The following section provides general guidance for the installation of Vinidex AquaPRO® Systems. For more detailed information refer to AS/NZS 2566.2 – Buried flexible pipelines: Part 2, Installation.

Handling & Storage

Being manufactured from tough polypropylene, Vinidex AquaPRO® pipes are robust and are suitable for use in all site conditions. The pipes are relatively light weight and can generally be manhandled. However, care should be taken when pipes are loaded, unloaded, stacked or distributed on sites.

When pipes are lifted mechanically, web or rope slings should be used. Pipes should not be allowed to overhang by more than 1 metre. Transport should not have sharp projections which could cause damage to pipes. Pipes should not be dragged along the ground as this can damage the pipe, causing difficulty with jointing and testing.

Pipes should be stacked on flat firm ground, which has been cleared of debris. Pipes should be laid flat on transverse bearers at least 75mm wide at maximum 1.5m centres.

Pipe sockets should be supported so that the ends are free from loading, with sockets in each layer opposite to the previous layer. Framed crates must be stored timber on timber and may go up three crates but should not exceed 3m in height.

Rubber rings should be stored away from direct sunlight or weathering. Rubber rings should never be placed on the ends of pipes which are being stored.

Trench Preparation

The trench should not be excavated too far in advance of pipe laying and should be backfilled as soon as possible. The trench width should be 1700 mm wide.

The trench should be excavated deep enough to allow for the specified grade, the required depth of underlay and the minimum cover.

An efficient and appropriate excavation methodology should be employed which takes into account local conditions. From the commencement of earthworks the excavation should be maintained in a stable condition to prevent collapse and the length of excavation open at any one time should be minimized.

Minimum excavation dimensions should be as follows:
Depth of bedding below the bottom of the system = 150 mm
Distance between pipe and excavation wall = 350 mm
Depth of overlay = 200 mm

Excavation under normal conditions

Excavation for Pump Chamber Assembly

Excavation where system is to subjected to vehicular loading

Please note:

In cases where the system must withstand vehicular loads, the system should be installed as follows:

Place and compact standard backfill material around the pipe leaving any tees, end caps and chambers that will be subjected to vehicular loading exposed.

Place and compact Cement Stabilised backfill material (minimum strength 2 MPa) around the fittings for Vehicle loading up to 5 tonnes

Place and compact Cement Stabilised backfill material (minimum strength 4 MPa) around the fittings for Vehicle loading over 5 tonnes

Component preparation

1. Clean Pipe Spigots & Sockets

All dust, dirt and grit which could prevent an effective seal must be removed from pipe ends and sockets.

2. Position Sealing Rings

The correct position for the sealing ring is between the first and second corrugations from the pipe spigot end. Ensure the sealing ring is correctly sealed and not twisted. The ring will be under slight tension, thus ensuring good underside contact. The ring can be removed for cleaning and securely re-seated.

3. Apply Lubricant

Vinidex lubricant should be applied generously to the whole of the inside area of the socket. Make sure the lubricated socket does not become contaminated with dirt.

4. Make Joint

Offer up pipe to socket, align pipe and push home to the witness mark. A small depression in the trench bedding immediately underneath the socket will keep the socket clear of material during jointing. Alignment is important to facilitate jointing. Improper alignment will make it difficult to joint.

A good method is to lift the spigot end of the pipe by passing a rope underneath. This makes it easier to align spigot into socket. The pipe may be subsequently deflected to line and gradient. Any such subsequent deflection should be limited to 3°

Whatever method is used to apply the necessary force, care must be taken to ensure that there is no risk of damaging the pipe. The most convenient method is to use the backhoe arm ensuring the pipe end or fitting end is protected.

Selection of Embedment Material

Embedment material for the system should preferably be granular, free-flowing material with a maximum particle size of 14mm for DN150 pipe and 20mm for larger pipes.

This type of embedment material requires less compactive effort to provide support for the pipe and minimise soil settlement. Consult AS/NZS 2566.2 for more information.

Pipe Laying

The bedding material should be placed and graded to invert level, and compacted as required. In conditions where the trench bottom is wet, soft or irregular, it may be necessary to first stabilise, fill and level, and compact the base. In order to ensure uniform support along the pipe barrel, a small indentation should be excavated in the pipe bedding zone to accommodate the pipe sockets.

The pipe side support material should be placed evenly on both sides of the pipeline and compacted such that relative compaction is consistent with design. Side support material should be worked under the sides of the pipe to minimise voids and provide maximum pipe haunching, taking care to minimise distortion of the pipe and maintain alignment and grade. The pipe overlay material should be levelled and compacted in layers, to a minimum height of l00mm above the crown of the pipe, or as specified.

Backfill should be placed on the pipe overlay and compacted as specified but generally not in layers in excess of 300mm. Complete the backfilling operation to finished surface levels.

Notes on Installation

Leakage Testing

Leakage testing is carried out to identify installation faults and sources of infiltration and exfiltration in pipelines AS/NZS 2566.2 specifies detailed procedures for leakage testing using hydrostatic testing, air or vacuum testing or infiltration testing of non pressure pipelines. These methods are summarised as below. Notwithstanding this, leakage testing should be carried out in accordance with local authority requirements.

Method 1: Air Test

Introduce air slowly by suitable means until a pressure of 25kPa is obtained. Maintain for a period of at least 3 minutes. If no leaks are observed after 3 minutes, shut off the air supply. If the pressure of air contained in the pipes under test does not fall below 18kPa within the time period specified the pipeline shall be considered satisfactory. If, however, the pressure is not maintained within the specified limits, reintroduce the air and examine the pipeline for leaks by pouring a concentrated solution of soft soap and water over the joints and fittings. Identify and repair any leaks. After any repairs, the pipeline should be re-tested.

Method 2: Vacuum Test

Apply a vacuum until a negative pressure of 25 kPa is obtained. Maintain for a period of at least 3 minutes. If no leaks are observed after 3 minutes, isolate the test section from the vacuum pump. Monitor the pressure for the time specified in Table 7. If the vacuum does not drop below 18 kPa within the specified time period, the pipeline shall be considered satisfactory. Where the pipeline section fails the test, reapply the vacuum and examine the pipeline for leaks. Identify and repair any leaks. After any repairs, the pipeline should be re-tested.