Bonded System - Design: Water Quality

Introduction
Bonded system - Design 4.1.1

The bonded system takes its name from the fact Water quality
that carrier pipe, polyurethane foam and casing
Treated water must be used to avoid corrosion in
pipe are bonded together.
carrier pipe. The water treatment depends on local
The outer surface of the carrier pipe and the inner conditions, but the following key points should be
surface of the casing pipe are pretreated to ensure complied with:
that the foam adheres to the pipes, and that
stresses can be transmitted through the foam.
The elements of the bonded pipes expand and pH 9.5 - 10
move together. The movements are restricted by No free oxygen
the friction between soil and casing pipe. Total salinity < 3000 mg/l
The mode of operation depends on the pipe laying

method applied.
Pressure
During operation, varying temperatures may lead to
movements absorbed by foam pads placed on the Nominal pressure for T-fitting and compensators is
outside of the casing or by built-in compensators. PN 16. For other components it is PN 25. T-fittings
and compensators for PN 25 can be supplied to
In heat-prestressed and cold laid systems, order.
temperature variations during operation result in
stress variations in the pipes. Pressure test using cold water (20°C) up to max.
1.5 x nominal working pressure
Bonded system features a wide range of pipes,
components and joints that ensures that the right Heat loss and pipe design
solution can be found for any application.
The principles for calculating heat loss are
Material properties of steel, P235GH and St. 37.0 described in chapter 3 page 3.4.1
BW The principles of pipe design are described in
chapter 3 page 3.4.3.
Mechanical properties: For calculation of heat loss and pipe design,
LOGSTOR has developed a calculation programme
Density 7850 kg/m3 StaTech.
Tensile strength > 350 N/mm2
Yield stress > 235 N/mm2 The programme calculates heat loss on new as
Young's modulus 2.1 . 105 N/mm2 well as old pipes with or without diffusion barrier.
The programme also calculates the economic
Thermal properties: consequences of heat loss and ageing.
Coefficient of expansion 1.2 . 10-5 K-1
Specific heat 0.48 kJ/kg K
Thermal conductivity, λsteel 76 W/m K
Version/2007.03.UK
LOGSTOR A/S . Danmarksvej 11 . DK-9670 Løgstør . Tel. +45 99 66 10 00 . Fax +45 99 66 11 80 . logstor@logstor.com
Change of direction

LOGSTOR’s steel pipe systems allow minor Steel pipe Casing pipe Bending
directional adjustments to be made either in the diameter diameter radius
casing joints or by using the flexibility of the pipes. mm mm m
Dependent on the joint system directional changes 26.9 90 13

of up to 6° in joints are allowed, provided that the
33.7 90 17
steel pipe is not overstressed. The pipe ends must
be mitred and bevelled in accordance with the 42.4 110 21
welding proceduces.
48.3 110 24
Gentle curves can be achieved by utilising the 60.3 125 30
flexibility of the pipes. The adjacent table gives the
smallest, permissible bending radius. 76.1 140 38
The bending radius is calculated as 500 times the 88.9 160 44

outer steel pipe diameter, which corresponds to a 114.3 200 57
maximum bending stress of 210 N/mm2.
139.7 225 70
Tighter curves can be created by using curved
pipes or elbows. 168.3 250 84
219.1 315 110
273.0 400 137
323.9 450 162
355.6 500 178

406.4 560 203
457.0 630 229
508.0 710 254
610.0 800 305

711.0 900 356
813.0 1000 407

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Possible applications for on-site curved
pipes
Description Design
Preinsulated pipes in dimensions ø 26.9 - 88.9 Design with on-site curved pipes partly
mm can be formed on site as the pipes are depends on the radii obtainable with the
installed. bending tools.
If, for instance, an angle displacement with

dimension ø 42.4 mm is required, a radius of
either 5.8, 9.4 or 16 m can be chosen.
We recommend that the number of the tool to

be used is stated on the drawing and,
possibly, also the radii obtainable.
Other radii than those obtainable with the

Bending method tools may be part of the project, when it is
Four different tools are available for curving pipes taken into account during installation.
on site. Please, see installation instructions.
By means of the 4 tools a number of different radii
can be obtained dependent on the dimension of If the radius of the trench differs from the
the pipe to be formed. radius obtainable with the tool, there are
The table indicates the obtainable radii. different possibilities of forming the pipes after
Steel pipe Tool No.:
the trench.
out. ø mm 1 2 3 4 1.
26.9 4,9 8,2 18 39
By combining the radii obtainable with the
33.7 *4,3 6,7 12 25
42.4 5,8 9,4 16
elasticity of the pipes (elastic curves) the pipes
48.3 *5,4 8,5 13,3 can very often be pulled into postion.
60.3 7,5 11,0
2.
76.1 *6,9 9,6
88.9 9,1
By leaving a straight piece of pipe between
the curves an “artificial curve” with a larger
Conditions radius can be installed.
It is a condition that the curved pipes are installed
horizontally and covered with min. 0.4 m soil.
The bold figures are the radii for which the
particular tool has been primarily constructed.
The figures in the hatching state the radii for which
the tools are not necessary as the pipes can be
installed as elastic curves. See table on page
4.1.2.
The figures marked with *) state the radii which
can be formed with the tool for which,
however, a larger installation depth than 0.4 m is
required. See table for curved pipes.
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Curved pipes

The table below gives the relationship between L=6m L = 12 m L = 16 m
pipe length L, angle β, rising height h and design β h Rd h Rd h Rd
radius Rd. m m m m m m
Maximum angles β for standard curved pipes are 13° 0.28 26 0.45 53 0.57 70
given in the Bonded system - Components section.
14° 0.30 24 0.49 49 0.61 65
L=6m L = 12 m L = 16 m 15° 0.33 23 0.52 46 0.65 61
β h Rd h Rd h Rd
16° 0.35 21 0.56 43 0.70 57
m m m m m m
17° 0.37 20 0.59 40 0.74 54
1° 0.02 344 0.03 688 0.04 917
18° 0.39 19 0.63 38 0.78 51
2° 0.04 172 0.07 344 0.09 458
19° 0.41 18 0.66 36 0.83 48
3° 0.07 115 0.10 229 0.13 306
20° 0.43 17 0.70 34 0.87 46
4° 0.09 86 0.14 172 0.17 229
21° 0.46 16 0.73 33 0.91 44
5° 0.11 69 0.17 137 0.22 183
22° 0.48 15 0.76 31 0.96 42
6° 0.13 57 0.21 115 0.26 153
23° 0.50 15 0.80 30 1.00 40
7° 0.15 49 0.24 98 0.31 131
24° 0.52 14 0.83 29 1.04 38
8° 0.17 43 0.28 86 0.35 115
25° 0.54 14 0.87 27 1.08 37
9° 0.20 38 0.31 76 0.39 102
26° 0.56 13 0.90 26 1.13 35
10° 0.22 34 0.35 69 0.44 92
27° 0.58 13 0.94 25 1.17 34
11° 0.24 31 0.38 62 0.48 83
28° 0.61 12 0.97 24 1.21 33
12° 0.26 29 0.42 57 0.52 76
29° 0.63 12 1.00 24 1.26 31
30° 0.65 11 1.04 23 1.30 30
31° 0.67 11 1.07 22 1.34 29

32° 0.69 11 1.11 21 1.38 28
33° 0.71 10 1.14 21 1.43 28
34° 0.73 10 1.17 20 1.47 27
35° 0.75 10 1.21 19 1.51 26

36° 0.77 9 1.24 19 1.55 25
37° 0.79 9 1.27 18 1.59 25
38° 0.82 9 1.31 18 1.64 24
39° 0.84 9 1.34 17 1.68 23

40° 0.86 8 1.38 17 1.72 23
41° 0.88 8 1.41 17 1.76 22
42° 0.90 8 1.44 16 1.80 22
43° 0.92 8 1.47 16 1.85 21

44° 0.94 8 1.51 15 1.89 21
45° 0.96 7 1.54 15 1.93 20

Version/2007.03.UK
Application ranges for curved pipes

Description Conditions
The table for horizontal installation is based on
Curved pipes are preinsulated pipes which are the following conditions:
produced in 2 different ways dependent on the
dimension and the required design angle: Installation methods I, II, and III
- On-site curved pipes - are formed with a special p: earth pressure in N/mm² each pipe
tool h: soil cover (m)
- Machine curved pipes - are formed in a v°max: max. angular displacement each 12 m
machine Rp: min. design radius (m)
v°max and Rp refer to the centre line of the
trench
Application range for on-site curved pipes
Steel pipe p=0.05 p=0.058 p=0.065 p=0.073 p=0.09
ø out. h=0.4 h=0.5 h=0.6 h=0.7 h=0.8
mm v°max Rp v°max Rp v°max Rp v°max Rp v°max Rp
26.9 5.9 5.1 4.6 4.1 3.8
33.7 7.6 6.6 5.9 5.3 4.8
42.4 7.7 6.9 6.2 5.5 5.1
48.3 9.3 8.0 7.2 6.4 5.2
60.3 12.0 10.0 9.0 8.0 7.3
76.1 13.0 12.0 10.0 9.2 8.3
88.9 15.0 13.0 12.0 11.0 9.6
Application range for machine curved pipes

Steel pipe p=0.05 p=0.058 p=0.065 p=0.073 p=0.09
ø out. h=0.4 h=0.5 h=0.6 h=0.7 h=0.8
mm v°max Rp v°max Rp v°max Rp v°max Rp v°max Rp
114.3 38 18 38 18 38 18 38 18 38 18
139.7 34.5 20 40.5 17 43 16 43 16 43 16
168.3 28.5 24 33 21 36 19 40.5 17 46 15
219.1 23.5 29 27.5 25 30 23 34.5 20 38 18
273 21 33 24.5 28 27.5 25 31 22 33 21
323.9 17 40 19.5 35 22 31 24.5 28 27.5 25
355.6 17 40 20 34 23 30 25.5 27
406.4 13 53 15 46 17 40 19 36
457 12.5 55 14.5 47
508 9.0 76
559 5.0 138
610 5.0 138
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Pipe trench

Trenches for laying LOGSTOR pipes should be Pipe trenches
made in accordance with instructions below.
The trench cross-section must allow pipe
installation and jointing to be carried out in a
suitable manner and access for backfilling to be
compacted.
Place the casings C at intervals of min. 150 mm; we
recommend an increased distance according to the
table.
Casing pipe diameter Distance between

D, mm casings C, mm
90 - 180 150
200 - 560 250
630 - 900 300
Take account of cables and pipes already in the Pack the backfilling with a shovel and compact the
ground and the need for gravel around the pipes by hand. According to
trench drainage. specifications, the pipes must be covered with a
In areas with poor subsoil quality, it may be layer of min. 100 mm backfilling.
necessary to replace some of the soil to a As the backfilling progresses any supports under
substantial depth to avoid settlement. the pipes should be removed.
Warning tape is placed at least 200 mm above both
Backfilling material
pipes, and the trench is refilled, if possible with the
The following specification for backfilling material dug out material.
should be observed as regards pipe ends that are Compaction from 200-500 mm above the pipes
subject to movements: can be carried out using a flat-bed vibrator with a
maximum ground pressure of 100 kPa.
In areas with a substantial traffic load, or where
Maximum grain size < 32 mm a soil cover of min. 500 mm cannot be observed,
Maximum 9% weight < 0.075 mm the pipes must be protected, e.g. by means of a
or 3% weight < 0.020 mm steel plate.
d60
Non-uniformity figure > 1.8
d10
The dug up material can be used immediately in the

friction fixated stretches after elimination of objects
bigger than 60 mm. The backfilling material must
not contain more than 2% organic material. It must
be compressed to such an extent that the
requirements for surface stability are observed.
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Maximum fitting length of pipe

Friction Maximum fitting length of pipe
The frictional force between the casing pipe and Axial stress in the steel pipe increases with the
the soil can be calculated using the formula given distance from an expansion point.
below. The maximum permissible fitting length of pipe
Lmax, is thus determined by the maximum
permissible axial stress in the steel pipe.
( 1 + Ko ) . . . . .
F = π D z γ μ Lmax can be calculated on the basis of the following
2
formula.
F =frictional force per unit length, N/m
D =casing pipe diameter, m
z =laying depth from centreline of pipe, m σa perm . A
Lmax =
γ =specific gravity (of soil), N/m3 F
µ =coefficient of friction between soil
and casing pipe. For normal movement Lmax = maximum fitting length of pipe, m
use μ = 0.4. σa perm = permissible axial stress in the steel
Ko = coefficient of rest pressure (normally 0.5) pipe, N/mm2
A = cross-sectional area of steel pipe, mm2
Example (Series 1)
Example continued (Series 1)
d = 168.3 mm
D = 250 mm σa perm = 150 N/mm2
z = 725 mm A = 2065 mm2
γ = 18000 N/m3
µ = 0.4 150 . 2065
Lmax = = 101 m
3075
( 1 + 0.5) . .
F = π 0.250 . 0.725 . 18000 . 0.4
2
The tables on the following pages give F and Lmax
for range of pipe dimensions for Series 1, 2 and 3.
F = 3075 N/m
Version/2007.03.UK
Series 1

The table below gives sets of values for pipe Assumptions
dimension d, soil cover H, frictional force F and
maximum fitting length of pipe Lmax for the
traditional laying methods for pipelines with normal γ = 18000 N/m3
insulation (series 1). μ = 0.4
The following pages have the same tables for σa perm = 150 N/mm2
Series 2 and Series 3.
Diameter Wall Cross-sec. Diameter Soil cover H

Steel pipe thickness area casing pipe 0.5 m 0.75 m 1.0 m
steel pipe steel pipe
d s A D F Lmax F Lmax F Lmax
mm mm mm2 mm N/m m N/m m N/m m
42.4 2.6 325 110 1036 47 1502 32 1969 25
48.3 2.6 373 110 1036 54 1502 37 1969 28
60.3 2.9 523 125 1193 66 1723 46 2253 35
76.1 2.9 667 140 1354 74 1948 51 2541 39

88.9 3.2 862 160 1574 82 2253 57 2931 44
114.3 3.6 1252 200 2036 92 2884 65 3732 50
139.7 3.6 1539 225 2338 99 3292 70 4246 54
168.3 4.0 2065 250 2651 117 3711 83 4771 65

219.1 4.5 3034 315 3514 130 4850 94 6186 74
273.0 5.0 4210 400 4750 133 6447 98 8143 78
323.9 5.6 5600 450 5535 152 7443 113 9352 90
355.6 5.6 6158 500 6362 145 8482 109 10603 87

406.4 6.3 7919 560 7410 160 9785 121 12160 98
457.0 6.3 8920 630 8710 154 11382 118 14054 95
508.0 6.3 9930 710 10298 145 13310 112 16321 91
610.0 7.1 13448 800 12215 165 15607 129 19000 106
711.0 7.1 15701 900 14505 162 18322 129 22139 106
813.0 8.0 20232 1000 16965 179 21206 143 25447 119
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Series 2

steel pipe thickness area casing pipe 0.5 m 0.75 m 1.0 m
26.9 2.6 198 110 1036 29 1502 20 1969 15

33.7 2.6 254 110 1036 32 1502 22 1969 17
42.4 2.6 325 125 1193 41 1723 28 2253 22
48.3 2.6 373 125 1193 47 1723 32 2253 25
60.3 2.9 523 140 1354 58 1948 40 2541 31

76.1 2.9 667 160 1574 64 2253 44 2931 34
88.9 3.2 862 180 1802 72 2565 50 3328 39
114.3 3.6 1252 225 2338 80 3292 57 4246 44
139.7 3.6 1539 250 2651 87 3711 62 4771 48

168.3 4.0 2065 280 3040 102 4228 73 5415 57
219.1 4.5 3034 355 4080 112 5586 81 7091 64
273.0 5.0 4210 450 5535 114 7443 85 9352 68
323.9 5.6 5600 500 6362 132 8482 99 10603 79

355.6 5.6 6158 560 7410 125 9785 94 12160 76
406.4 6.3 7919 630 8710 136 11382 104 14054 85
457.0 6.3 8920 710 10298 130 13310 101 16321 82
508.0 6.3 9930 800 12215 122 15607 95 19000 78

610.0 7.1 13448 900 14505 139 18322 110 22139 91
711.0 7.1 15701 1000 16965 139 21206 111 25447 93

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Series 3

steel pipe thickness area casing pipe 0.5 m 0.75 m 1.0 m
26.9 2.6 198 125 1193 25 1723 17 2253 13

33.7 2.6 254 125 1193 28 1723 19 2253 15
42.4 2.6 325 140 1354 36 1948 25 2541 19
48.3 2.6 373 140 1193 47 1723 32 2253 25
60.3 2.9 523 160 1574 50 2253 35 2931 27

76.1 2.9 667 180 1802 56 2565 39 3328 30
88.9 3.2 862 200 2036 63 2884 45 3732 35
114.3 3.6 1252 250 2651 71 3711 51 4771 39
139.7 3.6 1539 280 2651 87 3711 62 4771 48

168.3 4.0 2065 315 3514 88 4850 64 6186 50
219.1 4.5 3034 400 5535 82 7443 61 9352 49
273.0 5.0 4210 500 6362 99 8482 74 10603 60
323.9 5.6 5600 560 7410 113 9785 86 12160 69

355.6 5.6 6158 630 8710 106 11382 81 14054 66
406.4 6.3 7919 710 10298 115 13310 89 16321 73
457.0 6.3 8920 800 12215 110 15607 86 19000 70
508.0 6.3 9930 900 14505 103 18322 81 22139 67

610.0 7.1 13448 1000 16965 119 21206 95 25447 79
Version/2007.03.UK
Installation method 1
Compensated

The compensated system must be covered before
heating.
Expansion is absorbed either in axial compensators
or in loops placed along the route. The distance
between compensators/loops depends on the
frictional force between the casing pipe and the soil
and by the permissible stress in the steel pipe.

The axial force, and thus the axial stress in the pipe, This formula does not include the influence on the
increases with the distance from an expansion axial stress that comes from the internal pressure,
element. since this stress has only minor influence on the
expansion.
Consequently, the fitting length of pipe, L, must be
limited to ensure that the permissible stress for the When the pipe is cooled down, the retraction is
steel pipe is not exceeded. This means that L must approx half of the first expansion.
not be bigger than Lmax. Elbows needed to absorb expansion are installed
Frictional force F, between casing pipe and soil, as with foam pads, see later on in this section.
well as determination of Lmax, is described under
section Maximum fitting length of pipe. Example (Series 1)
d = 168.3 mm
D = 250 mm = 0.25 m
H = 0.6 m => z = 0.725 m
γ = 18000 N/m³
µ = 0.4
td = 90°C
ti = 20°C
L = 120 m
A = 2065 mm2
Which gives:
F = 3075 N/m
ΔL = 0.050 m = 50 mm
Expansion
The first expansion of the steel pipe after covering
can be determined by means of the formula below.
F . L2
ΔL = α (td - ti) L -
2.E.A
ΔL = expansion, m
α = coefficient of expansion of the steel pipe,
1.2.10-5 K-1
td = design temperature, °C
ti = installation temperature, °C
L = length of pipe, m
E = Young's modulus;
2.1.105 N/mm2 for steel
Version/2007.03.UK
F = frictional force N/m
Compensated

Branch pipes
Branchings that are not placed midway between
two compensators or close to an anchoring point
must be installed with foam pads, corresponding to
the sidewards movement to which the branching
point is exposed.
The sidewards movement follows from the
formula below:
. .
ΔLT = α (td - ti) LT - F (2L. - L. T) LT
2 E A
ΔLT = movement at the branching point, m

α = coefficient of expansion, steel,
1.2.10-5 K-1
L = fitting length of pipe, m
LT = distance from branching to nearest
anchor, m
E = Young's modulus;
2.1.105 N/mm2 for steel
F = frictional force N/m
Version/2007.03.UK
Heat prestressed

Before covering the pipe system is heated to a The axial stress in the restrained area can be
temperature (preheating temperature) that lies calculated on the basis of the following formula.
between the installation temperature and the
operating temperature.
Foam pads are not used. σa = E . α . Δt
Preheating can be carried out with heat from the σa = axial stress, N/mm²
existing system or by means of electricity or E = Young's modulus, N/mm2
vacuum steam. α = coefficient of expansion, K-1
After covering, the system is heated to operating Δt = temperature difference, K
temperature.
Elbows are fastened by the filling material and the If (td - ti) ≤ 120°C , the preheating temperature is
soil. calculated as:
Using foam pads will change the
beregningsforudsætningerne jf. method 1.
(ti + td )
If the system is subsequently cooled to below the tpre =
2
preheating temperature, tensile stress will occur in
the steel pipes. ti = installation temperature, °C
When selecting the preheating temperature, efforts td = design temperature, °C
should be made to ensure that the compressive tpre = preheating temperature, °C
stress at operating temperature and the tensile
stress during cooling are the same, and that they
do not at any time exceed the maximum Example
permissible stress.
ti = 10°C
td = 90°C
tpre = 50°C
Cooling to installation temperature:

Δt = 50 - 10 = 40 K
σa = 2.1.105 . 1.2.10-5 . 40 = 101 N/mm²
Heating to operating temperature:

Δt = 90 - 50 = 40 K
σa = 2.1.105 . 1.2.10-5 . 40 = 101 N/mm²
If during operation the temperature of the pipes is

expected to be lower than the installation
temperature, this lower temperature must be used
when calculating preheating temperature.
Version/2007.03.UK
Heat prestressed

Expansion
The expansion, ΔL1, in the open trench, when

heating to the preheating temperature, can be
calculated as described for free expansion. In the
formula, just replace ΔL by ΔL1 and Δt = (tpre- ti).
The friction between the casing pipe and the
underlying soil is disregarded.
Example
Installation and working temperatures,

calculated as in the example on the
previous page.
Δt = 40K
L = 100 m
α = 1.2 . 10-5 K-1
ΔL = 1.2 . 10-5 . 40 . 100 = 0.048 m = 48 mm
The friction between casing pipe and soil resulting

from its own weight may hinder expansion. This
problem can be solved by lifting up the pipes during
preheating or by splitting the preheating into
several, smaller sections.
Version/2007.03.UK
Heat prestressed with start-up compensators

The heat prestressed system with start-up Example
compensators is a combination of the
compensated and the heat prestressed systems.
Foam pads are not used. L = 100 m
ti = 8°C
The pipes are laid in the trench and the start-up td = 80°C
compensators mounted.
The pipes are covered before heating. However, it ΔL = ½ (80 - 8) . 100 . 1.2 . 10-5
is necessary to leave access holes at the start-up
compensators. ΔL = 0.043 m
Elbows are fixed by the filling material and the soil. The start-up compensator is preset to 43 mm.
Application of foam pads will change the
assumptions for the calculation ref. method 1.
Branch pipes
The distance between two start-up compensators
must not exceed Lmax (see Maximum fitting length). Branchings that are not placed midway between
The distance from an anchoring point to a start-up two compensators or close to an anchoring point
compensator must not exceed ½ Lmax. must be installed with foam pads, corresponding to
the sidewards movement to which they are
exposed.
The sidewards movements at the branching point
can be calculated, using the formula below.
ΔLT = ½ (td - ti) . (½ L - LT) α
ΔLT = movement at the branching point

LT = distance between branching and
nearest start-up compensator
L < Lmax
Before installation, the start-up compensator is

preset to the calculated movement which it must
absorb during the preheating. The start-up
compensator is welded when fully compressed.
The maximum movement is indicated on the
start-up compensator.
The presetting of the start-up compensator can be
calculated, using the formula below:
ΔL = ½ (td - ti) L. α
ΔL = expansion to be absorbed in the

compensator, m
α = coefficient of expansion, K-1
L = distance between 2 start-up
Version/2007.03.UK
compensators (max value is Lmax), m
Cold installation

The cold installed system must be backfilled before Reinforcements
heating.
In cold installed sections where axial stresses are
When cold installation is used, no compensating higher than 150 N/mm2, reinforced T-fittings must
elements are applied. The temperature load is be applied and reinforcement must be made where
sustained as stress only. borings are used. It is not allowed to build in
reductions.
Max temperature load
Change of direction
Curved pipes and flexible bends can be built into
the sections which have been installed using the
cold installation method. Mitring must be kept at a
minimum according to the table due to the high
stress level:
Δtmax, K max angle
rm/t= 28.7 90 2°
100 1°
110 0.5°
>110 0°
Expansion
At the beginning and at the end of a cold laid
section allowance must be made for the high stress
The figure gives the max temperature load Δt as a
level. In elbows supplied with foam pads, the
function of the ratio between the mean radius of the
movements will be larger than in sections where
carrier pipe and the wall thickness for P235GH and
traditional installation is used. It is recommended to
St. 37.0 BW.
either make specific calculations of the elbows or
For dimensions up to 323.9 mm with standard wall to combine the terminations of the cold installed
thickness the max temperature load is Δt = 130 K. section with laying methods 3 or 4.
For larger dimensions the max temperature load
decreases: Parallel trenching
In the case of parallel trenching during operation,
d, mm Δtmax, K allowance must be made for the high stress level
406.4 118 and the following risk of instability. The distance to
a parallel trench must be calculated on the basis of
508.0 96 the actual stress level.
610.0 90
813.0 78
The table describes the range where the pipes can

be laid using the cold laying method without any
risk of buckling.
Version/2007.03.UK
Absorption of expansion
Foam pads

If expansion is to be absorbed by U-loop, L- or
Z-offsets, foam pads must be placed along the 70 mm < ΔL < 105 mm: 3 layers of foam pads
moving leg, B.
It is sufficient to install foam pads at 2/3 of the
length, B.
If the expansion is less than 10 mm, no foam pads 2/3 B
are used. B
Each layer of foam pads can absorb 35 mm

of expansion.
The foam pad is cut to a height corresponding to
the diameter of the casing. Cut the foam pad in a
ridge. The pad is wrapped around the casing and Example
fixed with filament tape.
10 mm < ΔL < 35 mm: 1 layer of foam pads

B
2/3 B
B
U-elbow:
d = 168.3 mm
D = 250 mm
ΔL = 64 mm (32 mm per leg)
B = 4.5 m (determined on the basis of
35 mm < ΔL < 70 mm: 2 layers of foam pads the U-loop curve)
Since ΔL per leg < 35 mm, 1 layer of foam

pads must be used.
2/3 B The legs in the U-loop must be installed with
B foam pads on at 2/3 of the length, B = 3.0 m.
The length of the foam pads is 1000 mm. This
means that a total of 6 pads are required.
Version/2007.03.UK
Change of direction

Expansion can be absorbed in a change
of direction.
A change of direction of less than 45° is not able to
absorb expansion. β
For changes of direction at angles between 45° and

90°, the resulting expansion can be determined on ΔL1*
ΔL2*
the basis of the following.
ΔL2
ΔL1
ΔL2 ΔL1
ΔL1* = +
tanβ sinβ
ΔL1 ΔL2
ΔL2* = +
tanβ sinβ
ΔL1 and ΔL2 are the free expansion.
Example
β = 45°
ΔL1 = 40 mm
ΔL2 = 25 mm
25 40
ΔL1* = + ~ 82 mm
tan 45° sin 45°
40 25
ΔL2* = + ~ 75 mm
tan 45° sin 45°
Once the resulting expansion has been calculated,

the length of the moving leg can be determined by
consulting the graphs on the following pages.
The moving leg must be installed with foam pads

on 2/3 of its length, B.
Version/2007.03.UK
L-offset

In an L-offset, expansion is absorbed as shown on ΔL is the expansion, calculated on the basis of the
the following drawing. laying method applied. Once ΔL is known, the
length of the moving leg, B can be read.
ΔL In the figure below, B is shown as a function of the

expansion, ΔL.
Example
B
d = 168.3 mm, ΔL = 30 mm, B = 3.0 m
B [m]
20 813.0
711.0
610.0
457.0 508.0
355.6 406.4
273.0 323.9
219.1
10
9
168.3
8 139.7
114.3
7
88.9
6 76.1
60.3
5
48.3
42.4
4
33.7
26.9
3
1
10 20 30 40 50 100 150
ΔL [mm]
Version/2007.03.UK
U-loop

In a U-loop, expansion is absorbed as shown on ΔL is the expansion, calculated on the basis of the
the drawing below. laying method applied. Once ΔL is known, the
Foampads are placed to absorb ΔL1 and ΔL2
ΔL = ΔL1 + ΔL2 B2
respectively.
B2 > ½B
In the figure below, B is shown as a function of the
expansion, ΔL.
B
Example
ΔL1
ΔL2
d = 168.3 mm, ΔL = 50 mm, B = 1.9 m
813.0
711.0
610.0
508.0
457.0
B [m]
9 406.4 355.6
323.9
273.0
8 219.1
6 168.3
139.7
114.3
5
88.9
76.1
4
60.3
48.3
3 42.4
33.7
26.9
1
30 40 50 60 70 80 90 100 200 300
Version/2007.03.UK
ΔL [mm]
Z-offset

In a Z-offset, expansion is absorbed as shown on ΔL is the expansion, calculated on the basis of the
the drawing below. laying method applied. Once ΔL is known, the
ΔL1 In the figure below, B is shown as a function of the

expansion, ΔL.
Example
B
d = 168.3 mm, ΔL = 45 mm, B = 3.5 m
ΔL2
ΔL = ΔL1 + ΔL2
813.0
B [m] 711.0
20 610.0
457.0 508.0
355.6 406.4
273.0 323.9
219.1
168.3
139.7
10 114.3
9 88.9
76.1
8
7 60.3
48.3
6
42.4
5 33.7
26.9
4
1
20 30 40 50 100 200 300
ΔL [mm]
Version/2007.03.UK
Anchoring of pipes

The anchoring block must be designed on the The block is assumed to be loaded from one side.
basis of the geotechnical conditions.
The following information can be used as a
guideline. B
A concrete block is cast on solid ground, and the L
backfilling around it compacted.
If the ground is impermeable, drainage must be
provided to avoid damming up the trench at
the anchor.
The concrete block must be cured and backfilled
before the system is heated. H
The following recommended dimensions for

concrete blocks are based on the following
assumptions:
Soil pressure = 150 kN/m2 over the Diameter Permissible

whole block steel pipe axial force Concrete block Reinforcem.
Reinforcement = Rib bar steel Ks 410, d L H B No. of Dim.

mm kN m m m brack. mm
fyk > 410 N/mm2
26.9-48.3 30-60 1.0 0.50 1.0 4 8
Concrete = Concrete 20 N/mm2
fck > 20 N/mm2 60.3-76.1 80-100 1.2 0.50 1.0 4 8
88.9-114.3 130-200 1.8 0.70 1.0 4 10
139.7 250 2.3 0.80 1.0 4 12
168.3 300 2.3 0.90 1.0 4 12

219.1 500 2.8 1.20 1.0 6 12
273.0 650 3.0 1.50 1.0 6 16
323.9 850 3.8 1.50 1.0 6 20
The system designer is responsible for calculating

the block size required.
Version/2007.03.UK

Bonded System - Design: Water Quality

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Introduction

Bonded system - Design 4.1.1

The mode of operation depends on the pipe laying

Bonded system - Design 4.1.2

Dependent on the joint system directional changes 26.9 90 13

The bending radius is calculated as 500 times the 88.9 160 44

273.0 400 137

323.9 450 162

355.6 500 178

457.0 630 229

508.0 710 254

610.0 800 305

813.0 1000 407

If, for instance, an angle displacement with

We recommend that the number of the tool to

Other radii than those obtainable with the

Bonded system - Design 4.1.4

30° 0.65 11 1.04 23 1.30 30

31° 0.67 11 1.07 22 1.34 29

33° 0.71 10 1.14 21 1.43 28

34° 0.73 10 1.17 20 1.47 27

35° 0.75 10 1.21 19 1.51 26

37° 0.79 9 1.27 18 1.59 25

38° 0.82 9 1.31 18 1.64 24

39° 0.84 9 1.34 17 1.68 23

41° 0.88 8 1.41 17 1.76 22

42° 0.90 8 1.44 16 1.80 22

43° 0.92 8 1.47 16 1.85 21

45° 0.96 7 1.54 15 1.93 20

Bonded system - Design 4.1.5

Application range for machine curved pipes

Bonded system - Design 4.1.6

Casing pipe diameter Distance between

630 - 900 300

The dug up material can be used immediately in the

Bonded system - Design 4.1.7

Bonded system - Design 4.1.8

Diameter Wall Cross-sec. Diameter Soil cover H

48.3 2.6 373 110 1036 54 1502 37 1969 28

60.3 2.9 523 125 1193 66 1723 46 2253 35

76.1 2.9 667 140 1354 74 1948 51 2541 39

114.3 3.6 1252 200 2036 92 2884 65 3732 50

139.7 3.6 1539 225 2338 99 3292 70 4246 54

168.3 4.0 2065 250 2651 117 3711 83 4771 65

273.0 5.0 4210 400 4750 133 6447 98 8143 78

323.9 5.6 5600 450 5535 152 7443 113 9352 90

355.6 5.6 6158 500 6362 145 8482 109 10603 87

457.0 6.3 8920 630 8710 154 11382 118 14054 95

508.0 6.3 9930 710 10298 145 13310 112 16321 91

Bonded system - Design 4.1.9

26.9 2.6 198 110 1036 29 1502 20 1969 15

42.4 2.6 325 125 1193 41 1723 28 2253 22

48.3 2.6 373 125 1193 47 1723 32 2253 25

60.3 2.9 523 140 1354 58 1948 40 2541 31

88.9 3.2 862 180 1802 72 2565 50 3328 39

114.3 3.6 1252 225 2338 80 3292 57 4246 44

139.7 3.6 1539 250 2651 87 3711 62 4771 48

219.1 4.5 3034 355 4080 112 5586 81 7091 64

273.0 5.0 4210 450 5535 114 7443 85 9352 68

323.9 5.6 5600 500 6362 132 8482 99 10603 79

406.4 6.3 7919 630 8710 136 11382 104 14054 85

457.0 6.3 8920 710 10298 130 13310 101 16321 82