steelpipe sales catalogue 4th edition may 12

8/10/2019 Steelpipe Sales Catalogue 4th Edition May 12

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N E W Z E A L A N D

F o u r t h E d i t i o n M a y 2 0 1 2


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Table of Contents

DisclaimerSteelpipe New Zealand has provided this manual and the guidelines contained within asgeneral recommendations regarding the manufacture, supply and installation of spiralwelded steel pipe and are intended to be informative only. Nothing contained withinthis Manual creates a contractual obligation on the part of Steelpipe New Zealand, adivision of Steelpipe Limited and pipe owners, designers, contractors and pipe installersmust rely on their own expertise with respect to the actual design performance andinstallation of pipe on specific projects and comply with all applicable laws, regulations

and code requirements

1 Company Data2 Steelpipe New Zealand

3 The Steelpipe Advantage4 Product Features and Benefits5 Capability6 Process / Manufacturing Facilities7 Steelpipe Specifications8 Export Range9 Management Systems10 Management Systems11 Sustainability12 Coating Systems

16 Lining Systems18 Joint Details21 Structural & Pile Casing25 High-Spec Spiral Welded Linepipe To API 5L30 Water & Wastewater Reticulation32 Water & Wastewater Specifications33 Water & Wastewater Fittings34 Typical Water & Wastewater Fittings42 Safe Maximum Support Spans Guidelines46 Transportation48 Handling and Installation Guidelines

49 Transportation50 Unloading and Handling52 Stacking and Storage54 Bedding55 Laying and Jointing57 Backfilling58 Repairs and Testing


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Company DataSteelpipe New Zealand

Street Address 224 Neilson Street, Onehunga, Auckland, New

Zealand

Postal Address PO Box 13 514, Onehunga, Auckland, New Zealand

Contact Numbers Telephone: +64-9-622 4580 Facsimile: +64-9-636 6196

Site Details Manufacturing Buildings 6,250 sqm Administration Buildings 240 sqm Yard Space 28,000 sqm

Quality System AS/NZS ISO 9001:2008 Certified AS/NZS 4801: Certified

Product Certification Bureau Veritas NZS 4442

Email [email protected]

Website www.steelpipe.co.nz

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Steelpipe New Zealand

Steelpipe New Zealand has an engineering background spanning over a century. Today,Steelpipe New Zealand is a vibrant and progressive enterprise with its primary focus

being the manufacture of high-quality steel pipe technology for the reticulation ofwater and sewage to high spec applications, structural and foundation work.

Steelpipe New Zealand is part of the McConnell Group, one of New Zealands largestprivately owned construction, property and infrastructure groups whose passion iscreating and building project based businesses.

HistorySteelpipe New Zealand hasbeen at the forefront of pipetechnology and innovationsince it commenced tradingas Spiral & Lock-Bar SteelPipe Company of NewZealand Limited in 1903.

Over the years the companyhas refined its spiralforming process with thedevelopment of butt weldedspiral pipe in the 1950s.

Today Steelpipe New Zealand

operates three modern spiralmills utilising automaticdouble submerged arcwelding, with world classnon-destructive testingequipment, to producepipes to the highest international standards for domestic and overseas markets. Thecompany has also taken internationally recognised coating and lining systems andadapted these processes to suit the New Zealand and offshore market requirements.

In the domestic market, Steelpipe New Zealand has manufactured thousands of

kilometres of spiral-welded pipe for town water supply, sewage, irrigation and gasreticulation schemes. Pipes have also been supplied to many of the countrys hydro-electric generation and other major energy projects. Each new project adds to thecompanys wealth of knowledge of pipe manufacture and use.

In 2006 Steelpipe Australia was established to capatalise on the resource boomthroughout the previous decade. Steelpipe Australia focuses primarily on the pilingand structural markets and supports Steelpipes longer term growth aspirations.

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Steelpipe New Zealand manufactures and markets a range of spiral-welded steel pipe,steel pipe fittings and protection systems, and is single-minded in its commitment to

Total Quality Management through its operation.

Steelpipe New Zealand aims to manufacture all products to a high level of quality thatcomplies with product standards and unique customer requirements. To ensure thatthese aims are met, the company has established a fully documented quality systemthroughout all business activities.

The company is able to compete successfully, on a local and international level, by its:

extensive use of locally manufactured steel, which virtually eliminates inward freightcosts and provides maximum flexibility of supply;

strong quality focus; capacity for designing innovative solutions to customers problems; flexible manufacturing system; price competitiveness arising from stringent cost control, and an experienced team

able to give sound advice. proven delivery performance to meet clients requirements

Not to mention peace of mind that the product has been designed and manufacturedto do the job it was intended to do.

Convenient LocationConveniently located in Auckland, Steelpipe New Zealand has ready access to all major

highways as well as rail and sea transport.

Committed PeopleSteelpipe New Zealand can boast a committed team of qualified sales engineers andtechnical staff who take pride in all facets of their work. Steelpipe New Zealands keypeople are available to offer advice at any given stage of a contract.

The Steelpipe Advantage

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It has long been accepted that spiral-welded steel pipe makes for quality pipelines andfoundations. Now project designers are realising it has inherent advantages over

conventional longitudinal seam and girth welded barrel rolled pipe. The spiral formingprocess produces accurately manufactured pipe which ensures ease of use and, whencombined with high quality welding and testing, guarantees toughness, flexibility,versatility, safety in service, dependability and cost-effectiveness.

Benefits of Steel PipeSteelpipe New Zealand produces spiral-welded steel pipe to the highest quality. Thispipe is used throughout the world in a wide variety of applications including waterand sewage transmission, outfalls, pile casings, high-spec pipelines and commercialstructures. Spiral welded steel pipe offers numerous advantages over conventionalpipe, as detailed below.

Greater strength in proportion to wall thickness of any competitive product. It operatessafely at higher pressures and its strength provides distinct handling and layingadvantages in difficult locations. The weld is significantly less affected by circumferentialstress than alternative products.

Dependability and longevity.Recent major advances in steel fabricating, weldingtechniques and coatings development ensure theuseful life of the product and, once installed, it canbe depended upon to do the job for which it wasdesigned.

Ease of layingdue to longer pipe lengths, whichmeans less jointing; welded joints provide a pipelinethat acts as a structural member.

Flexibility of product permits it to live in theground secure against soil movement or abnormalshocks.

Accuracy of manufacturemeans an exceptionallystraight and circular product. This represents

significant advantages when matching pipes andpromotes ease of driving for pile purposes. Theconsistent circularity also produces advantageswhen jointing in the field and contributes to ease ofsplicing.

Versatilityof the spiral forming process enables awide range of diameters to be manufactured fromone common feed stock, which encourages pricecompetitiveness.

Product Features and Benefits

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Steelpipe New Zealand offers a broad spectrum of technical advice.

Component ManufactureSteelpipe New Zealand has large and well-equipped manufacturingfacilities and is able to offer:

Specialised manufacturing equipment and machinery Hi-spec welding High quality corrosion protection systems Pipe/specials fabrication.

Non-destructive Testing ProtocolsThroughout the manufacturing process, testing procedures are stringent andcomprehensive. Hydrostatic and real-time X-Ray equipment is used for the non-destructive testing of weld seams and it allows 100% of the seam to be inspectedon-screen. A permanent record can be achieved by storage on high-definition videoequipment.

In addition to these sophisticated testing procedures, all other quality requirements ofthe specifications nominated by the customer are maintained throughout the process.

Protection SystemsA range of coatings is available to provide added value to the product, including PolykenSynergy, Polyken YGIII, epoxy systems and metal spraying. Steelpipe New Zealand alsooffers a range of linings including, concrete and epoxy linings.

Technical Customer SupportRegular contact with clients onsite keeps the Steelpipe New Zealand team in touchwith current industry requirements. Experienced personnel are able provide technicaladvice on corrosion protection and Installations.

Steelpipe New Zealand will work with a client and exercise its full range of capabilityto deliver a solution. The expertise and facilities at Steelpipe New Zealand are alsoavailable for more specific workbriefs, such as:

Solutions to challenging requirements (innovation and development) Specialist and production fabrication Site support

Steelpipe New Zealand undertakes project work for many industries. These typicallyinclude:

Energy (Hydro, Geothermal, Co-gen, Wind) Water and sewerage Structural Irrigation

Capability

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Process / Manufacturing Facilities

Type of ManufactureAll pipe produced by Steelpipe New Zealand is by the spiral forming process.

The method of manufacture comprises the engagement of Hot Rolled Coil (HRC), whichis decoiled, flattened, trimmed and prepared for welding. From there, the steel is spiralformed and welded both internally and externally using the automatic submerged arcprocess.

Available FacilitiesSteelpipe New Zealand offers broad spectrum services for the manufacture of spiral-welded steel pipe. Subsequently its manufacturing facilities are comprehensive, asdetailed below.

Hot Rolled Coil

Trimming

Inside and OutsideWelding

Flying Cut-off

Forming

Skelp End Welding

Manufacturing Process

PROCESS DESIGNATION CAPABILITIES

Spiral Mill Mill No.1 345mm OD - 2030mm OD4.8mm WT - 16.0mm WT

Mill No.6 323mm OD - 812.8mm OD4.8mm WT - 9.53mm WT

Mill No.7 121mm OD - 345mm OD4.8mm WT - 6.2mm WT

Hydrotesters (3) 1, 6, 7 As per Mill capabilities

Real Time X-Ray X-Ray 508mm OD - 2030mm OD

Bevellers 1 508mm OD - 1930mm ODLining Concrete 121.9mm OD - 2030mm OD

Coating Polyken SynergyHeat Fused Polyethylene

345mm OD - 1254mm OD

Polyken YGIIICold Applied Polyethylene

121mm OD - 2030mm OD

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Steelpipe Specifications

This information is intended as a guide to assist in the preparation of specifications forspiral-welded steel pipe for a range of applications.

Steel SpecificationsSteelpipe New Zealands steel requirements are supplied by New Zealand Steel, fromtheir Glenbrook facility in Auckland. The steel is purchased as Hot Rolled Coil in eithermill edge or slit edge format. The product, which is manufactured using a continuouscast method, fully complies with international specifications, including:

Pipe SpecificationsSteelpipe New Zealand manufactures pipe using an automatic submerged arc processto most internationally recognised standards, including:

Polyethlene Tape Specifications

SPECIFICATION CODE GRADE

Australia / New Zealand Standard AS/NZ 1594 Grade 250 & Grade 350

European Standard EN 10025 Grade 250 & Grade 350

American Petroleum Institute API 5L Grade X42 - Grade X52

SPECIFICATION CODE PRODUCT USE

New Zealand Standard NZS 4442 Water/Sewage/Piling

Australia Standard AS 1579 Water/Sewage/Piling

British StandardBS 534 Water/Sewage/Piling

BS 3601 Structural/PilingAmerican Standard ASTM A252 Structural/Piling

Japanese Standard JIS 5525 Structural/Piling

American Petroleum Institute (Non-monogrammed)

API 5L Petrochemical /Geothermal

SPECIFICATION CODE PRODUCT USE

American Water Works Association AWWA C214 Cold applied tape wrapsAWWA C225 Hot applied tape wraps

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Management Systems

The company has achieved certification to the International Standards Organisation (AS/NZS ISO 9001-2008), the international standard for monitoring quality. In addition, the

company is able to comply with the majority of international specifications, includingAustralian, British and US standards. Specifications nominated by clients outside ofthese standards can also be accommodated.

QualitySteelpipe New Zealand is accredited as a supplier to the Quality ManagementSystem AS/NZS ISO9001. These policies and procedures and our adherence to themare regularly audited through independent bodies such as Telarc New Zealand (forour ISO 9001: 2008 Certification) and Bureau Veritas (for our Product Certification).Formal certification of SPNZ Quality Management System ensures our commitment toproviding the highest quality product to our customers.

Steelpipe New Zealand offer quality plans which include a comprehensive inspectionand test plans for the production of pipe shell through to coating and lining options. Thecompany can easily cater for unique customer contract requirements, and modificationto plant can be made to accommodate production timeframes.

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Management Systems

Health and SafetySPNZ is a static manufacturing site and has Certification to the Australia / New

Zealand Standard for Occupational Health and Safety Management Systems (AS/NZS4801:2001). This has been achieved by integrating the requirements of AS/NZS 4801into the ISO 9001 Quality System. Steelpipe reports monthly on a range of health andsafety metrics, incidents, audits and inspections.

EnvironmentalSPNZ as a heavy industrial manufacturing site has a number of environmental controlsand systems required by law. SPNZ is committed to ongoing continual improvementof our environmental performance.

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Sustainability

Supplier Statement of PositionSteelpipe New Zealand is committed to sustainability and

being a good corporate citizen by conducting business inan ethical, legal, environmentally and socially responsiblemanner.

The major raw material used in spiral welded pipe is steelwhich we source from New Zealand Steel Ltd

Unique Steel Made in New Zealand, for New ZealandNew Zealand Steel is the only steel manufacturer in the world to make steel fromironsand. High quality steel is manufactured from the vast inland ironsand depositson New Zealands west coast of the North Island. All materials used in New ZealandSteels manufacturing process are sourced locally in New Zealand and the end to endsteel making process is all conducted at the plant in Glenbrook, South of Auckland. Itis 100% New Zealand made.

New Zealand Steel recycles hot gases and steam in its Cogeneration plant to create upto 70% of its own electricity needs.

Up to 80% of waste from the steel making process is recycled back into the process orin to co-products. It is New Zealand Steels goal to achieve Zero Waste.

Land Restoration 25% of mined sand is extracted as Titanomagnetite (ironsand). Theremainder is returned to the mined areas, which are then planted with marram grass

and pine trees. Once restored there is little or no trace of mining.

New Zealand Steel also has rigorous sustainability processes and practices in place. Ithas ISO14001 environmental accreditation, has been judged best practice in energyefficiency by The Hatch Report, an International body and been awarded an Ministry ofEnvironment Award for waste reduction.

Steelpipe as a Sustainable Material Steel is 100% recyclable and is the most recycled material in the world. It does not suffer product degradation through endless recycling. Steel is relatively easy to recover from waste streams.

The metal recycling industry in New Zealand is well established. More than 90% of commercial steel construction waste is recycled. 40% of global steel output is made from recycled scrap. Steel contributes low levels of construction waste (6%) (Source: MfE). Steel is strong, long lasting and versatile, non-combustible and non-toxic. Steel lends itself to design for re-use.

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Coating Systems

Modern external coating systems are the primary line of defence against corrosion ofsteel pipe systems and are very effective when properly applied. Steelpipe New Zealand

offers several internationally specified coating systems. The requirements of each varywith the type of construction, system operating conditions, and the aggressiveness ofthe environment in which it will serve. The effectiveness of each coating system hingeson a range of parameters including:

Permanence and the degree to which it can resist physical hazards such astransportation, installation, soil stress and pressure;

Resistance to water penetration or absorption; Effective electrical insulation properties; Chemical inertness to soil, air, water and bacterial action.

General criteria - such as ease of application, high adhesion and compatibility of usewith cathodic protection - will also determine coating efficiency.

Coating SelectionIt is difficult to identify the corrosion potential of a steel pipe exterior due to the varietyof environments encountered. Resistivity of the soil is the greatest determinant ofcorrosiveness. Of secondary importance are soil chemical and physical analyses, pH,moisture content, and existence of stray electrical currents; each play an important rolein the selection process.

Once the level of soil corrosiveness is determined, subsequent conditions that affect thelong-term performance of protective coatings should be considered. Among these are:

Distorting stresses exerted on the coating during compaction and settling of thebackfill;

Mechanical stresses created by certain soils having very high expansion andshrinkage during wet and dry cycles;

Penetration by growing roots; Action of bacteria and fungus in soil surrounding the pipeline; Attack by soil chemicals or industrial wastes, chemicals and solvents that may be

present along the pipeline route.

Coating performance depends on putting the pipeline into service with the least amount

of coating damage. The system selected must not only meet the corrosion-controlneeds, but should also allow economical transportation, handling, storage, and pipelineconstruction with minimal coating damage. To ensure precise control of applicationand quality, the coatings are applied in a controlled factory environment. SteelpipeNew Zealand can provide a guide for appropriate protection during transportation,handling, and storage of pipe for a specific coating system.

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The flowchart (below) provides a generic rule of thumb for most steel pipe applications.It is important to note that outside these basic criteria, Steelpipe New Zealand should

be consulted for advice on the best solution.

Which Coating System?

Coating Systems continued

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Pipe work aboveor below ground?

Below ground

Above ground

Diameter 121 -1254 mm?

Polyken Synergy

Polyken YGIII

Yes

No

Diameter 1255

mm

Inside abuilding?

Epoxy / Vinyl System orHot Dip Galv

Yes

Marineexposure?

Hot Metal Spray and / orEpoxy System

Epoxy System

No

No

Yes


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Steelpipe New Zealand is able to apply a range of coating systems at its manufacturingfacility in Onehunga, Auckland.

Polyken SynergyTM

Polyken, as the industry leader in coating technology, has developed and commercialised,SynergyTM; a revolutionary new plant coating system. SynergyTMis a heat fused systemconsisting of primer, anti-corrosion layer and mechanical protection outerwrap, thatcombine to form a coating system that excels in toughness, corrosion protection andversatility.

Each component of SynergyTM has its specific attributes. Stress corrosion crackinginhibitors, heat-enhanced shear resistance, cathodic disbondment resistance andhigh adhesion properties characterise the primer. The innerwrap layer serves as animpermeable barrier to water and corrosive elements, and possesses an aggressiveadhesive engineered for high shear resistance and a polymeric alloy backing whichfuses completely with the outerwrap. The Polyken mechanical outerwrap layer is non-adhesive and comprises a polymeric alloy blended film, which is designed to fuse toitself to the innerwrap during application. This total fusion process creates a coatingwith excellent shear resistance, mechanical protection, superior impact resistance andoutstanding cathodic disbonding resistance.

Polyken products have been used by Steelpipe New Zealand since the early 1980s andhas proven performance throughout the world as illustrated in the Product ReferenceLists as attached (one for Polyken Synergy the other for Polyken products).

The Polyken Synergy product is applied to the American Water Works Associationstandard AWWA C225-2007: AWWA Standard for Fused Polyolefin Coating Systemsfor the Exterior of Steel Water Pipelines.

Polyken YGIIIThe Polyken YGIII coating system is a highly effective, cold applied anti-corrosionsystem for in-ground pipelines. Once again, a Polyken primer is employed. An anti-corrosion innerwrap and either one or two layers of outerwrap makeup the secondarycomponents of YGIII.

Polyken innerwrap incorporates a butyl alloy adhesive designed for plant coating

operations, and delivers a superior bond and conformity when applied to primed steelpipe. It is this layer that provides key corrosion protection to pipelines, both chemicallyand electrolytically.

Designed to aggressively adhere to the innerwrap, the outerwrap is a tough protectivesteel pipe outerwrap that is Holiday (pin hole) free. Its high density polyethylene backingis renowned for its ability to protect the innerwrap from damage during transportation,handling and installation.

Steelpipe New Zealand offers YGIII coating for pipe sizes above 1254mm OD, inaccordance with the specification for cold applied tape wraps provided by the American

Water Works Association: AWWA C214.


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Specialist Coating SystemsSteelpipe New Zealand is able to assist with the specification of specialist protective

systems and has developed strong relationships with other companies for theapplication of the chosen system. The following table of applications cover some ofthe more common areas where specialist coating systems are required with some ofthe alternative options available on the market.

All coated pipe is examined for Holidays (pin holes) through the employment of highvoltage in line detection equipment, in accordance with the NACE standard. AnyHolidays detected are repaired in the factory environment.

It is imperative that Steelpipe technical staff are involved at the outset to determinethe nature of the environment that the pipe will end up in. As well as providing advice,qualified staff are also able to provide points of reference for each of the differentsystems.

PIPE APPLICATION COATING SYSTEM APPLICABLE

Treatment Plants Inorganic zinc, epoxy and modified urethaneEpoxy primer plus high build high solidsepoxy or modified urethane topcoatHot dip galvanising

Bridge Crossings Epoxy systemsHot metal spray, sealed

Sea or Fresh Water Outfalls Hot metal spray, sealed

High Temperature Zones Temperature resistant Polyken systemHigh heat silicaInorganic zincHot metal spray

Wharf or Marina Piling Epoxy systemsHot metal sprays - zinc/aluminum,sealed with vinyl or epoxy

Structural Applications(internal or external)

Epoxy systemsHot metal spray, sealed with vinyl or epoxyInorganic zincVinylsEnamels

Directional Drillingand Thrusting of Pipe

SynergyTMcoatingHigh build epoxyPolyurethane

Negative Buoyancy Polyken SynergyTMcoating, weight coating withreinforcement and allowance for cathodic protection.


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Lining Systems

Pipe linings, as a form of corrosion control, play an important role in determining apipelines life span. As with coatings, the requirements of a specific lining will vary with

the type of fluid being conveyed and the environment. But there are other factors toconsider when choosing a lining. For example, toxicological requirements for potablewater, abrasion resistance and chemical attack.

Lining SelectionThe ultimate function of an internal lining system is the prevention of internal corrosion,while secondary functions include the production and maintenance of a smooth surfaceto ensure maximum flow capacity. The flowchart (below) provides a straightforwardapproach to determining what the most effective lining for your pipeline might be.Steelpipe New Zealand should be consulted for advice on the best solution.

Which Lining System?

Sulphate resistant linings are available, please consult with Steelpipe New Zealand for

more information.

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Water, Wastewater

or other fluids

Water

OtherWastewater

Concrete Lining

Epoxy Linings or alternative

material

Diameter > 121mm

OD

Yes

Will pipe be full?

Yes

pH < 4 ? Yes

No

No


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Concrete LiningConcrete linings for steel water and/or wastewater mains are noted for their durability,

providing many years of excellent service (in many cases, in excess of 50 years). Thesesurfaces are safeguarded by the alkaline cement environment, developed by theformation of calcium hydroxide during hydration of the cement, to neutralise the steelcorrosion process. The neutralisation occurs quickly in newly-lined surfaces and is notaffected by moisture and oxygen absorbed through the mortar lining.

Additional benefits of this form of lining include low-hydraulic frictional resistance andenvironmental soundness. Between the manufacture and installation of the lined pipe,the linings might exhibit shrinkage cracking. Autogeneous healingwill take place once the pipeline is in service. Please ensure that pipeline is commissionedappropriately before use.

Concrete is composed of Portland cement, sand and water, with the addition ofaggregate. Steelpipe New Zealand is able to supply concrete-lined pipelines in lengthsfrom 6.0 metres to 12.0 metres, and in sizes up to 1900 NB diameter.

Concrete linings can be achieved in accordance with several international standardsincluding the New Zealand Standard (NZS 4442), and the Australian Standard (AS1281).

Alternative LiningsThe range of alternative linings is comprehensive, varying from epoxy systems tourethanes that are applied on an abrasively cleaned surface. When making a selection,

there are a number of considerations, especially weight factors, highly aggressive wateror an unpleasant taste.

The most common alternative lining, the epoxy system, demonstrates excellent corrosionresistance properties and offers the required smoothness to maintain flow capacity.The lining system is able to protect steel water and waste water lines by isolating pipesurfaces from the environment. Please note that products utilised by this system musthave received potable water certification.

Lining Systems continued

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Flanged JointsThe flanged joint typically comprises a steel ring with machined face and drilled holes

welded to the end of the pipe or fitting, in accordance with a range of standardspecifications. The flanged joint requires no site welding or special equipment forinstallment.

In reticulation applications, flanges are commonly required for attaching pipes topumps, valves or other pipe materials. When specifying flanges, it is important tonominate exact specifications, sizes and dimensions to eliminate the possibility ofmismatching. Remember that dressing sets are required and these include either arubber or neoprene gasket, with bolts.

Steelpipe New Zealand can offer advice on flange specifications to assist accuracy.Common flange specifications include AS 4807, AS 2129 and BS 4504.

Figure Joint.3

Typical Flanged Joint

flange

bolts

gasket

SummaryThe requirements for installation and operation of a pipe system may dictate the useof more than one type of field joint. The type of internal lining and pipe diameter mayalso be determining factors in joint selection.

Welded joints offer integrity and create a structurally-sound pipeline. Flanges, on theother hand, are typically used to marry steel pipe to valves, pumps, meters and other

flanged accessories. Thermal stresses can be accommodated through the employmentof flexible coupling, grooved or shouldered coupling, or expansion joints. Rememberthat external corrosion protection systems must be reinstated at each joint. Cathodicprotection of any joint system can also be accommodated.

Joint Details continued

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Structural & Pile Casing

Benefits of QualitySteelpipe New Zealands spiral-welded steel pipe is ideal for use in structural applications,

such as foundation work (pile casing or piling) and in wharf, bridge and buildingconstruction projects, because it offers major advantages over alternative materials.The spiral forming process produces accurately manufactured pipe that makes theproduct easy to use and, combined with high quality welding and testing, ensuresenduring dependability.

Accuracy of manufacturemeans an exceptionally straight and circular product. Thisrepresents significant advantages for jointing, and maintaining alignment when drivingin the field.

Reliabilityof the spiral-weld process ensures a totally secure weld throughout therigorous pile driving process. All pile products are manufactured using the same double-automatic submerged arc welding process employed on high-spec API pipeline. Weldintegrity can be confirmed by hydrostatic testing and the use of real-time X-ray ofwelds.

Economy.Spiral-welded steel pipe is able to support exceptionally high loads, thusreducing the quantity of piles and the amount of ancillary foundation work requiredwith other products.

Flexibility in end-preparation means that the closure plates, cone points, driving shoesand crosses are all compatible with spiral-welded steel pipe. As an alternative, pipescan be driven open-ended where minimum soil displacement is desired.

Efficient splicing on-site due to the consistent circularity of pipe ends and tighttolerances of diameters. Moreover, piles can be easily spliced to extend the pile length,which is a requirement for deep driving. Numerous combinations for jointing systems(including machine-bevelled ends, to API specifications or customer requirements)are available to guarantee fast, accurate jointing in the field. Internal welding bands,supplied loose or tack-welded into one end of the pipe, can also be employed to alignpiles for jointing and provide backing for welding.

Variable lengths can be manufactured to suit ground conditions and changingdriving depths to minimise on site welding.

Technical DataThis information is intended as a guide and provides technical data for all standardpipe sizes. Preferred diameters and wall thicknesses are detailed in the following table.Please contact Steelpipe New Zealand for alternative sizes.

Corrosion protection is an important consideration for all the above pile steelapplications, particularly in marine environments. Refer Coating Systems section forfurther information.

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Outside Wall Inside Area Moment Section Radius of

Diameter Thickness Diameter Mass Steel of Inertia Modulus Gyration

mm mm mm kg/m mm I = 106mm4 Z =104mm4 k = mm

168.3 5 158.3 20.13 2565.11 8.558 10.170 57.762

168.3 6.2 155.9 24.78 3157.36 10.386 12.342 57.353

219.1 5 209.1 26.40 3363.07 19.280 17.600 75.716

219.1 6.2 206.7 32.55 4146.84 23.515 21.465 75.303

273.1 5 263.1 33.06 4211.30 37.850 27.719 94.804

273.1 6.2 260.7 40.81 5198.64 46.316 33.919 94.389

323.9 4.8 314.3 37.77 4811.91 61.260 37.827 112.832

323.9 6.4 311.1 50.11 6383.72 80.472 49.690 112.276

355.6 4.8 346.0 41.53 5289.94 81.388 45.775 124.038

355.6 6.4 342.8 55.12 7021.08 107.055 60.211 123.482

406.4 4.8 396.8 47.54 6055.99 122.108 60.093 141.997

406.4 6.4 393.6 63.13 8042.48 160.891 79.179 141.439

406.4 9.5 387.4 92.99 11845.53 233.386 114.856 140.366

457.2 4.8 447.6 53.55 6822.03 174.549 76.356 159.957

457.2 6.4 444.4 71.15 9063.87 230.292 100.740 159.398

457.2 9.5 438.2 104.89 13361.66 334.919 146.509 158.321

508.0 4.8 498.4 59.57 7588.08 240.194 94.565 177.916

508.0 6.4 495.2 79.17 10085.27 317.236 124.896 177.357

508.0 8.0 492.0 98.65 12566.37 392.800 154.646 176.799

508.0 9.5 489.0 116.79 14877.80 462.314 182.013 176.278

508.0 12.7 482.6 155.13 19761.59 606.393 238.737 175.173

508.0 16.0 476.0 194.14 24730.62 749.090 294.917 174.040

558.8 4.8 549.2 65.58 8354.12 320.526 114.719 195.876

558.8 6.4 546.0 87.19 11106.66 423.701 151.647 195.316

558.8 8.0 542.8 108.67 13843.11 525.077 187.930 194.758

558.8 9.5 539.8 128.69 16393.93 618.504 221.368 194.236

609.6 4.8 600.0 71.59 9120.17 417.027 136.820 213.836

609.6 6.4 596.8 95.21 12128.06 551.662 180.991 213.275

609.6 8.0 593.6 118.69 15119.86 684.148 224.458 212.717

609.6 9.5 590.6 140.59 17910.06 806.424 264.575 212.194609.6 12.7 584.2 186.95 23815.25 1061.121 348.137 211.084

609.6 16.0 577.6 234.23 29837.59 1315.155 431.481 209.946

711.2 4.8 701.6 83.62 10652.26 664.467 186.858 249.756

711.2 6.4 698.4 111.24 14170.84 879.981 247.464 249.195

711.2 8.0 695.2 138.74 17673.34 1092.553 307.242 248.635

711.2 9.5 692.2 164.40 20942.33 1289.192 362.540 248.111

711.2 12.7 685.8 218.77 27868.91 1700.225 478.128 246.998

711.2 16.0 679.2 274.31 34944.56 2112.220 593.988 245.855

Structural & Pile Casing: Dimensions, Masses and Technical Data

Structural & Pile Casing continued

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762 6.4 749.2 119.25 15192.24 1084.294 284.591 267.155

762 8 746 148.75 18950.09 1346.830 353.499 266.594

762 9.5 743 176.29 22458.46 1589.909 417.299 266.070

762 12.7 736.6 234.67 29895.74 2098.725 550.846 264.956

762 16 730 294.34 37498.05 2609.733 684.969 263.811

812.8 6.4 800.0 127.28 16213.63 1318.010 324.314 285.114

812.8 8.0 796.8 158.78 20226.83 1637.784 402.998 284.554

812.8 9.5 793.8 188.20 23974.59 1934.094 475.909 284.029

812.8 12.7 787.4 250.59 31922.57 2555.088 628.713 282.914

812.8 16.0 780.8 314.40 40051.54 3179.823 782.437 281.768

914.4 6.4 901.6 143.31 18256.42 1881.564 411.541 321.034

914.4 8.0 898.4 178.83 22780.32 2339.610 511.726 320.473

914.4 9.5 895.4 212.00 27006.86 2764.605 604.682 319.948

914.4 12.7 889.0 282.41 35976.23 3657.093 799.889 318.831

914.4 16.0 882.4 354.49 45158.51 4557.502 996.829 317.683

1016.0 6.4 1003.2 159.35 20299.21 2586.457 509.145 356.955

1016.0 8.0 1000.0 198.87 25333.80 3217.798 633.425 356.393

1016.0 9.5 997.0 235.81 30039.12 3804.202 748.859 355.867

1016.0 12.7 990.6 314.23 40029.89 5037.623 991.658 354.749

1016.0 16.0 984.0 394.58 50265.48 6284.794 1237.164 353.599

1066.8 6.4 1054.0 167.37 21320.61 2996.849 561.839 374.915

1066.8 8.0 1050.8 208.89 26610.55 3729.207 699.139 374.353

1066.8 9.5 1047.8 247.71 31555.26 4409.743 826.723 373.827

1066.8 12.7 1041.4 330.15 42056.72 5842.142 1095.265 372.708

1066.8 16.0 1034.8 414.63 52818.97 7291.901 1367.060 371.557

1117.6 6.4 1104.8 175.38 22342.00 3448.506 617.127 392.875

1117.6 8.0 1101.6 218.92 27887.29 4292.119 768.096 392.313

1117.6 9.5 1098.6 259.61 33071.39 5076.358 908.439 391.787

1117.6 12.7 1092.2 346.06 44083.55 6728.061 1204.019 390.667

1117.6 16.0 1085.6 434.67 55372.46 8401.237 1503.443 389.515

1219.2 6.4 1206.4 191.42 24384.79 4483.524 735.486 428.796

1219.2 8.0 1203.2 238.96 30440.78 5582.342 915.738 428.233

1219.2 9.5 1200.2 283.41 36103.65 6604.551 1083.424 427.707

1219.2 12.7 1193.8 377.88 48137.21 8759.790 1436.973 426.586

1219.2 16.0 1187.2 474.76 60479.43 10946.370 1795.664 425.433

1371.6 6.4 1358.8 215.47 27448.97 6394.966 932.483 482.676

1371.6 9.5 1352.6 319.12 40652.05 9428.261 1374.783 481.587

1371.6 12.7 1346.2 425.61 54217.70 12515.956 1825.015 480.465

1371.6 16.0 1339.6 534.90 68139.89 15654.350 2282.641 479.310



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1422.0 6.4 1409.2 223.43 28462.33 7129.686 1002.769 500.495

1422.0 9.5 1403.0 330.93 42156.25 10514.013 1478.764 499.405

1422.0 12.7 1396.6 441.39 56228.57 13960.765 1963.539 498.283

1422.0 16.0 1390.0 554.79 70673.27 17465.944 2456.532 497.128

1524.0 6.4 1511.2 239.53 30513.16 8784.550 1152.828 536.557

1524.0 9.5 1505.0 354.82 45200.45 12960.102 1700.801 535.467

1524.0 12.7 1498.6 473.34 60298.19 17216.558 2259.391 534.344

1524.0 16.0 1492.0 595.03 75800.35 21549.281 2827.990 533.189

1676.4 9.5 1657.4 390.53 49748.85 17279.304 2061.477 589.348

1676.4 12.7 1651.0 521.07 66378.68 22967.513 2740.099 588.224

1676.4 16.0 1644.4 655.17 83460.81 28764.602 3431.711 587.067

1828.8 9.5 1809.8 426.23 54297.25 22465.097 2456.813 643.228

1828.8 12.7 1803.4 568.80 72459.17 29874.739 3267.141 642.104

1828.8 16.0 1796.8 715.30 91121.27 37433.754 4093.805 640.947

1965.0 9.5 1946.0 458.14 58362.15 27897.623 2839.453 691.382

1965.0 12.7 1939.6 611.46 77893.31 37112.623 3777.366 690.257

1965.0 16.0 1933.0 769.04 97967.43 46520.530 4734.914 689.099

2030.0 12.7 2004.6 631.82 80486.69 40944.190 4033.910 713.237

2030.0 16.0 1998.0 794.69 101234.68 51331.703 5057.311 712.079



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High-Spec Spiral Welded Linepipe To API 5L

Benefits of QualitySteelpipe New Zealands spiral-welded steel pipe is widely used throughout the world

in a variety of applications, including oil and gas pipelines (both high and low pressure).And it is more than comparable with other linepipe due to its strength, straightness,versatility, and safety in service.

Steelpipe New Zealand offers non-monogrammed high spec spiral welded pipeindependantly certified in accordance with API 5L.

Great strengthin proportion to wall thickness of any competitive product. The spiralforming process produces an extremely reliable weld which is significantly less affectedby circumferential (hoop) stress than longitudinal or seam and girth pipelines. Thelikelihood of weld failure is substantially reduced.

An inherently straighter pipedue to the method of manufacture. The spiral formingprocess does not require heat treatment, so risks of bending, distortion and weld failurefrom insufficient heat treatment are eliminated. The end product is improved pipelinealignment and reliability.

Flexibility of productpermits the pipe to be used in difficult terrain.The pipe is secureagainst the normal settling and movement of unstable soils and is able to withstandabnormal internal and external shocks without distorting to the extent of conventionalproducts.

Accuracy of manufacturemeans high levels of circularity (or roundness) combined

with tight diameter tolerances. The circularity of spiral-welded steel pipe, together withcircumferential tolerances that are 50 percent tighter than the API 5L specifications,represents significant advantages when jointing in the field.

Versatilityof the spiral forming process enables a wide range of diameters and steelgauges to be manufactured from one common feed stock, which encourages pricecompetitiveness for small run pipelines of varying diameter and gauge.

Reliability and operating safety.The spiral-welded steel pipe provides a high levelof operating safety. The spiral forming process induces material working whichincreases the tensile strength of the steel by approximately eight percent (which is not

commonly accounted for in the design). In deliberate destructive testing, the failureis typically contained within a single helix length. Its resistance to crack propagationresults from the rolling direction and grain flow of the material. Pipes can be custommade to meet clients needs.

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High-Spec Spiral Welded: Dimensions, Masses and Test Pressures

OutsideDiameter

Wall Inside Mass Grade B Grade Grade Grade

Thickness Diameter Per Mtr Std. Alt. x42 x46 x52

mm ins mm mm kg/m MPa MPa MPa MPa MPa

508 20 6.4 495.2 79.17 3.6 4.6 6.6 7.2 8.1

508 20 7.9 492.2 97.43 4.5 5.6 8.1 8.9 10.0

508 20 9.5 489 116.78 5.4 6.8 9.7 10.7 12.1

508 20 11.1 485.8 136.01 6.3 7.9 11.4 12.5 14.1

508 20 12.0 484 146.78 6.8 8.5 12.3 13.5 15.2

508 20 12.7 482.6 155.12 7.2 9.0 13.0 14.3 16.1

508 20 14.3 479.4 174.10 8.1 10.2 14.6 16.1 18.1

508 20 15.9 476.2 192.95 9.1 11.3 16.3 17.9 20.2

609.6 24 6.4 596.8 95.20 3.0 3.8 5.5 6.0 6.8

609.6 24 7.9 593.8 117.22 3.7 4.7 6.7 7.4 8.4

609.6 24 9.5 590.6 140.59 4.5 5.6 8.1 8.9 10.0

609.6 24 11.1 587.4 163.83 5.3 6.6 9.5 10.4 11.7

609.6 24 12.0 585.6 176.84 5.7 7.1 10.2 11.2 12.7

609.6 24 12.7 584.2 186.94 6.0 7.5 10.8 11.9 13.4

609.6 24 14.3 581 209.93 6.8 8.5 12.2 13.4 15.1

609.6 24 15.9 577.8 232.79 7.5 9.4 13.6 14.9 16.8

660 26 6.4 647.2 103.15 2.8 3.5 5.0 5.5 6.2

660 26 7.9 644.2 127.04 3.5 4.3 6.2 6.8 7.7

660 26 9.5 641 152.39 4.2 5.2 7.5 8.2 9.3

660 26 11.1 637.8 177.62 4.9 6.1 8.7 9.6 10.8

660 26 12.0 636 191.76 5.3 6.6 9.5 10.4 11.7

660 26 12.7 634.6 202.72 5.6 7.0 10.0 11.0 12.4

660 26 14.3 631.4 227.70 6.3 7.8 11.3 12.4 14.0

660 26 15.9 628.2 252.55 7.0 8.7 12.5 13.7 15.5

711.2 28 6.4 698.4 111.23 2.6 3.3 4.7 5.1 5.8

711.2 28 7.9 695.4 137.01 3.2 4.0 5.8 6.3 7.2

711.2 28 9.5 692.2 164.39 3.9 4.8 6.9 7.6 8.6

711.2 28 11.1 689 191.64 4.5 5.6 8.1 8.9 10.1

711.2 28 12.0 687.2 206.91 4.9 6.1 8.8 9.6 10.9

711.2 28 12.7 685.8 218.76 5.2 6.5 9.3 10.2 11.5

711.2 28 14.3 682.6 245.75 5.8 7.3 10.5 11.5 13.0

711.2 28 15.9 679.4 272.62 6.5 8.1 11.6 12.8 14.4

762 30 6.4 749.2 119.25 2.4 3.0 4.4 4.8 5.4

762 30 7.9 746.2 146.91 3.0 3.7 5.4 5.9 6.7

762 30 9.5 743 176.29 3.6 4.5 6.5 7.1 8.0

762 30 11.1 739.8 205.54 4.2 5.3 7.6 8.3 9.4

762 30 12.0 738 221.94 4.6 5.7 8.2 9.0 10.1

762 30 12.7 736.6 234.67 4.8 6.0 8.7 9.5 10.7

762 30 14.3 733.4 263.67 5.4 6.8 9.8 10.7 12.1

762 30 15.9 730.2 292.54 6.0 7.5 10.9 11.9 13.4

High-Spec Spiral Welded Linepipe continued

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High-Spec Spiral Welded: Dimensions, Masses and Test Pressures

OutsideDiameter

Wall Inside Mass Grade B Grade Grade GradeThickness Diameter Per Mtr Std. Alt. x42 x46 x52

mm ins mm mm kg/m MPa MPa MPa MPa MPa

812.8 32 7.9 797 156.81 2.8 3.5 5.1 5.5 6.3

812.8 32 9.5 793.8 188.19 3.4 4.2 6.1 6.7 7.5

812.8 32 11.1 790.6 219.45 3.9 4.9 7.1 7.8 8.8

812.8 32 12.0 788.8 236.97 4.3 5.3 7.7 8.4 9.5

812.8 32 12.7 787.4 250.58 4.5 5.6 8.1 8.9 10.1

812.8 32 14.3 784.2 281.58 5.1 6.4 9.2 10.0 11.3

812.8 32 15.9 781 312.46 5.7 7.1 10.2 11.2 12.6

863.6 34 7.9 847.8 166.70 2.6 3.3 4.8 5.2 5.9

863.6 34 9.5 844.6 200.09 3.2 4.0 5.7 6.3 7.1

863.6 34 11.1 841.4 233.35 3.7 4.6 6.7 7.3 8.3

863.6 34 12.0 839.6 252.01 4.0 5.0 7.2 7.9 9.0

863.6 34 12.7 838.2 266.49 4.3 5.3 7.7 8.4 9.5

863.6 34 14.3 835 299.50 4.8 6.0 8.6 9.4 10.7

863.6 34 15.9 831.8 332.38 5.3 6.7 9.6 10.5 11.9

914.4 36 7.9 898.6 176.60 2.5 3.1 4.5 4.9 5.6

914.4 36 9.5 895.4 211.99 3.0 3.8 5.4 5.9 6.7

914.4 36 11.1 892.2 247.26 3.5 4.4 6.3 6.9 7.8

914.4 36 12.0 890.4 267.04 3.8 4.7 6.8 7.5 8.5

914.4 36 12.7 889 282.40 4.0 5.0 7.2 7.9 9.0

914.4 36 14.3 885.8 317.41 4.5 5.7 8.1 8.9 10.1

914.4 36 15.9 882.6 352.30 5.0 6.3 9.0 9.9 11.2

965.2 38 9.5 946.2 223.89 2.8 3.6 5.1 5.6 6.3

965.2 38 11.1 943 261.16 3.3 4.2 6.0 6.6 7.4

965.2 38 12.0 941.2 282.07 3.6 4.5 6.5 7.1 8.0

965.2 38 12.7 939.8 298.31 3.8 4.8 6.8 7.5 8.5

965.2 38 14.3 936.6 335.32 4.3 5.4 7.7 8.5 9.5

965.2 38 15.9 933.4 372.21 4.8 6.0 8.6 9.4 10.6

1016 40 9.5 997 235.79 2.7 3.4 4.9 5.3 6.0

1016 40 11.1 993.8 275.07 3.2 3.9 5.7 6.2 7.0

1016 40 12.0 992 297.10 3.4 4.3 6.1 6.7 7.6

1016 40 12.7 990.6 314.22 3.6 4.5 6.5 7.1 8.1

1016 40 14.3 987.4 353.24 4.1 5.1 7.3 8.0 9.1

1016 40 15.9 984.2 392.13 4.5 5.7 8.1 8.9 10.1

1066.8 42 9.5 1047.8 247.69 2.6 3.2 4.6 5.1 5.7

1066.8 42 11.1 1044.6 288.97 3.0 3.8 5.4 5.9 6.7

1066.8 42 12.0 1042.8 312.14 3.3 4.1 5.9 6.4 7.2

1066.8 42 12.7 1041.4 330.13 3.4 4.3 6.2 6.8 7.7

1066.8 42 14.3 1038.2 371.15 3.9 4.8 7.0 7.6 8.6

1066.8 42 15.9 1035 412.05 4.3 5.4 7.8 8.5 9.6

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Water & Wastewater Reticulation

Benefits of QualitySteelpipe New Zealands product is used universally in a variety of applications including

water and sewage transmission and outfalls.

In recent years, spiral-welded steel pipes market share has continued to develop overother products due to its inherent toughness, flexibility, versatility, safety in service andcompetitive cost.

Greater strength in proportion to wall thickness of any competitive product. Thepipe operates safely at higher pressures and its strength provides distinct handling andlaying advantages in complex locations.

Durability and longlife. In New Zealand, steel pipelines dating back to the early1900s, and without the benefit of modern corrosion protection systems, are still inservice in major city water supply systems. Recent major advances in steel fabricatingtechniques and coatings development ensure the useful life of todays steel pipe hasbeen significantly lengthened.

Flexibility of product permits the pipe to be used in difficult terrain where othermaterials either cannot be employed or installed only with great difficulty and addedexpenditure. The pipe is secure against the normal settling and movement of unstablesoils and is able to withstand abnormal internal and external shocks (surge, waterhammer, earthquakes and extreme temperature changes) without cracking, shatteringor leaking.

Ease of layingdue to longer pipe lengths (up to 12 metres), which means less jointing,greater reliability and cost-effectiveness.

Accuracy of manufacturemeans a straight and circular product. This representssignificant advantages when matching pipes in the field for welding, jointing and theconnection of fittings. The New Zealand Standard for water pipe (NZS 4442), createdwith the spiral forming process in mind, and has 50 per cent tighter tolerance onstraightness and circularity than the equivalent American Petroleum Institute linepipestandard.

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High carrying capacitymeans pipelines can cope with increasing demand. Correctlylined and coated spiral-welded pipe, being resistant to corrosion or encrustation,

can be relied on to maintain its carrying capacity longer than alternative materials. Inaddition, a wide safety margin is engineered into the spiral-welded steel pipe, enablingcapacity to be increased (by boosting the pressure) while still remaining within thedesigned safety limits.

Reliabilityof spiral-welded steel pipe enables the pipeline to do the job for which itwas designed. The spiral forming process produces an extremely reliable weld which issignificantly less affected by circumferential (hoop) stress than a longitudinally weldedseam. In deliberate destructive testing, the failure is typically through rupture of thesteel as opposed to the weld seam, and is usually contained within one helical seam.

An additional benefit of the spiral forming process is its ability to increase the tensilestrength of the steel by approximately eight percent. This additional safety margin isnot accounted for in design calculations, and dramatically reduces pipeline risks interms of unanticipated internal or external loads.

Water & Wastewater Reticulation continued

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Water & Wastewater Specifications

This information is intended as a guide to assist in the preparation of specifications forspiral-welded steel pipe in water and sewage applications.

WeldingAll spiral-welded steel pipes are manufactured using an automatic double submergedarc welding process.

Steel Pipe DiameterSteelpipe New Zealand currently manufactures a standard range of pipes from aminimum of 121mm OD to 1,965mm OD by the spiral forming process. However,larger pipe diameters can be supplied using alternative manufacturing techniques.

NB: Because the flexibility of the spiral forming process allows for the manufacture ofnon-standard diameters, wall thicknesses and lengths, customers with specificrequirements are encouraged to contact Steelpipe New Zealand staff to discuss theirspecific needs.

Steel ProductThe steel utilised in the manufacture of Steelpipe New Zealands spiral-welded pipecomplies with the following standard or its equivalent:

Australia / New Zaland Standard AS / NZ 1594 (grades within this are HA 250 and HA 350)

PipePipe shall be manufactured and tested in accordance with NZS 4442:1998 or AS 1579:2001.

FittingsShall be fabricated in accordance with and to the dimensions detailed in NZS 4442:1998.Fittings fabricated from previously hydrostatically tested pipe shall require testing ofthose welds that have not been tested. This testing shall be dye penetrant or magneticparticle, X-ray or ultra-sonic methods.

LiningPipes shall be concrete-lined in accordance with NZS 4442:1988 or AS 1281-2001.

Coating(see coating section)

JointingShall be achieved using: Welded joints - ends with hemispherical slip in joints for on site welding (test holes required over 600 NB) ie: spigot & socket. Welding bands - fitted or loose with a steel gauge no less than that of the pipe.


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Water & Wastewater Fittings

The wide range of design options made possible by the spiral forming process providesthe means to solve almost any problem involving fittings and specials. The design andfabrication of pipe layouts, especially intricate ones, is greatly enhanced by the use ofstandardised dimensions along the pipe centre line.

The details and dimensions for several types of fittings and specials are detailed inTable Water.1, and are in accordance with NZS 4442:1988. For economic reasons, andinstallation advantages specials can often be welded directly into pipes thus reducingthe amount of field welding required.

Table Water.1 Standard Fitting Dimensions

i) Additional notes are given in NZS 4442:1988.ii) or pipe sizes greater than 1000 NB, consult with Steelpipe New Zealand.iii) For Tee measurement B=1/2 OD of barrel (D) plus

Nominal Outside Tee Bends BendsPipe Size Diameter 0o - 35o 36o- 90o

D (mm) A B F G H

100 121.9 229 152 229 330 152

150 177.3 305 152 367 381 203

200 232.2 305 152 305 432 254

225 259.1 381 203 305 432 254

250 286.0 381 254 305 457 279

300 345.4 381 254 305 483 305

375 426.2 305 305 381 533 356

400 457.2 305 305 381 610 406

450 508.0 381 305 381 660 457

500 558.8 381 305 457 686 508

550 587.2 381 305 533 711 559

600 667.0 381 305 533 762 610

700 746.8 381 305 533 813 660

750 762.0 457 381 610 864 711

800 812.8 457 381 610 914 762

850 857.2 457 381 610 965 813

900 914.4 457 381 610 1016 864

1000 1016.0 610 381 762 1118 965


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Double Mitre 36o- 90

o

DH

G G

Single Mitre 0o- 35

o

D

F F

B

A

D

AA

eeTlauqEeeT

d D

D

DD

Angle Tee

dd

Scour Tee

(Profile)

Concentric Reducer

d D

D

100 100

Eccentric Reducer

dD

D

100 100

Flange Adaptor

300mm(at least)

Attachment of Flange

6mm

Bends can also be fabricated in 3 or more mitres, and can be fabricated on the end of full lengths

of pipe, or to any dimensions.

When attaching flat face flanges a fillet weld is used internally and externally. When using

butterfly valves it is important to rebate the concrete or cement mortar linings to ensure that thevalve opens correctly.

No standard dimensions are offered for reducers where d < 1D. The parallel ends can be any length,

but at least 100mm.

Tees can be fabricated to suit construction requirements. Branches can be located anywhere on pipe

lengths but should be located less than 400mm from pipe end to ease fabrication. Otherwise lengths

will require additional cutting and joining to ensure adequate repairs are made.

Bends

Tees

Reducers

Flanges

2

Typical Water & Wastewater Fittings


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Nominal Outside Wall Lining Inside Approximate ApproximateBore Diameter Thickness Thickness Diameter Steel Mass Lined Mass

mm mm mm mm mm kg/m kg/m

100 121.9 4.8 7 98.3 13.9 19.4

150 177.3 4.8 7 153.7 20.4 28.9

200 232.2 5 10 202.2 28.0 44.0

225 259.1 6.2 10 226.7 38.7 56.5

250 286 5 10 256 34.6 54.7

300 345.4 4.8 10 315.8 40.3 64.9

300 345.4 6.4 10 312.6 53.5 77.8

375 426.2 4.8 13 390.6 49.9 89.4

375 426.2 6.4 13 387.4 66.3 105.5

400 457.2 4.8 13 421.6 53.5 96.2

400 457.2 6.4 13 418.4 71.1 113.4

450 508 4.8 13 472.4 59.6 107.1

450 508 6.4 13 469.2 79.2 126.4

500 558.8 4.8 13 523.2 65.6 118.1

500 558.8 6.4 13 520 87.2 139.4

500 558.8 8 13 516.8 108.7 160.6

550 587.2 4.8 13 551.6 68.9 124.3

550 587.2 6.4 13 548.4 91.7 146.7

550 587.2 8 13 545.2 114.3 169.0

600 650.2 4.8 13 614.6 76.4 137.9

600 650.2 6.4 13 611.4 101.6 162.8

600 650.2 8 13 608.2 126.7 187.6

650 667 4.8 13 631.4 78.4 141.6

650 667 6.4 13 628.2 104.3 167.1

700 746.8 4.8 16 705.2 87.8 174.8

700 746.8 6.4 16 702 116.9 203.5

700 746.8 8 16 698.8 145.8 232.0

750 812.8 4.8 16 771.2 95.6 190.6

750 812.8 6.4 16 768 127.3 221.9

750 812.8 8 16 764.8 158.8 253.0

800 857.2 6.4 16 812.4 134.3 234.2

800 857.2 8 16 809.2 167.5 267.1

800 857.2 9.5 16 806.2 198.6 297.8

850 914.4 6.4 16 869.6 143.3 250.1

850 914.4 8 16 866.4 178.8 285.3

850 914.4 9.5 16 863.4 212.0 318.1

850 914.4 6.4 16 869.6 143.3 250.1

850 914.4 8.0 16 866.4 178.8 285.3

850 914.4 9.5 16 863.4 212.0 318.1

Standard Water Pipe Dimensions and Masses


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Nominal Outside Wall Lining Inside Approximate Approximate

Bore Diameter Thickness Thickness Diameter Steel Mass Lined Mass

mm mm mm mm mm kg/m kg/m

900 965.2 6.4 16 920.4 151.3 264.3

900 965.2 8 16 917.2 188.8 301.4

900 965.2 9.5 16 914.2 223.9 336.1

950 1016 8 16 968 198.9 317.6

950 1016 9.5 16 965 235.8 354.2

950 1016 12 16 960 297.1 414.9

1000 1066.8 8 16 1018.8 208.9 333.7

1000 1066.8 9.5 16 1015.8 247.7 372.2

1000 1066.8 12 16 1010.8 312.1 436.0

1050 1124 8 18 1072 220.2 368.1

1050 1124 9.5 18 1069 261.1 408.6

1050 1124 12 18 1064 329.1 475.9

1150 1254 8 18 1202 245.8 411.4

1150 1254 9.5 18 1199 291.5 456.7

1150 1254 12 18 1194 367.5 532.0

1300 1371.6 9.5 18 1316.6 319.1 500.2

1300 1371.6 12 18 1311.6 402.3 582.8

1500 1524 9.5 18 1469 354.8 556.6

1500 1524 12 18 1464 447.4 648.6

1550 1575 9.5 18 1520 366.7 575.5

1550 1575 12 18 1515 462.5 670.6

1600 1676.4 9.5 18 1621.4 390.5 613.0

1600 1676.4 12 18 1616.4 492.5 714.4

1800 1828.8 9.5 18 1773.8 426.2 669.4

1800 1828.8 10.5 18 1771.8 470.8 713.7

1900 1965 9.5 18 1910 458.1 719.8

1900 1965 12 18 1905 577.9 839.0

1950 2030 12 18 1970 597.2 867.0

1950 2030 16 18 1962 794.6 1063.4

Standard Water Pipe Dimensions and Masses


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Recommended Maximum Working Pressures & Hydrostatic TestPressures for Mild Steel PipePrior to being lined or coated, all spiral-welded pipes for water, high-spec and generalapplications are hydrostatically tested in accordance with the specified standard. Asan example, the New Zealand Standard (NZS 4442) requires a test pressure sufficientto induce a circumferential (hoop) stress of 75 percent of the minimum specified yieldstress of the steel from which the pipe is manufactured.

Steelpipe New Zealand suggests an extreme limit of 700 metres head or approximately7.0 MPa as the maximum test for smaller diameter pipes, even if the formula indicatesa higher pressure (theoretically).

When calculating the maximum recommended working pressure, bear in mind that aconservative value of 50 percent of the specific minimum yield stress has been utilised.A figure of 60 percent may be adopted, but only if the pipe is subject to internalpressure and not any other load.

The above is a guideline only.

Hydrostatic TestingThe following table details the maximum recommended test pressures for spiral-weldedpipe, using steel coil that complies with the New Zealand Standard (NZS 4442). Thetables maximum recommended pressures are based on the following format:

a) Column A: Test pressure based on a circumferential stress of 75 percent of theminimum yield stress of the steel.

b) Column B: Working pressure based on a circumferential stress of 50 percent of theminimum stress of the steel.

Design Guidelines


Test Pressure Working Pressure

Key: P

t=Test Pressure (MPa)

Pw=Working Pressure (MPa)

t=Steel pipe wall thickness (mm) S=Circumferential (hoop) stress induced in pipe (MPa), i.e. 250 MPa D=Outside diameter of pipe (mm)

.PD

tSx

20 75t = .P

D

tSx

20 5w =

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Water and Wastewater Pipe: Test and Working Pressures

(A) Max (B) Max

Nominal Wall Recom. Test Recom. Working

Bore External Diameter Thickness Pressure Pressure

mm mm inches mm MPa MPa

100 121.9 4.80 4.8 7.000 7.000

150 177.3 6.98 4.8 7.000 6.768

200 232.2 9.14 5 7.000 5.383

225 259.1 10.20 6.2 7.000 5.982

250 286 11.26 5 6.556 4.371

300 345.4 13.60 4.8 5.211 3.474

300 345.4 13.60 6.4 6.948 4.632

375 426.2 16.78 4.8 4.223 2.816375 426.2 16.78 6.4 5.631 3.754

400 457.2 18.00 4.8 3.937 2.625

400 457.2 18.00 6.4 5.249 3.500

450 508 20.00 4.8 3.543 2.362

450 508 20.00 6.4 4.724 3.150

500 558.8 22.00 4.8 3.221 2.147

500 558.8 22.00 6.4 4.295 2.863

500 558.8 22.00 8 5.369 3.579

550 587.2 23.12 4.8 3.065 2.044

550 587.2 23.12 6.4 4.087 2.725

550 587.2 23.12 8 5.109 3.406

600 650.2 25.60 4.8 2.768 1.846

600 650.2 25.60 6.4 3.691 2.461

600 650.2 25.60 8 4.614 3.076

650 667 26.26 4.8 2.699 1.799

650 667 26.26 6.4 3.598 2.399

700 746.8 29.40 4.8 2.410 1.607

700 746.8 29.40 6.4 3.214 2.142

700 746.8 29.40 8 4.017 2.678

750 812.8 32.00 4.8 2.215 1.476

750 812.8 32.00 6.4 2.953 1.969750 812.8 32.00 8 3.691 2.461

800 857.2 33.75 6.4 2.800 1.867

800 857.2 33.75 8 3.500 2.333

800 857.2 33.75 9.5 4.156 2.771

850 914.4 36.00 6.4 2.625 1.750

850 914.4 36.00 8 3.281 2.187

850 914.4 36.00 9.5 3.896 2.597


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The following table details pressure equivalents in metres head, feet head, poundsper square inch and Megapascals.

Metres Feet

Head Head PSI MPa

1 3.28 1.42 0.0098

2 6.56 2.84 0.0196

3 9.84 4.26 0.0294

4 13.12 5.68 0.0392

5 16.40 7.10 0.0490

6 19.69 8.52 0.0588

7 22.97 9.94 0.0686

8 26.25 11.36 0.0784

9 29.53 12.79 0.0881

10 32.81 14.21 0.0979

11 36.09 15.63 0.1077

12 39.37 17.05 0.1175

13 42.65 18.47 0.1273

14 45.93 19.89 0.1371

15 49.21 21.31 0.1469

16 52.49 22.73 0.1567

17 55.77 24.15 0.1665

18 59.06 25.57 0.1763

19 62.34 26.99 0.1861

20 65.62 28.41 0.1969

21 68.90 29.82 0.2057

22 72.18 31.25 0.2155

23 75.46 32.67 0.2253

24 78.74 34.09 0.2351

25 82.02 35.51 0.2449

26 85.30 36.93 0.2547

27 88.58 38.36 0.2644

28 91.86 39.78 0.2742

29 95.14 41.20 0.2840

30 98.43 42.63 0.2938

31 101.71 44.04 0.3036

32 104.99 45.46 0.3134

33 108.27 46.88 0.3232

34 111.55 48.30 0.3330

35 114.83 49.72 0.3428

Metres Feet

Head Head PSI MPa

36 118.11 51.14 0.3526

37 121.39 52.56 0.3624

38 124.67 53.98 0.3722

39 127.95 55.40 0.3820

40 131.23 56.82 0.3918

41 134.51 58.24 0.4016

42 137.80 59.66 0.4114

43 141.08 61.08 0.4212

44 144.36 62.50 0.4310

45 147.64 63.93 0.4407

46 150.92 65.35 0.4505

47 154.20 66.77 0.4603

48 157.48 68.19 0.4701

49 160.76 69.61 0.4799

50 164.04 71.03 0.4897

51 167.32 72.45 0.4995

52 170.60 73.87 0.5093

53 173.88 75.29 0.5191

54 177.17 76.71 0.5289

55 180.45 78.13 0.5387

56 183.73 79.55 0.5485

57 187.01 80.97 0.5583

58 190.29 82.39 0.5681

59 193.57 83.81 0.5779

60 196.85 85.23 0.5877

61 200.13 86.65 0.5975

62 203.41 88.07 0.6073

63 206.69 89.50 0.6170

64 209.97 90.92 0.6268

65 213.25 92.34 0.6366

66 216.54 93.76 0.6464

67 219.82 95.18 0.6562

68 223.10 96.60 0.6660

69 226.38 98.02 0.6758

70 229.66 99.44 0.6856

Pressure Conversion Chart


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Metres Feet

Head Head PSI MPa

71 232.94 100.86 0.6954

72 236.22 102.28 0.7052

73 239.50 103.70 0.7150

74 242.78 105.12 0.7248

75 246.06 106.54 0.7346

76 249.34 107.96 0.7444

77 252.62 109.38 0.7542

78 255.91 110.80 0.7640

79 259.19 112.22 0.7738

80 262.47 113.64 0.7836

81 265.75 115.07 0.7933

82 269.03 116.49 0.8031

83 272.31 117.91 0.8129

84 275.59 119.33 0.8227

85 278.87 120.75 0.8325

86 282.15 122.17 0.8423

87 285.43 123.59 0.8521

88 288.97 125.01 0.8619

89 291.99 126.43 0.8717

90 295.28 127.85 0.8815

91 298.56 129.27 0.8913

92 301.84 130.69 0.9011

93 305.12 132.11 0.9109

94 308.40 133.53 0.9207

95 311.68 134.95 0.9305

96 314.96 136.37 0.9403

97 318.24 137.79 0.9501

98 321.52 139.21 0.9599

99 324.80 140.64 0.9696

100 328.08 142.06 0.9794

101 331.36 143.48 0.9892

102 334.65 144.90 0.9990

103 337.93 146.32 1.0088

104 341.21 147.74 1.0186

105 344.49 149.16 1.0284

106 347.77 150.58 1.0382

107 351.05 152.00 1.0480

108 354.33 153.42 1.0578

109 357.61 154.84 1.0676

110 360.89 156.26 1.0774

Metres Feet

Head Head PSI MPa

111 364.17 157.68 1.0872

112 367.45 159.10 1.0970

113 370.73 160.52 1.1068

114 374.02 161.94 1.1166

115 377.30 163.36 1.1264

116 380.58 164.78 1.1362

117 383.86 166.21 1.1459

118 387.14 167.63 1.1557

119 390.42 169.05 1.1655

120 393.70 170.47 1.1753

121 396.98 171.89 1.1851

122 400.26 173.31 1.1949

123 403.54 174.73 1.2047

124 406.82 176.15 1.2145

125 410.11 177.57 1.2243

126 413.39 178.99 1.2341

127 416.67 180.41 1.2439

128 419.95 181.83 1.2537

129 423.23 183.25 1.2635

130 426.51 184.67 1.2733

131 429.79 186.09 1.2831

132 433.07 187.51 1.2929

133 436.35 188.93 1.3027

134 439.63 190.35 1.3125

135 442.91 191.78 1.3222

136 446.19 193.20 1.3320

137 449.48 194.62 1.3418

138 452.76 196.04 1.3516

139 456.04 197.46 1.3614

140 459.32 198.88 1.3712

141 462.60 200.30 1.3810

142 465.88 201.72 1.3908

143 469.16 203.14 1.4006

144 472.44 204.56 1.4104

145 475.72 205.98 1.4204

146 479.00 207.40 1.4300

147 482.28 208.82 1.4398

148 485.56 210.24 1.4496

149 488.85 211.66 1.4594

150 492.13 213.08 1.4692

Pressure Conversion Chart


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Formula 5:Calculate the maximum span distance:

Key: S=maximum span in metres

This calculation gives the span and the deflection for a pipe at capacity with freshwater, based on 120 degree support saddles. The restrictive factor for span distance isthe compressive strength of concrete lining, which is limited to 34.5MPa (5000psi) inFormula 5.

SW W W 9.81

8 34.5 10 Z

1 2 3

6

=+ + #

# # #

^ h

Example:Determine the approximate maximum span for a 609.6mm OD x 9.5mm wall pipe witha 12mm cement mortar lining filled with water.

a)

b)

c)

d)

e)

=140.6 Kg/m steel pipe mass

=52.4 Kg/m cement motar mass

=252.1 kg/m fresh water mass

=0.00277m2

=13.2 metresS140.6 52.4 252.1 9.81

8 34.5 10 0.002776

=+ + #

# # #

^ h

Z4 10

609.6 9.59

2

=#

# #r

W4000

609.6 2 9.5 123 =

- +r ^ h6 @

W4 10

590.6 590.6 2 12 24002 6

2 2

= - -#

# #r ^ h6 @

W4 10

609.6 609.6 2 9.5 78501 6

2 2

=- -

#

# #r ^ h6 @

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Safe Maximum Support Span

Outside Wall Concrete Lining Total Mass Max Span Deflection

Diameter Thickness Thickness incl Water Water Filled

mm mm mm kg/m m mm

121.9 4.8 7 27.0 7.6 18.3

177.3 4.8 7 47.5 8.5 15.8

232.2 5 10 76.1 9.0 13.6

259.1 6.2 10 96.9 9.9 14.7

286 5 10 106.2 9.5 12.2

345.4 4.8 10 143.2 9.7 10.6

345.4 6.4 10 154.6 10.7 12.9

426.2 4.8 13 209.3 10.0 9.0

426.2 6.4 13 223.4 11.1 11.1

457.2 4.8 13 235.7 10.1 8.6

457.2 6.4 13 250.9 11.2 10.7

508 4.8 13 282.4 10.2 8.0

508 6.4 13 299.3 11.4 10.0

558.8 4.8 13 333.1 10.4 7.5

558.8 6.4 13 351.8 11.6 9.4

558.8 8 13 370.4 12.6 11.0

587.2 4.8 13 363.2 10.5 7.2

587.2 6.4 13 382.9 11.7 9.1

587.2 8 13 402.4 12.7 10.7

650.2 4.8 13 434.6 10.6 6.7

650.2 6.4 13 456.4 11.9 8.4

650.2 8 13 478.1 13.0 10.0

667 4.8 13 454.7 10.6 6.6

667 6.4 13 477.0 12.0 8.3

746.8 4.8 16 565.4 10.7 5.9

746.8 6.4 16 590.5 12.0 7.5

746.8 8 16 615.5 13.1 9.0

812.8 4.8 16 657.7 10.8 5.6

812.8 6.4 16 685.1 12.2 7.1

812.8 8 16 712.3 13.3 8.4

857.2 6.4 16 752.6 12.3 6.8

857.2 8 16 781.4 13.4 8.1

857.2 9.5 16 808.2 14.3 9.3

914.4 6.4 16 844.1 12.4 6.5

914.4 8 16 874.8 13.5 7.8

914.4 9.5 16 903.5 14.5 8.9


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Safe Maximum Support Span

Outside Wall Concrete Lining Total Mass Max Span Deflection

Diameter Thickness Thickness incl Water Water Filled

mm mm mm kg/m m mm

965.2 6.4 16 929.6 12.4 6.2

965.2 8 16 962.1 13.6 7.5

965.2 9.5 16 992.5 14.6 8.6

1016 8 16 1053.5 13.7 7.2

1016 9.5 16 1085.5 14.7 8.2

1016 12 16 1138.7 16.1 9.9

1066.8 8 16 1148.9 13.8 6.9

1066.8 9.5 16 1182.6 14.8 8.0

1066.8 12 16 1238.4 16.2 9.5

1124 8 18 1270.6 13.8 6.6

1124 9.5 18 1306.1 14.9 7.6

1124 12 18 1365.0 16.3 9.1

1254 8 18 1546.1 14.0 6.1

1254 9.5 18 1585.8 15.1 7.0

1254 12 18 1651.7 16.5 8.4


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Transportation

Steelpipe New Zealand is committed to ensuring all product is delivered to the customeron time and without damage. When purchasing spiral-welded steel pipe (or any of the

companys other products), there is a range of transportation options available to thebuyer.

Domestic MarketEXW - ExWorksThe client holds responsibility for arranging all transportation, including unloading.Steelpipe New Zealand will load a customers truck at no additional cost to ensure thatthe product is safely secured.

DAP - DeliveredSteelpipe New Zealand will load and secure the product, then deliver to the customerssite/facility. The customer holds responsibility for the unloading of product and up toone hour per load should be allocated for this task.

Export (All Markets)CIF - Cost, Insurance, FreightCost, Insurance, Freight incorporates all costs associated with the product, includinginsurance for the carriage of goods at sea and all freight costs, to deliver the productto a specified port.

FAS - Free Alongside ShipFree alongside Ship incorporates all product costs, packaging, marking and delivery toa designated ships side. The customer holds responsibility for loading of product, sea

freight charges, insurance and all relevant documentation.

Export (Australia Only)DDP - (FOT Australia)Delivered to named destination. Includes all charges including customs duties andtaxes. Unloading is the responsibilities of the purchaser.

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Steelpipe New Zealand is able to specifically tailor the packaging of spiral-welded steelpipe to suit the type of pipe that is being delivered (plain steel or coated and lined) and

the method of transport adopted (road, rail or sea freight).

Road TransportationThe most popular transportation option is by road and Steelpipe New Zealand hasgeneral procedures for each type of product. Typically pipes are packaged into packs

constrained by either weight or volume.

Plain SteelTimber is laid across the truck and the outer pipes are secured with wedges andwebbing straps (loadbinders). This format is repeated with each subsequent layer.

Coated SteelThis product is loaded and packaged in a similar format to plain steel, but each layer issupported by individual wedges.

In addition, rubber padding is utilised to ensure that the coated surface does not come

into contact with the timber packing.

Sea FreightWhen freighting over water, timber is once again utilised but pipes are packaged into abreak-bulk unit. The size of the unit is determined by the specific dimensions of thepipe being transported. The heavily strapped and dunnaged unit is typically no morethan 2.4 metres wide by 2.4 metres high and 12 metres in length. Units will not weighmore than 25 metric tonne.

Transportation continued

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Transportation

Protect the Pipe and CoatingAll dunnage, supports and restraints in contact with pipe surfaces should be coveredor wrapped with material suitable to prevent chafing and shock damage during transit.The recommended skid protection is Polyken mechanical resistant tape or mediumdensity jandal rubber.

For a standard 12 metre pipe, four lengths of dunnage should be utilised per layer. Onelength should be placed approx 1 metre from each pipe end and then evenly spacedin between.

The width of the dunnage must provide sufficient support to protect the pipe coating.A minimum width of 150mm is required.

Wedges should be used to separate pipes in the same row space so that they do nottouch.

Secure the LoadAll pipes and fittings must be secured by straps to prevent movement during transitand in compliance with all local and regional regulations on load restraint.

Securing loads for transport must comply with all local Transport Authority regulations.

The load should be strapped securely using webbing straps with a minimum lashingcapacity of 2000kg. Chains should not be used.

The strapping should be securely anchored with approved ratchet type devices.

Handling and Installation continued

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Unloading and Handling

Personnel involved in unloadingand handling should wearpersonal protection equipmentsuch as hard hat, safety shoes,safety glasses, safety vest andother equipment as required bythe Occupational Health andSafety Act and in accordance withsite safety rules.

Attention to the followingitems improves efficiency of the

operation, maximises safety andminimises risk of damage.

Steel pipes and fittings are not susceptible to breakage, but poor handling can result indamaged coatings and/or linings and damage to the pipe ends.

Damage to pipe components may be caused by:

Inadequate support and restraint during transportation to site Improper use of handling equipment Use of unsuitable lifting equipment

Incorrect site storage Incorrect handling of load Unloading on uneven or sloping ground

Before unloadingChoose and prepare suitable pipe storage sites along the pipeline route. If possible,select unloading and storage areas which are clear of overhead power lines.

Make sure the truck is on level ground before releasing the straps.

Unloading

Immediately upon receipt, all items should be visually examined for damage to:

The pipe itself (particularly the ends) The internal lining The external coating

All repair work should be carried out promptly.

Unload the truck evenly to keep it stable.


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Lifting operationsAll lifting operations must meet legal and occupation, health and safety requirements

applicable to the site.

It is the clients responsibility to ensure suitably qualified personnel operate handlingequipment.

When lifting pipes it is recommended that an experienced rigger is used.

Lifting should be done smoothly without sudden jerking motions. Pipe movementshould be controlled by use of guide ropes and care taken not to knock other pipes orequipment.

Lifting and placing must be carried out so that the stability of the pipe stack, crane orvehicle is maintained.

When conditions are suitable, forklifts may be used. The contact surfaces of the forksmust be protected with minimum 10mm thick medium density jandal rubber.

Choosing equipmentWhen choosing lifting equipment consider: Pipe weight Type of stacking Outreach Site conditions

AccessoriesSlingsA spreader bar and/or other approved lifting device can be used in addition to slings,for use in the handling of pipes or pipe packs. See figure below.

Slings and lifting devices must comply with and be used in accordance with theappropriate safety requirements. Slings or lifting devices should offer protection againstdamage to externally coated pipes. This applies when lifting and when withdrawingthe sling from under the pipe, once it has been bedded.

Synthetic webbing slingsReversed eye, synthetic webbing slings or round slings (of endless fibre construction)are recommended for use in the handling of pipes. Woven synthetic slings must besheathed to prevent penetration of the fabric by grit, abrasion and deterioration. Theslings are fitted to the pipe using a choker hitch and in this configuration the sling israted to the SWL limit marked on the webbing.

Hooks / chainsHooks or chains should not be used for lifting pipes or fittings.


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Stacking and Storage

Storage areaThe storage area should: Have a firm foundation for pipe stacks and vehicle operation Have a suitable access for road vehicles Be free of overhead power lines wherever possible

Pipe supportCoated pipes should be at all times supported clear of the ground. Beware of protrudingrocks and uneven ground.

The pipe should be supported at two locations approx 2 metres from the end of eachpipe end.

It is recommended that pipes be supported on sand or sawdust filled bags or soilmounds. The supports should be positioned to ensure that each pipe is stable andcannot roll off the support. For long term storage, soil mounds should be protectedfrom erosion.

The entire pipe must be kept clear of the ground to protect the coating from damage.

Stacking heights for long term storagePipes 508 mm OD and larger should be stored in a single layer only. Pipes less than 508mm OD may be stacked three high.

Medium density jandal rubber lined dunnage with a minimum width of 150mmshould be used to separate layers.


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Storage of Concrete Lined PipesMinor cracking is common and quite acceptable for pipes conveying potable water.

These cracks will close and heal through autogenous healing.

Autogenous healing is a natural process that allows cracks in concrete lined pipes toclose and heal on exposure to water.

When pipes are to be stored for more than a few weeks in hot, dry conditions,precautions should be taken such as end capping (to reduce airflow and thus rate ofcracking) and adding water to the pipes (to minimise cracking).

Long Term Storage of Tape Coated PipesPolyken Synergy Coating is a polyethylene product and should be buried as a soon aspossible.

It is recommended that stored pipes be covered for protection from direct sunlight.

As with all plastic and thermoplastic materials they will degrade with exposure toUV radiation. In regards to the length of time that a polyethylene coating may beexposed to sunlight and UV irradiation is generally 6-12 months. This is a general ruleof understanding within the plastics industry.


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Bedding

Why beddingBedding evenly supports the pipe andprotects the external coating.

Bedding should be spread evenly along thetrench with socket holes or welding stationsprovided at each joint. The socket holesshould be deep enough to stop the socketof the pipe bearing any weight. Weldingstations should also be big enough to allowwelding and wrapping at welded joints.

Bedding should be compacted to ensure afirm, even base for pipe laying.

What to use for beddingBedding should be granular material such as sand with no stones or sharp objects.The maximum particle size should not exceed 7 mm. If the natural soil is not suitable,bedding should be brought in. A recommended bedding material is PAP 7.

The bedding layer under the pipe should be at least 75-100 mm thick when compactedas shown in the following diagram.

Allowance for sling withdrawalConsideration should be given to making a small depression in the bedding whereslings used to lift the pipe will come to rest after lowering and jointing. This will allowslings to be withdrawn from under the pipe more easily.


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Laying and Jointing of PipeThe recommended method for joint assembly is to pull the pipe being laid into the

socket of the previously laid pipe, using anchor slings and winch blocks or pullers.

PreparationIf a pipe has a threaded test hole (socket end) ensure that when the pipe is laid thetest hole is at the top of the pipe. This will ensure that an air leak tightness test can becarried out.

The first two pipes should be used as trial to determine the straight line entry. This isthe amount that the spigot will fit into the socket. When the pipes are fully fitted markthe socket where the spigot ends. Pull the pipes apart and measure the distance thatthe spigot has entered the socket this is the straight line entry. This distance can nowbe used on subsequent pipes to ensure full entry of spigot.

With the puller load on, deflect the pipe to the required grade and direction on thesand bedding. Hemispherical joints have a deflection of 3 degrees

The puller load must not be released until sufficient backfill is placed around the pipeto ensure that joint movement will not occur.

Care should be taken when withdrawing slings from under bedded pipes to avoiddamage to the Polyken Synergy/YGIII from sling eyes or hooks.

Internal Lining Reinstatement

For pipe sizes 600 mm OD and larger the field lining reinstatement is done from insidethe pipe. The gap between cement mortar linings at joints should be filled with cementmortar so that the lining is continuous.

For pipes sizes smaller than 600 mm OD the lining reinstatement needs to be doneprior to the pipes being jointed. Run a smooth bead of epoxy mortar against the endof lining (approx 20mm wide and to ensure a smooth and continuous lining thejointshould be pigged to remove surplus epoxy mortar prior to fully welding the joint.

Welding the JointsThe welding of the joint is the responsibility of the welder, hence no specific information

is detailed here. However, the fillet weld would be expected to be at least equivalent tothe thickness of the pipe wall thickness.

All welding should be carried out in accordance with the applicable welding standards.


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Zones of Backfilling

Zone A Bedding and CompactionBefore the pipe is laid the bottom of the trench shall be checked for any protrusionsand materials that may damage the

steelpipe sales catalogue 4th edition may 12

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