIPE INSULATION SECURED WITH BANDS OR WIRE3 RIGID INSULATION CUT TO FIT4 FLEXIBLE INSULATION FILLER5 FINISH JACKET (METAL SHOWN)6 SHEET METAL SCRES OR POP RIVETS7 BANDING AS REQUIRED8 BEVEL INSULATION FOR BOLT REMOVAL AND FINISH

WITH COATING



26/56

FIELD APPLIED LINING

1 HOUSING OR SHAFT

2 RIGID DUCT LINER

3 ADHESIVE WHERE NECESSARY

4 MECHANICAL FASTENERS5 JOINTS SEALED WITH INSULATION COATING

EMBEDDED IN REINFORCING MEMBRANE



27/56

CURVED SURFACES RIGIDBOARD INSULATION

1 INSULATION SCORED OR BEVELLED TO FIT

CURVATURE


3 BANDING

4 CELLULAR GLASS INSULATION ON BOTTOM 300mm

5 METAL JACKET6 HEAD FLASHING

7 CAULKING



28/56

NOZZLES AND INSULATED MANWAYS

1 VESSEL INSULATION

2 METAL OR REINFORCING MEMBRANE BANDED TO

NOZZLE

3 WEATHER BARRIER COATING OR CAULKING

4 METAL COVER LINED WITH RIGID INSULATION

5 METAL SEAM OR END CAP

6 MECHANICAL FASTENER AS REQUIRED

7 FLASHING



29/56

BLOCKS AND PRE-FORMED PIPE INSULATION

AROUND BREECHINGS AND EXHAUST DUCTS

1 AIR SPACE MATERIAL (BY OTHERS)2 RIGID BLOCK INSULATION3 WIRE OR BANDING4 METAL JACKET FINISH



30/56

HEAD INSULATION SECUREMENT

AND COVER FABRICATION

1 HEAD INSULATION 6 METAL FINISH JACKET

2 FLOATING RING 7 FLEXIBLE INSULATION

3 BANDING 8 SHEET METAL SCREWS

4 SHELL INSULATION 9 HIGHT COMPRESSIVE

5 HEAD INSULATION STRENGTH RIGID INSULATION

SUPPORT RING 10 REINFORCED MASTING

11 CAULKING / FLASHING



31/56

PIPING (0C THROUGH -40C)

1 INSULATION INNER LAYER

2 INSULATION OUTER LAYER WITH JOINTS

STAGGERED

3 LONGITUDINAL LAP ON VAPOUR BARRIER SEALED

4 BUTT JOINT VAPOUR BARRIER SEALED5 BANDING, WIRE OR TAPE AS REQUIRED



32/56

FITTINGS (0C THROUGH -40C)

1 MULTI-LAYER INSULATION; VAPOUR BARRIER

ON OUTER LAYER

2 PREFORMED INSULATION COVER

3 BANDING, WIRE OR TAPE

4 VAPOUR BARRIER TAPE

5 LONGITUDINAL LAP ON VAPOUR BARRIER

SEALED

6 PREFORMED FITTING COVER



33/56

FLEXIBLE INSULATION BLANKETS

1 SHAPED INSULATION BLANKET2 QUILTER WASHER

3 LACING HOOKS AND WIRE



34/56

REMOVABLE AND REUSABLE INSULATION

1 SEAMS STITCHED

2 QUILTING WASHERS3 LACING HOOKS AND WIRE



35/56

REMOVABLE INSULATED

METAL EQUIPMENT COVERS

1 METAL CASING LINED WITH INSULATION

2 SECTIONS OF THE FABRICATED COVER

3 SLIP JOINT OR LAP SEAM WITH SHEET METALSCREWS, POP RIVETS OR STANDING SEAM

4 CUT-OUTS FOR PIPES OR SHAFTS

5 CAULKING WHERE REQUIRED

6 SHEET METAL SCREWS OR POP RIVETS



36/56

REMOVABLE AND REUSABLE INSULATION

1 FLEXIBLE CLOSED CELL INSULATION

2 METAL FRAME

3 REMOVABLE TOP FORM FITTED

4 ADHESIVE



37/56

ELASTOMERIC REMOVABLE COVERS

1 PERMANENT INSULATION

2 COVERS FROM FLEXIBLE CLOSED CELL

INSULATION

3 ADHESIVE

4 THICKNESS OF INSULATION FILLER EQUAL TO

BOLT HEAD SIZE



38/56

TYPICAL FIRE STOP COMPONENTS FOR

FLOOR EXPANSION JOINT

1 COMPRESSION SEAL

2 ULC APPROVED FIRE STOP SEALANT3 COMPRESSABLE FIRE STOP (MINERAL WOOL)



39/56

TYPICAL FIRE STOP COMPONENTS

FOR FLOORS EXPANSION JOINT

1 ULC APPROVED FIRE STOP SEALANT2 COMPRESSABLE FIRE STOP (MINERAL WOOL)3 JOINT COVER (GALVANIZED STEEL)



40/56

TYPICAL FIRE STOP

FOR WALL PENETRATIONS

1 STEEL SLEEVE (OPTIONAL)2 ULC APPROVED FIRE STOP SEALANT

3 COMPRESSIBLE FIRE STOP (MINERAL WOOL)



41/56

TYPICAL FIRE STOP



3 COMPRESSIBLE FIRE STOP (MINERAL WOOL)4 PIPE INSULATION (INSTALLED AFTER FIRESTOP)



42/56

TYPICAL FIRE STOP


1 STEEL SLEEVE

2 ULC APPROVED FIRE STOP SEALANT3 COMPRESSIBLE FIRE STOP (MINERAL WOOL)



43/56

TYPICAL FIRE STOP


1 STEEL SLEEVE2 ULC APPROVED FIRE STOP SEALANT3 COMPRESSIBLE FIRE STOP (MINERAL WOOL)4 PIPE INSULATION (INSTALLED AFTER FIRE

STOP)



44/56

TYPICAL FIRE STOP



3 COMPRESSIBLE FIRE STOP (MINERAL WOOL)4 PIPE INSULATION (INSTALLED AFTER FIRE

STOP)



45/56

TYPICAL FIRE STOP FOR DEFLECTION

OF METAL STUD WALLS

1 ULC APPROVED FIRE STOP SEALANT2 COMPRESSIBLE FIRE STOP (MINERAL WOOL)3 METAL CHANNEL SIZED TO SUIT ALLOWANCE

FOR DEFLECTION & SIZE OF STUDS4 GYPSYM BOARD FIXED TO STUD AND FREE TO

SLIDE5 TAPE BREAKER



46/56

TYPICAL FIRE STOP COMPONENTS FOR

THE TOP OF THE MASONRY WALL

1 ULC APPROVED FIRE STOP SEALANT2 COMPRESSIBLE FIRE STOP (MINERAL WOOL)3 AIR SPACE



47/56

PRE-FORMED PIPE INSULATION

MULTIPLE LAYER CONSTRUCTION

1 PRE-FORMED PIPE INSULATION (AS SPECIFIED)2 INSULATION WITH STAGGERED JOINTS3 INSULATION FASTENING4 FINISH JACKET5 JACKET FASTENING



48/56

RECEIVING

When receiving the pipe and/or fittings shipment at the job site, the

contractor or purchaser should exercise established precautions.

Each shipment should be inventoried and inspected with care upon

arrival. The pipe and fittings are inspected and loaded with due

care at the factory using methods acceptable to the carrier. It is the

carrier's responsibility to deliver the shipment in good condition,

and it is the receiver's responsibility to ensure that there has been

no loss or damage.

The following procedures are recommended for acceptance of

delivery:

1. Conduct overall examination of the load. If the load is intact,

ordinary inspection while unloading should be sufficient to ensure

hat the pipe has arrived in good condition.

2. If the load has shifted, has broken bundles, or shows rough

reatment, carefully inspect each piece for damage.

3. Check total quantities and details of each item against shipping

documents.

4. Note any damaged or missing items on the delivery receipt.

5. Notify the carrier immediately and make a claim according to his

nstructions.

6. Do not dispose of any damaged material. The carrier will notify

you of the procedure to follow.

7. Replacements for shortages and damaged materials are not

reshipped without request. If replacement materials are needed,

reorder from your ROYAL distributor or representative.

UNLOADING

The means by which pipe and fittings are unloaded in the fie

the decision and the responsibility of the receiver.

The following recommendations should be followed:

1. Remove restraints from the bundles. These may be str

ropes, or chains with padding.

2. Remove any boards on the top or sides of the load that are

part of the pipe/fittings packaging.

3. When unloading fittings use industry-accepted means.

extreme caution when unloading fittings with any type

machinery, as fittings may be fiberglass wrapped for ad

strength. Damage to wrapping could reduce strength of fabric

fitting. Do not drop or throw fittings into trench. ROYAL isresponsible for damage to mishandled fittings.

4. Using a forklift (or a front-end loader equipped with fo

remove the top bundles of pipe, one at a time from the truck.

5. If a forklift is not available, use a spreader bar with fabric st

capable of carrying the load. Space straps approximately

metres (8 ft) apart. Loop straps under the load.

6. During the removal and handling, ensure that the bundle

not impact anything (especially in cold weather).

7. Place pipe bundles on level ground.

8. Do not handle bundles with individual chains or single ca

even if padded.

9. Do not attach lifting cables to bundles or bands.

10. Do not stack bundles more than 2.4 metres (8 ft) high.

11. Protect bundles with packing materials the same way

were protected while on the truck.

12. To unload lower bundles, repeat the unloading pro

described above.

13. Do not unload pipe bundles by hand.

14. If unloading equipment is not available, pipe may be unloa

by removing individual pieces. Care should be taken to ensure

pipe is not dropped or damaged.



49/56

STORAGE

The following procedures are recommended to prevent damage to

he pipe:

1. Store the pipe at the site in bundles.

2. Avoid compression, deformation or damage to bell ends of the

pipe.

3. When bundles are stacked, ensure that the weight of upper

bundles does not cause deformation to pipe in lower bundles.

4. Support pipe bundles at 2.4 metre (8 ft) intervals (1.2 metres (4

ft) from each end) on wood blocking to prevent damage to the

bottom surfaces during storage.

5. Store lubricant in tightly sealed containers under cover.

6. Do not store pipe/fittings where gaskets may be exposed to

ozone, UV radiation, or contamination (ie. grease, oil etc).

7. Protect the interior and sealing surfaces of pipe and fittings from

dirt and foreign material.

8. When the bundles are stacked, ensure that the stack remains

stable.

9. When pipe/fittings are being stored for a prolonged period, the

bundles should be covered with a translucent cover, to protect

against exposure to direct sunlight.

HANDLING

The following procedures are recommended:

1. When using mechanical equipment, exercise care to pre

damage to the pipe/fittings.

2. Lower pipe/fittings carefully from trucks and into trenches.

not drop pipe/fittings. Dropped pipe/fittings can be damaged

should not be used.

3. In sub-zero (freezing) temperatures, use caution to pre

impact damage. Handling methods considered acceptable

warm weather are unacceptable during very cold weather.

4. When distributing the pipe along a trench (stringing), place

on the opposite side of the trench from the excavated earth. P

pipe with bell ends in the direction of the work progress.



50/56

PIPE INSTALLATION INSTRUCTIONS

Alignment and GradeAll pipe should be laid to, and maintained at required lines and

grades established by the pipe system Design Engineer. Fittings,

valves, air vents and hydrants should be installed at the required

ocations with valve and hydrant stems plumb.

Trench Width

Trench width at the ground surface may vary with and depend

upon the depth, type of soils, and the position of the surface

structures. The minimum clear width of the trench, measured at

he spring line of the pipe should be 300mm (1ft) greater than the

outside diameter of the pipe. The maximum clear width of the

rench at the top of the pipe should not exceed a width equal to the

pipe diameter plus 600mm (2 ft). If the above defined trench widths

must be exceeded, or if the pipe is installed in a compacted

embankment, the pipe embedment should be compacted to a point

of at least 2.5 pipe diameters from the pipe on both sides of the

pipe or to the trench wall, whichever is less.

Preparation of Trench Bottom

The trench bottom should be constructed to provide a firm, stable

and uniform support for the full length of the pipe.

Bell holes should be provided at each joint to permit proper joint

assembly and pipe support. Any part of the trench bottom

excavated below grade should be backfilled to grade and should

be compacted as required to provide firm pipe support.

When an unstable sub-grade condition which will provide

nadequate pipe support is encountered, additional trench depth

should be excavated and refilled with a suitable foundation material

as recommended by the project's Geotechnical Engineer. Ledge

rock, boulders and large stones should be removed to provide

100mm (4") of soil cushion on all sides of the pipe and accessories.

Laying of Pipe

Proper implements, tools and equipment should be used

placement of the pipe in the trench to prevent damage.

Under no circumstances should the pipe or accessories

dropped into the trench. All foreign matter or dirt should

removed from the pipe interior. Pipe joints should be assem

with care. When pipe laying is not in progress, open ends o

installed pipe should be closed to prevent entrance of trench w

dirt and foreign matter into the line.



51/56

Mechanical Joint Restraint

ROYAL will recognize the use of any restraint device that ca

third party certification to ASTM F1674 (American Society

Testing and Materials), FM (Factory Mutual) and UL (UnderwrLaboratories). It is the responsibility of the restrainer manufact

to supply the necessary support data to prove that their pro

complies with these requirements and is compatible with

pipe/fittings.

It is important to note that ROYAL does not assume any lia

arising from the use of any restrainers on pipe or fitt

manufactured by ROYAL.

Thrust Blocking

Concrete reaction or thrust blocking should be provided at each

hydrant, valve, bend, tee and at reducers or fittings where changes

occur in pipe diameter or direction. Concrete thrust blocks shall becast in place, poured against undisturbed soil. Pre-cast blocks are

not permitted.

1

87

6

5

4

3

2

1. Through line connection

2. Through line connection (crossused as tee)

3. Direction change (tee used as

elbow)

4. Direction change (elbow)

5. Direction change (cross used

as elbow)

6. Vertical direction change

(elbow)7. Direction change

8. Through line connection (w

9. Hydrant runout

9

1. Through line connection (tee)2. Through line connection (cross

used as tee)

3. Direction change (elbow)

4. Change line size (reducer)

5. Direction change (tee used as

elbow)

6. Direction change (cross usedas elbow)

7. Hydrant Tee

8. Hydrant Boot

9. Valve Anchor

10. Vertical direction change

(bend anchor)

1 2

3 4

56

7 8

910



52/56

Pipe Embedment

PVC pipe should be installed with proper bedding providing

uniform longitudinal support under the pipe. Backfill material

should be worked under the sides of the pipe to providesatisfactory haunching. Initial backfill material should be placed to

a minimum depth of 300mm (1ft) over the top of the pipe. All pipe

embedment material should be selected and placed carefully.

Stones, frozen lumps and debris are not considered suitable for

use in the embedment area of the pipe. Proper compaction

procedures should be exercised to provide soil densities as

specified by the Design Engineer.

Final Backfill

After placement and compaction of pipe embedment materials, the

balance of backfill material may be machine placed. The final

backfill should contain no large stones or large rocks, frozen

material or debris. Proper compaction procedures should be

exercised to provide required soil densities.

Assembly of Gasket Joints

The patented "Double-Seal" gaskets are "Locked-In" to the be

the factory.

1. Clean the gasket, bell interior, and spigot area with a clean

brush or paper towel to ensure all debris is removed from bell

spigot ends of the pipe. Check the gasket position. Inspec

gasket, pipe spigot bevel and sealing surfaces for damag

deformation. Be sure that the gasket is installed properly. Do

remove gasket as it is locked in during manufacturing. Once

gasket is removed, it cannot be reinstalled.

2. Use only ROYAL recommended lubricant supplied with the p

Liberally apply lubricant to the spigot up to the reference mark

to the face of the gasket. Use of non-approved lubricants

promote bacterial growth and cause damage to the gasket

pipe, as well as void the manufacturer's warranty.

3. After lubrication, the pipe is ready to be joined. Good alignm

of the pipe is essential for ease of assembly. Align the spigot

the bell, and insert the spigot into the bell until it contacts

gasket uniformly. Do not suspend the pipe and "stab" it onto

bell. The spigot end of the pipe will be marked by ROYA

indicate the proper depth of insertion. The insertion line shoul

exposed in front of the face of the bell. Do not over insert the j

NOTE: Dual-Durometer gaskets are available upon reques

100 - 300mm (4 -12 in) diameter DR18 and DR25 pipe.



53/56

Field-Cut Pipe to Pipe

To join field-cut pipe, it is necessary to first prepare the pipe

end. A square cut is essential for proper assembly. The pipe

can be easily cut with a hacksaw, handsaw or a power sawwith a steel blade or abrasive disc. It is recommended that the

pipe be marked around its entire circumference prior to cutting

to ensure a square cut. The insertion line should be marked

on the cut piece of pipe.

The location of the insertion line is determined by using the

pipe bell as a guide. Measure the insertion depth of the bell.

This is the distance from the end of the bell to the start of the

bell taper. Subtract 13mm (in) from the insertion depth

distance. The result is the distance from the end of the spigot

to the insertion line.

Use a factory-finished beveled end as a guide for proper bevel

angle and depth of bevel plus the distance to the insertion

reference mark. The end may be beveled using a pipebeveling tool or a wood rasp which will cut the correct taper. A

portable sander or abrasive disc may also be used to bevel the

pipe end. Round off any sharp edges on the leading edge of

the bevel with a pocket knife or file.

Longitudinal Bending of Pipe and Pipe Joint Deflection

There are three common methods used to achieve change

direction for Royal PVC pressure pipe:

(A) Longitudinal Bending of Pipe (ROYAL C900 DR 18 pi

only)

ROYAL C900 DR18 Pressure Pipe can be bent to obtain

maximum angle of deflection as shown in the following table

To obtain this result, please follow the guidelines given in t

Uni-Bell Handbook of PVC Pipe.

NOTE: Do not install service taps of any kind into bent pip

because it is under stress.

(B) Pipe Joint Deflection (ROYAL C900 DR 18 pipe only)

ROYAL C900 DR18 Pressure Pipe can be deflected at the jo

by a maximum angle of deflection as shown in the followin

table:

The close tolerances of ROYAL joints limit the amount

unstressed deflection. The procedure is as follows:

Make a concentric assembly, but push the spigot into the b

only to a point about 13mm (1/2 in) short of the insertion lin

This incomplete assembly permits more movement of the en

of the pipe at the bottom of the bell. Do not exceed t

recommended maximum offset and use only manual effort.

NOTE: Do not combine Methods A and B.

ROYAL does not recommend longitudinal bending of pipe

deflection of joint to achieve change in direction for pip

diameters larger than 12".

(C) Use of Fittings (All pressure pipe)

Angle fittings or bends are available to obtain change

direction as required.

2

INSERTION LINE

PIPE

DIAMETER

15 BEVEL

Pipe DiameterMax. Angle of

Deflection

150mm (6) 4.0

200mm (8) 3.0

250mm (10) 2.5

300mm (12) 2.1

Pipe DiameterMax. Angle of

Deflection

150mm (6) 3.0

200mm (8) 3.0

250mm (10) 3.0

300mm (12) 2.5



54/56

FITTING INSTALLATION INSTRUCTIONS

1. Make sure both the bell and spigot are clean.

2. Cut the pipe square to the required length and bevel the pipe to

match that of a factory bevel. Use a piece of pipe with a factory

made bevel as a guide when making field bevels. Remove any

burrs or other sharp pieces that may harm the gasket when the

pipe is inserted into the bell.

3. Measure the insertion depth of the bell and mark the spigot with

his dimension. Mark the spigot with a line 360 around the pipe.

The insertion depth is from the lip of the bell to the beginning of the

aper inside the bell. Over insertion of PVC pipe is one of the

primary causes of failure for both PVC pipe and fittings. Over

nsertion of the spigot is characterized by a crushing of the spigot

n the bell, which causes the bell to crack at the taper of the fitting.

The crack will then move in both directions until it splits the bell,releasing the stress on the bell and causing a failure of the fitting.

4. Lubricate both the bell and the spigot with the lubricant supplied

by the manufacturer. The lubricant shall be applied in a 1 mm

hickness to the bell lip and gasket area and to 76mm (3in) from the

end of the spigot. This distance on the spigot includes the chamfer

of the pipe.

5. Check again that the bell and spigot are still free of debris, and

hen place the spigot at the bell lip positioning the spigot such that

he chamfer is resting against the edge of the gasket. Then, push

he spigot into the bell until the assembly line on the spigot is even

with the lip of the bell. See notes below.

Field-Cut Pipe To Fittings

Field cutting pipe to fittings should follow the procedure on p

12. Along with those instructions, the following procedure sh

be used. Cut pipe to required length. Measure the insertion leon the fitting as described in the "Field-Cut Pipe to Pipe" sec

and transfer that measurement to the pipe end, after the pipe

is beveled. Mark the measured length on the pipe with a ma

ensuring the mark is easily visible. Once the pipe is beveled

the insertion line is marked, insert the pipe into the fitting

suggested in previous sections.

NOTE: Do not insert the pipe past the measured insertion

Over insertion of the pipe into the fitting can cause failure of

fitting.

Cast iron fittings have shallower bells than PVC fittings. For

cast iron fittings, the edge of the PVC pipe should be square

For push-fit cast iron fittings, a small chamfer is required. For mdetailed information about assembly to cast iron fittings, ple

contact the fitting manufacturer.

Deflecting the Joint at Fittings

PVC pressure fitting joints by nature of their gasket design

insertion depth cannot accommodate large deflection angles.

maximum deflection should be 1 for all sizes of PVC pres

fittings. This is equivalent to 100mm (4in) of deflection over a

metres (20 ft) length of pipe. If the deflection exceeds 1, failu

characterized by a crack in the lip of the bell of the fitting w

propagates back towards the gasket causing a failure of the fit

When deflecting the pipe/fitting joint, use the following proced

1. When assembling the pipe/fitting joint, push the spigot into

bell until the assembly line on the spigot is 13mm (1/2in) sho

the lip of the bell. The 13mm gap allows for more movement a

end of the pipe being inserted.

2. Shift the end of the pipe being inserted by 100mm (4in) for a

metre (20 ft) length. This is equal to 1 of deflection.

3. If a large resistance force to the insertion of the spigot is fe

the installer, it could mean that the gasket has become dislod

In this case, disassemble the joint and re-assemble as per

instructions above.

ROYAL has the production capacity to make any degree brequired (from 5 to 89 degrees) in addition to our standard 11

22.5, 45 and 90 bends. Please contact your RO

representative for more details.

NOTES

For small diameters the assembly effort should be able to be

delivered by hand using a block and bar. Never push directly

against the pipe.

Always keep a piece of wood between the face of the pipe bell

and the bar used for pushing. This protects the pipe as well as

ensures even distribution of the force pushing the pipe into the

bell.

For larger diameters, mechanical assembly methods may be

required such as a come-along, jacks, pulleys and even the

backhoe bucket. Of all the methods the backhoe bucket is the

least preferred. A backhoe bucket cannot feel the resistance tothe spigot entering the bell and therefore cannot tell if the joint is

going together correctly. Over insertion by the backhoe will

damage the fitting joint and may also damage other joints

previously installed.



55/56

INSPECTION AND TESTING

Good practice dictates pressure testing portions of lines as they

are completed in advance of the entire system. Before testing, the

pipeline must be backfilled and braced sufficiently to prevent

movement under pressure.

The following three points should be considered when testing:

1. The pipe to be tested must be sufficiently backfilled to prevent

movement while under test pressure.

2. Thrust restraint at fittings should be permanent and constructed

o withstand test pressure. If concrete thrust blocks are used,

sufficient time must be allowed before testing to permit the

concrete to cure.

3. Test ends should be capped and braced to withstand the thrustshat are developed under test pressure.

Pressure and Leakage Test

A combined pressure and leakage test is recommended. The test

pressure and duration shall be as specified by the Design

Engineer. The test pressure should never exceed the pressure

rating of the pipe being tested.

Relieving Air From Pipe Line

The pipeline should be filled as slowly as possible (not more than

1 ft/sec) to avoid any unnecessary surges. Venting air from the line

s of utmost importance.

Pressure pipe is seldom laid to grade, so there are high and lowsections along the line. If the high section elevation is considerably

above the low part of the line, a larger amount of air will be trapped.

Corporation stops or automatic air relief valves should be installed

at these points. Air can be blown from hydrants in pipe sizes up to

200mm (8in). In larger diameter pipes, air will not enter the hydrant

branch, therefore it will be necessary to install air release valves at

high points.

The line should then be filled with water to static pressure, and all

air vents opened to allow air to escape. It is recommended practice

o let the line remain under static pressure for at least 15 minutes.

All air vents should then be opened again to allow any remaining

air to be released from the line, after which the line may be brought

up to full test pressure. The leakage shall not exceed that specifiedby the Design Engineer. Test pressure should never exceed the

pressure rating on the pipe being tested.

Air pressure testing of installed PVC pressure pipe is expressly

prohibited for safety reasons.

SERVICE CONNECTIONS AND TAPPING

Service lines can be connected to ROYAL PVC Pressure Pip

the following methods:

Direct Tapping

Up to 25mm (1in) corporation stops can be used.

Only 150 - 300mm (6 - 12in) diameter AWWA C900 Pressure

Class 150 (DR 18) and Pressure Class 200 (DR 14) pipe. Do

direct tap Pressure Class 100 (DR 25) pipe.

"Wet" (under-pressure) or "dry" (no-pressure) taps are permi

Approved Service Saddles for PVC Pressure Pipe

Can be used with any size or class of pipe.

Maximum outlet permitted is 50mm (2in).

Saddles must be sized to provide even support around the f

circumference of the pipe.

The strapping must provide a minimum of bearing width of 50(2in) along the axis of the pipe.

The design of the saddle should not have lugs that will inden

pipe when the saddle is tightened.

Can be used with wet or dry taps.

Tapping Sleeves and Valves

Should be used for services requiring larger than 50mm (2in

taps.

Should be supported independently of the pipe.

Thrust restraints are required.

Can be used with wet or dry taps.



56/56

General Tapping Recommendations

1. AWWA C800 (Mueller) threads are required.

2. Shell cutters (with or without slots) are necessary to retain andremove the coupon. The throat depth should be sufficient to handle

heavier DR 14 pipe. Do not use single slot cutters.

Do not use twist drill bits for tapping PVC. It is required that a sharp

apping tool and tapping lubricant be used in the tapping process.

3. The tapping machine shall have an independent boring bar feed

mechanism. Manufacturers instructions for operating the tappingmachine should be followed.

This is a sample of a proper tapping coupon.

4. The tapered thread of the corporation stop shall be spirally

wound with 2-3 layers of Teflon tape. This procedure is also

required when installing corporation stops in tap couplings.

5. A torque wrench should be used to tighten the corporation stop

using 36.6Nm (27ftlb), 2-3 threads should be showing after

removal of the tapping machine. If leakage is apparent after final

orque tightening of 47.5Nm (35ftlb), the corporation stop will

have to be reinstalled. The line pressure should be relieved; the

corporation stop removed; new Teflon tape wrapped on the

hreads and the corporation stop reinstalled to a torque of 36.6Nm

(27ftlb).

6. Taps should be made at 10 o'clock or 2 o'clock on the pipe.

7. Horizontal goose-necks of the service line are suggested to

allow the expansion and contraction of the service line.This is a sample of a proper tapping coupon.

8. Pipe temperature should be between 0 - 40C (32 - 104F)

when direct tapping under pressure. Be extremely cautious when

9. When making more than one tap on a length of pipe the

locations should be staggered at least 600mm (2ft) a

longitudinally.

10. Taps should not be made in areas of the pipe that h

become discoloured.

11. NEVER DIRECT TAP IN AN AREA OF THE PIPE THAT

BEEN BENT.

12. Do not tap closer than 600mm (2 ft) from the ends of the p

Basic Safety Precautions

When drilling or tapping any pressurized water pipe, basic sa

precautions are advised to assure personal safety of the work

in the event of a sudden and unexpected pipe failure. Altho

such failures are extremely infrequent, the following sapractices are recommended.

A second workman or supervisor should always be present in

immediate vicinity when making "wet" taps.

Normal protective clothing: including hard hat, safety shoes,

goggles or face mask, should be worn.

A heavy protective blanket, 1.2 metres x 1.8 metres (4ft x 6f

should be used to cover the exposed pipe in the area of the

The blanket should have a hole in the center permitting acce

and operation of the drilling and tapping machine.
