IS : 7634 (Part II) - 1975

(Reaffirmed 2002)

Edition 1.2 (2003-06)

Indian Standard
CODE OF PRACTICE FOR PLASTICS PIPE WORK FOR POTABLE WATER SUPPLIES
PART II LAYING AND JOINTING POLYETHYLENE (PE) PIPES (Incorporating Amendment Nos. 1 & 2)

UDC

621.643.2[678.742.2].696.115:628.155

BIS 2003 BUREAU

MANAK BHAVAN , 9 BAHADUR SHAH ZAFAR MARG NEW DELHI 110002

OF

INDIAN

STANDARDS

Price Group 4

IS : 7634 (Part II) - 1975

Indian Standard
CODE OF PRACTICE FOR PLASTICS PIPE WORK FOR POTABLE WATER SUPPLIES
PART II LAYING AND JOINTING POLYETHYLENE (PE) PIPES Sanitary Appliances and Water Fittings Sectional Committee, BDC 3
Chairman SHRI V. D. DESAI Members Ministry of Health ADVISER SHRI H. R. B ADYAL Indian Iron & Steel Co Ltd, Calcutta SHRI K. D. BISWAS ( Alternate ) SHRI V. D. CHADHA Ministry of Railways SHRI S. P. CHAKRABARTI Central Building Research Institute (CSIR), SHRI S. K. SHARMA ( Alternate ) Roorkee CHIEF E NGINEER Central Public Works Department, New Delhi SUPERINTENDING ENGINEER ( Alternate ) CHIEF E NGINEER Local Self Government Engineering Department, Lucknow SUPERINTENDING ENGINEER ( Alternate ) CHIEF E NGINEER Tamil Nadu Water Supply & Drainage Board, Madras CHIEF E NGINEER (WATER) Municipal Corporation of Delhi DRAINAGE ENGINEER ( Alternate ) CITY ENGINEER Bombay Municipal Corporation HYDRAULIC ENGINEER ( Alternate ) SHRI H. N. D ALLAS Indian Institute of Architects, Bombay LALA G. C. DAS National Test House, Calcutta SHRI M. T. KANSE Directorate General of Supplies & Disposals SHRI S. C. KAPOOR Delhi Development Authority SHRI R. V. LELE Central Glass & Ceramic Research Institute (CSIR), Calcutta PROF N. MAJUMDAR National Environmental Engineering SHRI J. M. DAVE ( Alternate ) Research Institute (CSIR), Nagpur SHRI R. N. MALLICK Directorate General of Technical SHRI N. R. SRINIVASAN ( Alternate ) Development SHRI R. M. MEHRA Bombay Potteries and Tiles Ltd, Bombay ( Continued on page 2 ) BIS 2003 BUREAU OF INDIAN STANDARDS This publication is protected under the Indian Copyright Act (XIV of 1957) and reproduction in whole or in part by any means except with written permission of the publisher shall be deemed to be an infringement of copyright under the said Act. Representing Bombay Municipal Corporation

IS : 7634 (Part II) - 1975

( Continued from page 1 ) Members Representing Public Health Engineering Department, SHRI D. APPUKUTTAN NAYAR SHRI K. RAMACHANDRAN ( Alternate ) Government of Kerala, Trivandrum DR A. V. R. RAO National Buildings Organization, New Delhi SHRI G. T. B HIDE ( Alternate ) SHRI P. JAGANATH R AO E. I. D-Parry Ltd, Madras SHRI T. S. C HINTAMANI ( Alternate ) *SHRI B. B. RAU Institution of Engineers (India), Calcutta REPRESENTATIVE Public Health Engineering Department, Government of Rajasthan COL K. B. SETH Engineer-in-Chiefs Branch, Army SHRI I. S. BEDI ( Alternate ) Headquarters SHRI J. L. SETHI Public Health Engineering Department, SHRI A. N. MEHANDALE ( Alternate ) Government of Haryana, Chandigarh SHRI R. K. SOMANY Hindustan Sanitaryware & Industries Ltd, SHRI V. S. BHATT ( Alternate ) Bahadurgarh SHRI D. AJITHA S IMHA, Director General, ISI ( Ex-officio Member ) Director (Civ Engg) Secretary SHRI V. KALYANASUNDARAM Assistant Director (Civ Engg), ISI

Plastic Pipes Subcommittee, BDC 3 : 8

Convener SHRI K. D. MULEKAR Members DEPUTY CITY E NGINEER (PLANNING & DESIGNS) ( Alternate to Shri K. D. Mulekar ) ADVISER SHRI V. A. A NANDADOSS ( Alternate ) DR B. R. C. ANAND SHRI S. MITRA ( Alternate ) SHRI N. S. BHAIRAVAN Bombay Municipal Corporation

Ministry of Health

Calico Mills Chemicals & Plastics Division, Bombay Public Health Engineering Department, Government of Kerala, Trivandrum CHIEF ENGINEER (WATER) Municipal Corporation of Delhi DEPUTY CHIEF E NGINEER (WATER) ( Alternate ) CHIEF ENGINEER Tamil Nadu Water Supply & Drainage Board, Madras MAJ P. S. CHILKA Ministry of Defence SHRI B. R. N. GUPTA ( Alternate ) SHRI J. M. DAVE National Environmental Engineering SHRI R. PARAMASIVAM ( Alternate ) Research Institute (CSIR), Nagpur ( Continued on page 16 ) *Shri B. B. Rau is also alternate to Adviser, Ministry of Health.

IS : 7634 (Part II) - 1975

Indian Standard
CODE OF PRACTICE FOR PLASTICS PIPE WORK FOR POTABLE WATER SUPPLIES
PART II LAYING AND JOINTING POLYETHYLENE (PE) PIPES 0. F O R E W O R D 0.1 This Indian Standard (Part II) was adopted by the Indian Standards Institution on 4 January 1975, after the draft finalized by the Sanitary Appliances and Water Fittings Sectional Committee had been approved by the Civil Engineering Division Council. 0.2 The preparation of a code of practice for plastics pipe work for potable water supplies was taken up to make available comparative properties of different types of plastic pipes as well as to give guidelines for their selection for different situations arising in practical usage and also to recommend sound practices for the installation, jointing and testing of such pipe systems. It is hoped that this code will assist in greater usage of plastic pipes. Part II of the standard covers laying and jointing polyethylene (PE) pipes. 0.2.1 The other parts of the standard are the following: Part I Choice of materials and general recommendations Part III Laying and jointing of unplasticized PVC pipes 0.3 In the formulation of this standard due weightage has been given to international Co-ordination among the standards and practices prevailing in different countries in addition to relating it to the practices in the field in this country. This has been met by deriving assistance from BS : CP 312 : Part 3 : 1973 Code of practice for plastics pipe work (thermoplastics material) : Part 3 Polyethylene pipes for the conveyance of liquids under pressure issued by British Standards Institution. 0.4 This edition 1.2 incorporates Amendment No. 1 (October 1978) and Amendment No. 2 (June 2003). Side bar indicates modification of the text as the result of incorporation of the amendments. 0.5 For the purpose of deciding whether a particular requirement of this standard is complied with, the final value, observed or calculated, expressing the result of a test or analysis, shall be rounded off in accordance with IS : 2-1960*. The number of significant places retained in the rounded off value should be the same as that of the specified value in this standard.
*Rules for rounding off numerical values ( revised ).

IS : 7634 (Part II) - 1975 1. SCOPE 1.1 This standard (Part II) gives guidance on proper methods for laying and jointing of polyethylene (PE) pipe work systems. 1.2 The local byelaws shall be strictly observed whenever used in municipal water distribution systems. 2. JOINTING TECHNIQUES 2.1 The commonly used joints are as follows: a) Insert type joints, b) Compression fittings, c) Fusion welding, d) Threaded joints, e) Flanged joints, and f ) Telescopic joints. 2.1.1 There are insert type of fittings of both plastic and metals available for use with PE pipes. In corrosive locations plastic fittings are preferred because of their high resistance to corrosion. In less corrosive conditions gun metal fittings are frequently used and in normal or slightly corrosive environments, brass fittings are commonly employed. In certain cases, threaded malleable cast iron fittings are used. 2.2 Insert Type Joints ( see Fig. 1 ) 2.2.1 These are commonly used for LDPE pipes where in a serrated PE or metallic fitting is inserted into the pipe and tightened by a clip. 2.2.2 The outer serrations of HDPE/metal insert type fittings lock into the PE pipes to prevent their coming out under sudden pressure surge. If the pipe bore is slightly undersized, a little heating by immersion in boiling water in case of LDPE and oil bath (130C) in case of HDPE would soften the pipe to enable insertion of fitting. If the bore of the pipe is loose, the bore clip of worm drive type will secure the fitting and ensure a leak proof joint. The insertion of these fittings into the bore of the pipe is done with hand pressure only. As a measure of safety, worm drive type clip should be used in all cases. This type of jointing is used normally in small diameter pipes up to 110 mm. 2.3 Compression Fittings 2.3.1 They are used for LDPE and HDPE joints. They are detachable joints and are made of metals or plastics. 2.3.2 In the majority of cases the metal fittings are based on the type of compression fittings commonly used with copper tubes. In this type of 4

IS : 7634 (Part II) - 1975

FIG. 1

TYPICAL ILLUSTRATION OF M AKING INSERT TYPE JOINTS FOR HDPE PIPES 5

IS : 7634 (Part II) - 1975 joint the dimensions of the pipe are generally not altered. The joint is effected by an internal liner and a compression ring or sleeve which shrinks and therefore compresses the pipe wall on to the liner, thus gripping to the wall of the pipe. The liner and compression sleeve may also be an integral unit ( see Fig. 2 ).

FIG. 2

COMPRESSION FITTING (TYPE 1)

2.3.3 In other cases the flared pipe wall is compressed on a conica insert either by two male and female threaded metallic nuts ( see Fig. 3A ) or by backing loose flanges ( see Fig. 3B ). The water seal is made by compression of ends of PE flared pipe between sloping surface of metallic nuts/flanges and conical inserts. 2.3.4 Compression Joints with Collar/Pipe Ends and Flat Gaskets Aluminium alloy or brass fittings with male and female coupling parts are available for jointing with metallic fittings. The male and female ends of the coupling are inserted face to face on two ends of the pipes to be jointed. Collars are made on the pipe ends by heating the ends with hot plate or electric coil. The two collars are brought together and the female end of the coupling is tightened on the male end. A water tight seal is made between the flanges. This is a detachable type of jointing and is practicable up to 50 mm dia pipes ( see Fig. 4 ). 2.4 Fusion Welding 2.4.1 Fusion welding is commonly used in HDPE and is a permanent type of joint. 2.4.2 Procedure of Butt Welding of HDPE Pipes 2.4.2.1 The pipe should be cut square and the face of the pipe should be slightly scraped prior to welding to remove oxidized layer. At the time of welding, levelling of the pipes is essential particularly in case of larger diameter pipes. Welding temperature should be 200C and surfaces of heating mirror should be 210 5C [heating mirror is a metallic plate heated up to the required temperature either by electrical coil embedded inside or by blow torch. The word mirror has 6

IS : 7634 (Part II) - 1975 come because this heating plate radiates heat ( see Fig. 5 )]. The pipes to be welded should be held on either side of the heating mirror with only contact pressure of about 20 kPa (0.2 kgf/cm2). When the rim of molten material is found, the pipes are removed from the heating mirror and immediately the joint is made by application of moderate pressure of approximately 1 to 2 kg/cm2 for 2 to 3 seconds. The initial heating time for achieving molten rim, varies from 1 to 5 min depending upon the pipe wall thickness and size.

FIG. 3

COMPRESSION FITTING (TYPE 2) 7

IS : 7634 (Part II) - 1975

FIG. 4

COMPRESSION JOINT WITH COLLAR/PIPE E NDS AND FLAT GASKET

2.4.2.2 Cautions a) It is essential to see that the rim formed is not excessive. b) While jointing, the pressure should be maintained until the joint is luke-warm and after the pressure is relieved, the joint allowed to cool completely. c) The mirror should be kept exactly around 210C which needs about 30 min time (for electrical mirror). It is also essential to see that the temperature is maintained constant by the proper setting of regulator. For detecting the correct temperature, crayon chalk is used. For example at 210C the colour of crayon dot on the mirror changes within 2 seconds. But the dot made should be thin and if not, time taken will be more, indicating a wrong temperature. 2.4.3 Strength A satisfactory butt welded joint of HDPE will have the strength factor of one. Temperature is of primary importance and weld efficiency may decrease if the temperature does not fall with in the range of 200 10C. 2.5 Screwed Joints (Threaded Joints) 2.5.1 These can be used for LDPE and HDPE pipes with higher pressure ratings which have thicker walls. It should be noted that such threading reduces the factor of safety and hence working pressure in the lower classes will have to be assumed for design purposes. Ordinary metal cutting dyes of adjustable and guided variety may be used. As far as possible, a full thread should be cut in one operation. It is advisable to plug the end of the pipe during threading operation to avoid distortion due to flexibility. When threading the pipe, taper threads should be used and only the exact number of threads required for the joint should be cut so that when the joint is made, all the threaded portion of the pipe is totally enclosed in the fitting. 8

IS : 7634 (Part II) - 1975

FIG. 5

PROCEDURE OF BUTT WELDING OF HDPE PIPES

2.5.2 Galvanized iron fittings are suitable where there is no risk of corrosion. In corrossive conditions, PE or other corrosion-resistant material fittings should be used. 2.5.3 Under no circumstances should steel pipe wrenches be used on a plastic pipe of fitting. 2.6 Flanged Joints 2.6.1 These are used for jointing LDPE and HDPE pipes particularly of larger size to valves and vessels and large size metal pipes where strength in tension is required. 2.6.2 It consists of flanges either loose or welded to the pipe ends. It is recommended that suitable metallic backing plates be used to support 9

IS : 7634 (Part II) - 1975 the polyethylene flanges to enable them to be bolted together. Injection moulded polyethylene flanges with metal inserts of 6 to 9 mm thickness may also be used. In most cases, sealing is improved by incorporating a natural or synthetic rubber gasket between polyethylene flanges ( see Fig. 6 ).

FIG. 6

FLANGED JOINT

2.7 Telescopic Joint ( see Fig. 7 ) 2.7.1 Any joint (socket and spigot type) that permits sliding of the free end (spigot end) inside the socket with a rubber or suitable gasket, without any leakage is called telescopic joint.

FIG. 7

TELESCOPIC JOINT

2.7.2 The socket could be an integral part of the pipe at one end or two ends or a special coupler into which the free ends (spigot ends) of the pipes are pushed to achieve a water tight joint. 2.7.3 These joints are normally weak in longitudinal pull and hence need anchoring wherever such a tendency of longitudinal pull is likely in the pipe line. In the case of telescopic joints, one external anchorage is generally necessary at each end of the pipe line, at valve and at all changes of direction. The supports of the side connection should ensure 10

IS : 7634 (Part II) - 1975 that excessive lateral bending does not occur. In small diameter the coupler itself could be modified to have a split, threaded, grip type gasket of hard materials in addition to O ring type of rubber gasket (for water tightness) to prevent any slipping out of the free end of the pipe in longitudinal pull. 3. BENDING 3.1 Cold Bending Small diameter PE pipes have a degree of flexibility such that a substantial radius may be set up within a length of pipe itself without heating, and without causing residual stress. 3.1.1 This enables gradual curves to be negotiated without the need for special bends or flexible couplings. In low density PE pipes an inside radius of not less than 12 times the outside diameter of the pipe is permissible. In case of high density PE pipes, the radius of the bend shall be greater than 20 times the outside diameter of the pipe. Cold bends should only be used on pipes operating at ambient temperatures. 3.2 Hot Bending 3.2.1 Forming of small radius bend may easily be done by the application of heat either by hot air oven or by immersion in a suitable liquid at an appropriate temperature. For low density, the temperature range is 100 to 110C and suitable liquids are water, glycerol or a solution of calcium chloride. High density PE pipe should be heated in an inert liquid, such as glycerol (or any oil in emergency) at a temperature of 130C. Electrical heating coils or plates may be used only by experienced technicians. 3.2.2 In preheating operations, the low thermal conductivity of PE should be kept in mind. Over heating can usually be recognized by surface discolouration and distortion. On the other hand bending operations should not be performed at too low a temperature, because of excessive stress that could result. Naked flames for heating should be used only by experienced operators. 3.2.3 At bending temperature, the bore of the pipe tends to collapse and therefore requires support during the bending operation. Internal support should be affected before heating by packing the bore of pipe with warm fine dry sand or by inserting rubber pressure hose, rubber rod, or a flexible spring. After the pipe is uniformly heated, it should be pulled around a simple jig and held in the correct position until cool. 3.2.4 It is recommended that radius of the bend for pipe up to 50 mm size should not be less than three times the outside diameter of the 11

IS : 7634 (Part II) - 1975 pipe for low density PE and five times the outside diameter for high density PE. Pipes of large diameter will require an increase in radius. 4. STORAGE AND HANDLING 4.1 Storage 4.1.1 Black polythene pipe may be stored either under cover or in the open. It is suitably protected from ageing due to sunlight by the addition of the appropriate quantity and type of carbon black. Natural polythene pipe, however, should be stored under cover and protected from direct sunlight. 4.1.2 Coils may be stored either on edge or stacked flat one on top of the other, but in either case they should not be allowed to come into contact with hot water or steam pipes and should be kept away from hot surface. 4.1.3 Straight lengths should be stored on horizontal racks giving continuous support to prevent the pipe taking on a permanent set. 4.1.4 Storage of pipes in hot areas should be avoided. While storing the pipes at temperatures above 45C continuous support may be given by levelled sand layer or by other suitable methods. 4.2 Handling 4.2.1 Polythene is a tough resilient material which may be handled easily. However, because it is softer than metals it is more prone to damage by abrasion and by objects with a cutting edge. Such practices as dragging coils over rough ground should therefore be avoided. 4.2.2 If, due to unsatisfactory storage or handling, a pipe is damaged or kinked, the damaged portion should be cut out completely. 4.2.3 The material is not affected by low temperatures as much as are some other plastics materials, and there is no need for more cautious handling during cold weather. 5. INSTALLATION 5.1 While installing the pipes in trenches, the bed of the trench should be level and free from sharp edged stones. While laying in rocky areas suitable bed of sand or pebbles should be provided. The initial back fill to about 10 to 15 cm above the pipe should be fine sand or screened excavated material. Where hard rock is met with, bed concrete M-100, 15 cm thick may be provided, before putting in the soft sand/gravel. 5.2 Provisions shall be made for the effects of thermal movements between the anchors/supports. 12

IS : 7634 (Part II) - 1975 5.3 Plastics pipes in general need not be painted. Painting may disguise its character. Hazard might occur by mistaking this pipe for metal one in using it for load bearing support, or for electrical grounding. 5.4 Plastics pipes shall not be installed near hot water pipes or near any other heat sources. 5.5 Plastics pipe clamps may be used to support the pipe. Standard pipe clips may also be used but care shall be taken not to over tighten and cause the clips to bite into the pipe. Pipe clips should be correctly aligned and should provide a smooth flat surface for contact with pipe. Sharp edged supports should be avoided. All types of manual controls, and valves in particular should be anchored firmly so as to minimize the turning moment imparted to the pipe by operation of the hand wheel ( see Fig. 8 ). 5.6 Support Spacing Supports for horizontal run, such as pipe clamps, brackets should be used at approximately the spacing given in Fig. 9. 5.7 Effect of Temperature 5.7.1 Expansion and Contraction The coefficient of expansion is about twenty times (for low density polyethylene pipes) and fourteen times (for high density polyethylene pipes) than that for expansion experienced with metal pipes. This also holds good for contraction due to fall in temperature. 5.7.1.1 In many instances the normal changes in the direction of the pipe provide an adequate means of accommodating expansion. 5.7.1.2 In continuous straight runs of pipe it is necessary except where pipes are laid underground to insert units to absorb the expansion. Expansion loops, bellows or sliding gland expansion joints may be used. 5.7.1.3 Care should be taken to account for the high increase in surface temperatures of these pipes in cases of exposed laying or laying in the close proximity of artificial heat sources. 5.8 Surge Pressure HDPE pipes, by their visco-elastic nature and creep properties, can withstand much higher short term loads, that is, 2.3 times the working pressures, as such are suitable to withstand water hammer surges. 13

IS : 7634 (Part II) - 1975

FIG. 8 6. MAINTENANCE

VALVE C HAMBER DETAIL

6.1 Various methods may be employed for repairing leakages or damage to sections of PE pipes. In general, the best is to cut the damaged portion and to replace it by a new pipe or prefabricated replacement unit. The connections of new pipe to either ends of the old pipe may be done by insert type of fittings. When failure or damage occurs in a welded joint, the original weld shall be removed entirely before rewelding. 6.2 Freezing Although polyethylene pipe is not fractured by freezing the flow of water may be stopped. Direct application of intense heat, such as a torch or open flame should not be used. Any other method of applying heat can be acceptable as long as the temperature of the polyethylene piping material is not raised above 45C. Compounds, such as methanol, propanol and ethylene glycol can be used as antifreezers without detrimental effect to polyethylene plastic pipe. 14

IS : 7634 (Part II) - 1975

FIG. 9

DISTANCE B ETWEEN PIPE SUPPORTS FOR HDPE PIPE FOR TRANSPORTATION OF WATER/WASTE WATER

6.3 Pressure Check In any application where polyethylene pipe is attached to a pressure source which is higher than the pressure rating of the polyethylene pipe being installed, adequate pressure reduction devices shall be installed. Whenever such valves are installed, a regular check of such valves should be made to ensure their continued proper functioning as a protection to the polyethylene pipe. 6.4 Temperature Check Whenever polyethylene pipe is installed in a system in which the possibility of hot liquid could back-up or cross over into the polyethylene pipe, check valves should be installed to ensure against such back up or cross over. When such valves are installed, they should be inspected regularly to ensure their continued proper functioning.

15

IS : 7634 (Part II) - 1975

( Continued from page 2 ) Members SHRI S. K. DEY Representing

EMCO General Plastic Industries (P) Ltd, Calcutta SHRI R. K. JAIN Central Building Research Institute (CSIR), SHRI S. P. CHAKRABARTI ( Alternate ) Roorkee SHRI A. R. KANGA City and Industrial Development Corporation Ltd, Bombay DR S. L. KAPUR National Chemical Laboratory (CSIR), Poona SHRI A. E. LADHABHOY Imperial Chemical Industries (India) Ltd, SHRI P. C. SANYAL ( Alternate ) Calcutta SHRI R. A. MEHENDALE Garware Plastics (Pvt) Ltd, Bombay DR G. C. MOTWANI Union Carbide India Ltd, Calcutta SHRI G. V. DESAI ( Alternate ) SHRI R. PARIKSHIT Directorate General of Technical Development SHRI M. RAMABHADRAN Wavin India Ltd, Madras SHRI K. R. R ANGARAJAN ( Alternate ) DR A. V. R. RAO National Buildings Organization, New Delhi SHRI O. P. R ATRA ( Alternate ) SHRI G. S. RAO Central Public Works Department, New Delhi SHRI P. B. RAO Polyolefins Industries Ltd, Bombay REPRESENTATIVE Local Self Government Engineering Department, Lucknow REPRESENTATIVE Public Health Engineering Department, Government of Haryana, Chandigarh SHRI R. S IVARAMAKRISHNAN Chemicals & Plastics (India) Ltd, Madras SHRI R. KALIDAS ( Alternate ) SHRI A. K. SUBBARAMAN Housing & Urban Development Corporation SHRI B. K. C HAKRABARTY ( Alternate ) Ltd, New Delhi

16

Bureau of Indian Standards BIS is a statutory institution established under the Bureau of Indian Standards Act, 1986 to promote harmonious development of the activities of standardization, marking and quality certification of goods and attending to connected matters in the country. Copyright BIS has the copyright of all its publications. No part of these publications may be reproduced in any form without the prior permission in writing of BIS. This does not preclude the free use, in the course of implementing the standard, of necessary details, such as symbols and sizes, type or grade designations. Enquiries relating to copyright be addressed to the Director (Publications), BIS. Review of Indian Standards Amendments are issued to standards as the need arises on the basis of comments. Standards are also reviewed periodically; a standard along with amendments is reaffirmed when such review indicates that no changes are needed; if the review indicates that changes are needed, it is taken up for revision. Users of Indian Standards should ascertain that they are in possession of the latest amendments or edition by referring to the latest issue of BIS Catalogue and Standards : Monthly Additions. This Indian Standard has been developed by Technical Committee : BDC 3 and amended by CED 50 Amendments Issued Since Publication Date of Issue October 1978 June 2003

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