Consideration for design and installation

192

Calculation of expansion and contraction

192

Controlled pipework movement

192

191

Pipework expansion

Plumbing Engineering Services Design Guide

Consideration
for design and
installation

Calculation of
expansion and
contraction

All pipework will expand and contract

longitudinally and around the
circumference when subjected to
temperature variations.

The change in length of pipework, for

both expansion and contraction, due to
temperature variation can be calculated
using the following formula:

The temperature variations can occur as

a result of fluids within the pipework
being heated or cooled, or from the
effects of external heat sources, such as
the surrounding air temperatures, solar
heat, etc.

Formula 1

The temperature variations can range

from gradual, such as the increase and
decrease in room air temperatures, to
almost instantaneous, such as when hot
water is discharged from a sanitary
fitting, or when heated water is suddenly
circulated through the pipework.
Generally the change in diameter of
pipework used for Building Services
Engineering will not require detailed
consideration, other than to ensure that
adequate clearances are maintained
between pipes, pipe supports, joists,
building structures, etc, to allow free
movement of the pipework.
The expansion and contraction along the
length of pipework can however be very
significant, particularly for steam,
condensate, heating, domestic hot water
and certain waste pipework installations.
Expansion and contraction within cold
water pipework systems is minimal and
generally does not require any special
consideration.
It should be noted that the rate of
expansion and contraction varies as a
result of the type of material, as well as
the temperature variation. PVC pipework,
for instance, will expand at over three
times that of copper, for the same
temperature rise.
Damage and failure from stress and
strain can occur to pipework systems,
pipework support systems and building
structures unless careful consideration is
given to the change in pipework length
due to temperature change and the
direction in which the expansion and
contraction will take place.

192

What would be the increase in length and

the final length of a straight copper pipe 15
metres long when subjected to a
temperature increase from 20C to 80C.
From Table 1, the coefficient of linear
expansion for copper is 16.9 x 10-6rnm/K.
From Formula 1
AI = I x a x A t

= 15 x 16.9 ~ 1 0x. (80

~ - 20)
= 0.0152m (15.2mm)

AI = I x a x A t
where:
AI = The change in length of the pipe
due to temperature change.

Example 1

= The original length of the pipe.

a = The coefficient of linear expansion

(mm/K) .

Therefore the pipe would expand 0.0152m

and the final length of the pipe would be:
=15m + 0.0152m = 15.0152m.
Upon cooling down the pipe will return to its
original length, unless it has been heated
excessively to such a point where a loss in
form hasoccurred.

At = The change in temperature to

which the pipe is subjected (K).
NOTE
K denotes degrees Kelvin. This is the same
as a temperature rise measured in Celsius.
I can be any metric unit of measurement.
AI will be calculated in the same unit of
measurement as that used for 4: Generally
units of either metres (m) or millimetres (mm)
will be used.

Table 1 Typical coefficients of linear

exoansion for various materials
Material

Coefficient
fmmK x 1W61

ABS
Aluminium
Brass
Bronze
Cast iron
Chromium
Copper
Duralumin
Lead

60 to 110.2
25.6
19
18

Mild Steel

Nylon
Polyethylene High Density
Polyethylene Low Density
PVC unplasticised
Tin
Zinc

12
7

16.9
23
29
11.3
80
140.2

225
60 to 100
21
30

NOTE
1P6indicates that the decimal point of the
value being considered should be moved six
places to the left, eg: 10.2 x 1U6equates to
0.0000 102.

Controlled
pipework
movement
Freedom of movement
Consideration must be given during the
design and installation of all pipework
systems to ensure that they are free to
expand and contract. The following
important points should be considered:
a. Pipework passing through structures
should be provided with sleeves or
installed through neatly formed holes,
to enable unrestricted movement.
This includes walls, floors, ceilings,
floorboards, floor joists, etc. It must
be ensured that the pipework will not
come into contact with the sleeve or
wall of the hole. Any mastic or other
material used to fill the gap must
permit movement of the pipe.
b. Felt pads, or similar, should be
provided between pipework and
notched joists, and between adjacent
pipes which may come into close
contact with each other.
c. Pipe clips, supports and guides must
not restrict the movement of the pipe,
particularly on long pipe runs.
d. Where it is necessary to bury the
pipework in the screed, provision
must be incorporated to prevent
damage to the pipework and screed.
This could take the form of a
proprietary plastic coated pipe
wrapped in fibreglass and the whole
surrounded with expanded metal or
similar.

~~

Plumbing Engineering Services Design Guide

Dotted line indicates how the

pipework will expand away
from anchors

.----- - _ _ _ _ _ ,,

Anchor
A

Short length of pipe, taken

rom original of 'carryin
iipe' (the length split

Anchor)<,

Pipework expansion

Pipework provided with additional bends to

accommodate expansion shown in solid line,
with 4 anchor positions.

I
I

------ - - _ _ _ _ _ !

I
I
I

I
I
I
I
I
I

>(Anchor
/
Originally intended pipework route
shown dotted.

-L

Figure 7 Typical anchor positions

solder

Figure 2 Typical anchor for copper pipework

e. Ensure that any branches connected

to expanding pipework (eg:
connections to radiators), are of
adequate length to provide natural
flexibility to prevent the connection
shearing.
f.

Ensure that expanding pipework will

not clash with structures.

g. The direction of pipework expansion

must always be controlled using
suitable anchors, guides and clips.
Standard pipework clips may be
adequate for short pipework lengths
of small bore copper and plastic.
h. Open type pipe clips must not be
used where there is a possibility of
the pipe springing away from the clip.
The above requirements are also
essential to ensure that excessive
frictional noises do not occur as a result
of expansion and contraction.

I/

\I

Socket

Figure 3 Typical anchor for steel pipework

(light load)

Heavy mild steel strap

welded to pipe; bolt
to support

Angle or channel
support
dependent on

Locking
channel/an
not require
for lightly
loaded
anchors

Anchors
Where expansion is excessive, pipe
movement must be controlled by
installing anchors. Anchors restrain the
pipework ensuring that any movement
due to expansion occurs in a direction
away from the anchor.
Anchors are usually fixed to the middle of
the pipe to enable the pipe to move in
two directions, therefore effectively
halving the maximum change of
pipework length in any given direction.
Sometimes however, it is desirable to
provide an anchor at one end of a pipe
run, for instance, to prevent a pipe from
coming into contact with an adjacent
wall.
When anchors are installed to control
expansion, forces will be exerted on the
anchor. It is therefore essential to ensure
that:
a. The anchor is adequately secured to
the pipe

Figure 5 Providing additional bends to

accommodate pipework expansion

Plastic coated
saddle strap

Socket

channel

.;,

This anchor may be used for copper pipes

using brass strap.

LAnchor

AnchorA

Figure 6 Expansion loop/horseshoe section

Pipework expansion
devices
If expansion and contraction of pipework
cannot be controlled with the use of
anchors alone, then consideration must
be given to providing additional devices
to enable movement to take place. These
include:
a. Routing pipework with additional
bends or offsets
b. Providing purpose designed
loop/horseshoe sections in the
pipework
c. Installing expansion bellows or
comDensators

Figure 4 Typical light to medium load anchor

c. The anchor fixings to the building

structure are adequate
d. The building structure itself, to which
the anchor is fixed, is adequate to
accept the forces.
Where necessary, the advice of a
structural engineer should be obtained to
ensure the anchor and support
arrangements are adequate for the
anticipated forces which may be exerted.

d. Providing expansion couplings for soil

and waste pipework systems.
The provision of additional bends, offsets
or loop/horseshoe pipework systems
must provide adequate natural flexibility
to accommodate the pipework
expansion.
Expansion bellows or compensators are
proprietary manufactured devices,
designed to accommodate or absorb
expansion and contraction.Various
different types of these devices are
available. It is essential that the
manufacturer be consulted for their
particular recommendations regarding
the most suitable type for the situation
and for their requirements for anchors
and guides.

b. The anchor itself is structurally

adequate

193

Pipework expansion

The following points should be noted

when using expansion bellows or
compensators:
a. Axial type bellows must not be used
where the pipe is hung or suspended
freely. The pipe supports must guide
the pipe and allow only axial
movement along the entire length of
the pipe.
b. It is essential to ensure that the pipe
is guided carefully on each side of
the bellows. The guides must allow
only axial movement onto the
bellows.
c. It is essential to ensure that the pipe
is guided carefully at the necessary
intervals along the whole pipe run.

Plumbing Engineering Services Design Guide

For guides nearest the bellows, the

clearances between the outside pipe and
inside guide walls should not be greater
than 1.6mm for pipe diameter up to
IOOmm and not greater than 3.2mm for
larger pipes. For the guides along the
pipe run, maximum clearances of 3.2mm
and 6.4mm respectively should be used.

Supports and pipe guides

The purpose of a support is to transfer
the load of the pipe and the contents
within the pipe safely to a structure. The
pipe support should reduce deflection of
bending of the pipe.
The purpose of a pipe guide is to control
the direction in which a pipe will move
when it expands. A pipe guide is any
form of constraint which allows the pipe
true axial movement along its length but
prevents offset movement whether
horizontal or vertical. Pipe guides can,
however, be designed to also provide a
support facility. Some typical pipe guides
are indicated in Figures 7 to 11.

Guides nearest
the bellows
The function of guides closest to the
bellows is to ensure true axial movement
on to the bellows. This can be achieved
by using a tubular type guide (as Figure
10) of such length that the necessary
clearances to permit axial movement do
not allow appreciable offset movement.
Generally a tubular guide having a length
to diameter ratio of 6:l will be adequate.

d. Only the bellows unit should be

installed between two pipe anchors.
e. The line between two anchors should
be straight, in plan and in elevation,
with no sets or bends.
f.

Tubular guides are generally only fitted to

small pipes. For larger sizes (50mm and
over), proprietary straps and roller guides
are normally employed. Straps and roller
guides are short and individually cannot
control angular movement of the pipe. To
ensure alignment of the pipe onto the
bellows, an additional set of guides is
required as follows.

Pipe anchors must be of adequate

strength.

g. Bellows must be stretched by half the

total expansion movement (colddraw). This does not apply to special
applications or pre-cold drawn units.

Figure 7 Strap-type guide

h. Screwed end units must be held firm

when installing to prevent twisting of
the bellows.
The most common method of providing
the facility for expansion and contraction
in plastic soil and waste pipe systems is
the use of proprietary expansion
couplings incorporating socket and spigot
joints having rubber sealing rings. The
couplings should be of the same
manufacture as the pipework system.
The expansion couplings should be
introduced at 1.8 metre intervals or as
recommended by the manufacturer, to
connect pipes together.

I-IYz pipe

(c,

lllllllt

Figure 8 Strap-typeguide with tube roller

diameters

l-----I

5-6 pipe
diameters

Tubular guides

Figure 12 Guide near bellows

I

Figure 9 Strap-typeguide with roller and chair

Plastic pipework should be anchored and

supported in accordance with the
manufacturers recommendations.This
will depend on the system employed.

I/

Guides as
necessary

BeIIow s

I - I pipe
~
diameters

15-20 pipe
diameters

Figure 13 Installation of additional strap and

roller guides

figure 10 Tube-type Guide

Figure 11 Slip-on Flange Type Guide

Figure 14 Pipework failure may occur without

pipe guides

Bowing force

Clearance

1
194

Correct guides
Andhor

Anchor

No ghdes

Pipework expansion

Plumbing Engineering Services Design Guide

It is essential to ensure that the complete

pipe run is adequately guided and not
just local to the bellows. If this is not
carried out, the pipework may bow
outwards as a result of the compressive
forces imposed on it.
It is essential that all support
arrangements, except for purpose
designed anchors, enable controlled
pipework movement. If the pipework is
incorrectly restrained, damage to the
pipe supports or structure may result,
due to excessive friction or forces.

Ci = 0.3

~~

Figure 186 Line contact

Figure 18a Point contact

Cold draw of bellows

It is normal for bellows to be cold drawn

(eg. stretched) by half the total calculated

expansion when installed into a pipe. The
bellows will then absorb the total
expansion, half in tension and half in
compression from the neutral position.
This keeps the stress in the bellows
material to a minimum for a given
expansion and provides maximum
bellows life.
In steam and high temperature heating
applications, it is not necessary to allow
for ambient temperature variation
(dayhight, summer/winter) when
installing the bellows, since this variation
is very small compared with the working
temperature range. However, on low
temperature applications, allowances
must be made when calculating cold
draw. Where very small movements,
vibration or subsidence are to be
absorbed, the bellows manufacturers
often recommend that cold draw is not
used.

,1

II II I

II I 1 I I I I

Bellows - cold draw

1 Bellows - neutral

I I Bellows-

hot
I
Total expansion
Cold draw movement

U
Ci = 0.25

Ci = 0.4

Figure 18c Line contact

Figure 18d Face-to-face contact

Cold draw can be achieved by:

Calculating forces
on anchors

a. for flanged bellows:

Leaving a gap internally between the
bellows and pipe flange at one end of
the unit and then tightening up the
flange using over-sized flange bolts.
b. for screwed bellows:
Under-cuttingthe length of an
adjacent pipe section and allowing
the thread of a connecting union to
expand the bellows. Care must be
taken that the bellow is not twisted
during the tightening process.

c. for welded end bellows:

Installing a pair of flanges in the
pipework adjacent to the bellows with
a gap initially between the flange
faces and then tightening up the
flange using over-sized flange bolts.
d. for all bellows:
By purchasing pre-cold drawn
bellows.

The following main factors have to be

taken into consideration when
determining forces on anchors:
a. The effect of test pressure on the
cross-sectional area of any bellows
installed within the pipework system.
b. The elasticity force to stretch and
compress bellows installed through
the working movement.
c. Frictional forces between the pipe
and pipe supports, acting against the
direction of movement.
d. The slope of the pipe, affecting the
lower anchor (vitally important if the
pipe is vertical).
e. Fluid pulsation and flow effects in the
pipe.
f.

Differential forces due to changes in

pipe diameter.

Quoted friction coefficients between

pipework and supports vary considerably
but the values shown in Figures 18(a),
(b), (c), and (d) may be used as a
general guide for steel on steel.

Figure 15 Cold draw in expansion bellows

The frictional resistance (kg) = dead load

at point of support (kg) x coefficient of
friction.
Figure 16 Taking up cold draw on flanged bellows
Figure 19
Figure 17 Taking up cold draw on welded end bellows

BeIIow s

Anchor

Anchor
Guide at necessary
intervals

~~

195

Pipework expansion

This resistance acts against the direction

of movement e.g. it can act either way,
depending on whether the pipe is
warming up or cooling down.
Should the above figures give
unacceptably high forces consideration
could be given to using special PTFE
support pads which gives figures as low
as 0.02.

Plumbing Engineering Services Design Guide

Pipework system under test conditions

Thrust due to internal pressure on bellow
= test pressure x effective area
= 830 x 1O3 x 0.023N

= 190909 pushing outwards on anchors

Force due to bellows stiffness (bellows

stretched in cold-draw position)
= 6700N pulling inwards on anchors

Example 2

Frictional resistance

The following example illustrates the

calculation to determine the force imposed
on an anchor under normal working and
test conditions on a pipework installation
indicated in Figure 19, which incorporates
axial type bellows.

= NIL as pipe only moves under

temperature effect

Total thrust on anchor

=19090-6700
= 12390N pushing outwards on

The designer must obtain the relevant data

from the bellows manufacturer.
Pipe weight
Water weight
Lagging weight
Effective area of bellows

= 22kg/m
= 19.5kgh
= 6kgh
= 0.023m2

Thrust to compress or extend bellows

through full movement
= 6700N
from manufacturers data (Newtons)
Coefficient of friction between
pipe and supports
= 0.3
System working pressure = 550kPa
(550 x 1 0 3 ~ 4
System test pressure
Length of pipe

The following important points should be

considered when installing bellows:
I.

= 830kPa
= 42.5

Pipework system under

normal working conditions
Thrust due to internal pressure on bellows
= working pressure x effective area
= 550 x 103x 0.023N
= 12650N pushing outwards on anchors

Force due to bellows stiffness (bellows

compressed in working platform)
= 6700N pushing outwards on anchors.

Frictional resistance to pipe movement over

its supports:
= coefficient of friction x (total weight of
pipe + water + lagging)
= 0.3 x [(22 x 42.5) + (19.5 x 42.5)
+ (6 x 42.5)Ikg
= Converted to Newtons (1kg = 9.807N)
= 0.3 x [(22 x 42.5 + (19.5 x 42.5)
+ (6 x 42.5)] x 9.807N
= approximately 6000N against the

direction of movement, eg. pushing

outwards on anchors.
Total Thrust on Anchor
= 12650 + 6700 + 6000
= 25350N (Newtons) pushing outwards
on anchors.

196

anchors.
It can be seen in this instance that the
greatest force acting on the anchor is under
normal working conditions, this however is
not always the case.

When a fitting such as a bend, valve

or distance piece is installed into a
pipe and subjected to internal
pressure. The fitting will act just like a
pipe itself, holding the internal
pressure, but not pushing or pulling
on the pipe.

ii When an axial bellows is fitted into a

pipe and subjected to internal
pressure, it reacts to the internal
pressure by trying to open out
lengthways. An outward pressure is
therefore exerted by the bellows.
iii, When a pipe restrained by an anchor
at one end, but otherwise free to
move longitudinally, is subjected to
heat, it will expand away from the
anchor position, exerting an outward
force away from the anchor.
iv. When a pipe anchored at two points
and provided with a bellows between
the anchor points is subjected to
heat, pressure is exerted by both
pipework sections towards the
bellows. Meanwhile the pressurised
bellows is exerting pressure outwards
towards the two anchor points.
V.

When the pipe gets hot, it expands

towards the bellows and tries to
compress it. Meanwhile, the
pressurised bellows is trying to open
out lengthways. The expanding pipe
therefore has to overcome this
pressure force as well as the stiffness
of the bellows and the friction of the
pipe supports. Hence the need for
firm anchors at each end of the pipe
run, and careful guiding not only on
each side of the bellows but also
along the pipe run.

vi. The pipe between bellows and

anchors is frequently in compression
and unless the pipe is guided
carefully, and runs accurately in a
straight line from anchor to anchor,
the pipe may bow out sideways. This
will pull the bellows with it and may
cause failure.
vii. Never use axial bellows in pipework
systems incorporating suspended
hanger supports or any other support
systems which can readily swing.
viii. Confirmation should always be
obtained from the bellows
manufacturer regarding any special
requirements they may have
regarding the position of anchors and
guides.