Installation

Guide
for
PVC
Water Pipe

January 1999 Edition

 Preface
This booklet is intended for use by installers, supervisors, and
inspectors responsible for the installation of PWPipe’s PVC water
pipe. It is not a design manual. Rather it is intended as a guide for
the proper handling, installation, and testing of PVC pressure wa-
ter pipe. If used properly, this information can maximize product
performance and minimize the possibility of field problems.
This guide is not intended to assume the authority of the
engineer. Because system requirements and actual field condi-
tions may vary significantly, the sole responsiblity for all design and
installation decisions lies with the project engineer.
Table of Contents
Chapter I 1
General Information

Chapter II 5
Receiving, Unloading, Storage,
and Handling

Chapter III 13
Trench Construction

Chapter IV 29
Pipe Assembly

Chapter V 43
Testing

Chapter VI 49
Service connections

Chapter VII 67
Special Considerations

Index 79
Chapter I

General Information
 Specifications
PWPipe produces PVC municipal water (Cast Iron
Pipe Size) pipe in conformance with AWWA C900 and
C905, IPS (Iron Pipe Size) pipe in conformance with
ASTM D 2241 and D 1785 and PIP (Plastic Irrigation
Pipe) in conformance ASAE and SCS specifications.
PWPipe recommends that pipe be installed according to
this guide, AWWA 605, AWWA Manual M23, and ASTM D
2774.
 Warranty
PWPipe warrants that its PVC pipe products were
manufactured in accordance with applicable materials
and product specifications, and that the pipe is free from
all defects in materials and workmanship using the appli-
cable specifications as a standard.
Every claim under this warranty shall be deemed
waived unless presented in writing and received by
PWPipe within sixty (60) days of the date the defect was,
or should have been discovered or within two (2) years of
the date of PWPipe’s shipment of the product, whichever
occurs sooner.
PWPipe makes no other warranty or representa-
tion of any kind, expressed or implied, in fact or in law,
including without limitation the warrant of merchant-
ability or fitness ffor
or a par ticular purpose
particular purpose,, other than
the limited warranty set ffoo rrth
th above
ve..
above

Limitation of Liability
It is expressly agreed that the limit of PWPipe’s liability is the
replacement of defective product with the same quantity of non-
defective product, and that PWPipe shall have no such liability
unless the claim results solely from breach of PWPipe’s warranty.
In no event shall PWPipe be liable for any inciden-
tal or consequential damages of any kind, including
without limitation, any expense or removal or reinstal-
lation resulting from any defect.
Some states do not allow the exclusion or limitation of inciden-
tal or consequential damages, so the above limitation or exclusion
may not apply to you. This warranty gives you specific legal rights,
and you may have other rights which vary from state to state.

10
Chapter II

Receiving,
Unloading,
Storage,and
Handling

11
 Receiving
When receiving a pipe shipment, the contractor or pur-
chaser should exercise established precautions. Each pipe
shipment should be inventoried and inspected upon arrival.
The pipe was inspected and loaded with due care at the
factory using methods acceptable to the carrier. It is the
carrier’s responsibility to deliver the shipment in good condi-
tion, and it is the receiver’s responsibility to ensure that there
has been no loss or damage.

The following procedures are recommended for acceptance

of delivery:
1. Make overall examination of the load. If the load is intact,
ordinary inspection while unloading should be sufficient to
ensure that the pipe has arrived in good condition.
2. If the load has shifted, has broken packaging, or shows rough
treatment, carefully inspect each piece for damage.
3. Check total quantities of each item against shipping records.
4. Note any damaged or missing items on the delivery receipt.
5. Notify the carrier immediately and make a claim according to
his instructions.
6. Do not dispose of any damaged material. The carrier will notify
you of the procedure to follow.
7. Shortages and damaged materials are not re-shipped without
request. If replacement materials are needed, reorder from
PWPipe or your distributor.
 Unloading
The means by which the pipe is unloaded in the field is the
decision and the responsibility of the receiver. These recommen-
dations should be followed:
1. Remove restraints from the top unit loads. These may be
either straps, ropes, or chains with padding.
2. Remove any boards on the top or sides of the load which are
not part of the pipe packaging.
3. Using a fork lift with thin chisel forks (or a front-end loader
equipped with forks), remove the top units one at a time from
the truck.
4. If a fork lift is not available, use a spreader bar with fabric straps
capable of carrying the load. Space straps approximately

eight feet apart. Loop straps under the load. Cables may be
used only if they are cushioned to prevent damage to the pipe.
5. During the removal and handling, ensure that the units do not
impact anything (especially in cold weather).
6. Place pipe package units on level ground.
7. Do not handle units with individual chains or single cables,
even if padded.
8. Do not attach lifting cables to unit frames or bands.
9. Do not stack package units more than eight feet high.

14
10. Protect units with packing materials the same way they were
protected while on the truck.
11. To unload lower units, repeat the unloading process de-
scribed above.
12. Do not unload by hand.
13. WARNING: DO NOT STAND OR CLIMB ON CRATES
OR CONTAINERS.

Storage
The following procedures are recommended to prevent dam-
age to the pipe:
1. Store the pipe at the site in unit packages.
2. Avoid compression, deformation or damage to bell ends of the
pipe.
3. When unit packages are stacked, ensure that the weight of
upper units does not cause deformation to pipe in lower units.
4. Support pipe unit packages on wood blocking to prevent
damage to the bottom surfaces during storage. Space sup-
ports to prevent pipe bending.
5. Store solvent cement in tightly sealed containers away from
excessive heat.
6. Do not store pipe where gaskets may be exposed to ozone,
grease or oil.
7. Protect pipe interior and sealing surfaces from dirt and foreign
matter.
8. When unit packages are stacked, ensure that the stack re-
mains stable.

15
 Handling
The following procedures are recommended:
1. When using mechanical equipment, exercise care to prevent
damage to the pipe.
2. Lower pipe carefully from trucks and into trenches. Do not
drop pipe.
3. In subfreezing temperatures, use caution to prevent impact
damage. Handling methods considered acceptable for warm
weather may be unacceptable during very cold weather.

16
4. When distributing pipe along a trench (stringing), place pipe
on the opposite side of the trench from the excavated earth.
Place pipe with bell ends in the direction of the work progress.
Note: Hydraulic flow is not significantly affected by
the direction of the bell ends.

17
Chapter III

Trench
Construction
 General

1. Trench excavation should comply with all applicable laws and

regulations.
2. Excavated material such as debris and removed pavement is
not suitable for trench backfill.
3. Where dewatering is necessary, water should be removed
until the pipe has been installed and the backfill has been
placed to a sufficient height to prevent flotation of the pipeline.
4. The maximum earth load on flexible pipe is the weight of the
material directly over the pipe (prism load). Unlike rigid pipe,
the width of the excavated trench does not affect pipe load-
ing. Trench width is based solely on practical and economical
construction.
5. See Figure 3.1 for trench terminology.

FIGURE 3.1
TRENCH CROSS-SECTION SHOWING
TERMINOLOGY
 Narrow,
Unsupported,
Vertical-Walled
Trench
1. See Figure 3.1 for unsupported vertical-walled trench cross-
section.
2. The width of narrow trenches is the minimum working room
required for a worker to place haunching material. See
Table 3.1.
3. In narrow trenches, pipe embedment should be compacted
all the way to the trench wall.

TABLE 3.1
NARROW TRENCH WIDTHS, MINIMUM
NOMINAL
PIPE SIZE TRENCH WIDTH, MINIMUM

Diameter No. of Pipe

(Inches) Diameters Inches
4 4.3 18
6 2.9 18
8 2.9 24
10 2.5 26
12 2.4 30
15 2.0 30
18 1.8 32
21 1.6 34
24 1.5 36

22
 Sub-Ditch
Trench

The width of the subditch below the top of the pipe should
meet the minimum dimensions of Table 3.1.

Wide
Trench

1. In some soil conditions it may be more cost effective to use

wide trench construction.
2. Wide trenches are trenches where the width at the top of the
pipe is greater than six pipe diameters (2.5 diameters on each
side of the pipe.)
3. Compaction requirements:
a. Up to 10” pipe – Compact to 2.5 pipe diameters both
sides of pipe.
b. 12” to 24” pipe – Compact to two feet on both sides
of pipe.
4. Where trench widths are less than six pipe diameters, com-
pact to full trench width.

23
 Supported Trench
1. This type of trench is used where unstable or flowing soil
conditions are present in the trench walls.
2. Methods of support include sheeting, bracing, trench jacks, or
trench box.
3. If conditions are extremely severe, it may be necessary to
grout the soil adjacent to the trench to prevent migration be-
tween pipe embedment materials and trench wall soils.
4. See Table 3.2 for minimum trench widths.

TABLE 3.2

SUPPORTED TRENCH WIDTHS, MINIMUM

NOMINAL
PIPE SIZE TRENCH WIDTH, MINIMUM

Diameter, No. of Pipe

Inches Diameters Inches
4 8.5 36
6 5.7 36
8 4.3 36
10 4.0 42
12 3.4 42
15 3.1 48
18 2.7 48
21 2.4 50
24 2.2 52

The table values assume trench support thickness of six

inches at each wall. Where thicker supports are used, the values
should be varied accordingly.

5. Where timber sheeting is used below the top of the pipe, the
sheeting should extend 2 feet (60 cm) below the bottom of the
pipe and be left in place 1.5 feet (45 cm) above the top of the
pipe.
6. Compaction requirements: Compact the foundation and em-
bedment materials all the way to the trench wall or to the
sheeting left in place.

24
 Movable Trench Support

1. When trench supports are being moved, care should be exer-

cised to prevent disturbing the pipe or its embedment.
2. Use of movable trench boxes should be limited to:
a. wide trench construction, where at least 2.5 pipe diameters
exist on either side of the pipe.
b. a shelf above the top of the pipe with the pipe installed in a
narrow, vertical-wall subditch.
3. To avoid these location restrictions, a modified box may be
used which allows compaction of bedding at bottom cutouts.
See Figure 3.2.

FIGURE 3.2

4. Any voids left in embedment material by support removal should

be carefully filled and compacted.
5. Removal of bracing between sheeting should be done only
where backfilling proceeds and bracing is removed in a man-
ner that does not relax trench support.

Trench Depth
1. Where frost depth is a consideration, pipe burial should be 6
inches deeper than the record frost penetration.
2. Where frost is not a concern and live loads are not antici-
pated, a minimum cover of 12 inches is adequate.
3. Where live loads are significant, the design engineer should
consider such factors as size and type of equipment, impact,
type of soil, and soil compaction in determining cover require-
ments.

25
 Trench Bottom
1. The trench bottom should provide a uniform, stable support for
the pipe.
2. The soil surface at the bottom of the trench should be free of
any irregularities that could cause point loads on the pipe or
bell.
3. Where an unstable trench bottom condition occurs, special
foundations may be required. A layer of bedding material
should be placed between foundation and pipe.
4. Where rock subgrade or stones larger than 1.5 inches are
encountered, a minimum of 4 inches of bedding should be
placed under the pipe above the rock.

Embedment Materials

1. See Table 3.3 for soil classifications.

2. The high void ratio of Class I material limits its use to areas
where side support will not be lost due to migration of fines from
the trench walls and bottoms. Where such migration is pos-
sible, the minimum size range should be reduced and the
gradation designed to limit void size.
3. Class II material should be well graded (not uniformly graded or
gap graded) to prevent loss of side support as described in
item 2.
4. For Class IV materials, caution should be exercised in the
design and method of compaction due to difficulty in control-
ling moisture content in field conditions.
5. Class V materials are not recommended for bedding, haunching,
or initial backfill.
6. See Table 3.4 for degree of compaction information for vari-
ous compaction methods and embedment materials.
7. For PVC pipes 6 inches in diameter and greater, limit particle
size in the embedment zone to 1 1/2 inches or less. For pipe
diameters less than 6 inches, limit particle size in the embed-
ment zone to 3/4 inch or less.

26
 TABLE 3.3
Description of Embedment Material Classifications

SOIL SOIL DESCRIPTION OF

TYPE MATERIAL CLASSIFICATION
Manufactured angular, granular material,
SOILS*
CLASS I

1/4 to 1 1/2 inches (6 to 40 mm) size,

including materials having regional
significance such as crushed stone or
rock, broken coral, crushed slag, cinder, or
crushed shells.

GW Well graded gravels and gravel-sand

mixtures, little or no fines. 50% or more of
coarse fraction retained on No. 4 sieve.
More than 95% retained on No. 200 sieve.
Clean.
CLASS II SOILS**

GP Poorly graded gravels and gravel-sand

mixtures, little or no fines. 50% or more of
coarse fraction retained on No. 4 sieve.
More than 95% retained on No. 200 sieve.
Clean.

SW Well-graded sands and gravelly sands, little

or no fines. More than 50% of coarse
fraction passes No. 4 sieve. More than
95% retained on No. 200 sieve. Clean.

SP Poorly graded sands and gravelly sands,

little or no fines. More than 50% of coarse
fraction passes No. 4 sieve. More than
95% retained on No. 200 sieve. Clean.

GM Silty gravels, gravel-sand-silt mixtures. 50%

or more of coarse fraction retained on No.
4 sieve. More than 50% retained on No.
CLASS III SOILS***

200 sieve.

GC Clayey gravels, gravel-sand-clay mixtures.

50% or more of coarse fraction retained on
No. 4 sieve. More than 50% retained on
No. 200 sieve.

SM Silty sands, sand-silt mixtures. More than

50% of coarse fraction passes No.4 sieve.
More than 50% retained on No.200 sieve.

SC Clayey sands, sand-clay mixtures. More

than 50% of coarse fraction passes No. 4
sieve. More than 50% retained on No. 200
sieve.

27
 SOIL SOIL DESCRIPTION OF
CLASS TYPE MATERIAL CLASSIFICATION
ML Inorganic silts, very fine sands, rock
flour, silty or clayey fine sands. Liquid
limit 50% or less. 50% or more passes
No. 200 sieve.

CL Inorganic clays of low to medium

CLASS IV SOILS

plasticity, gravelly clays, sandy clays,

silty clays, lean clays. Liquid limit 50%
or less. 50% or more passes No. 200
sieve.

MH Inorganic silts, micaceous or

diatomaceous fine sands or silts,
elastic silts. Liquid limit greater than
50%. 50% or more passes No. 200
sieve.

CH Inorganic clays of high plasticity, fat

clays. Liquid limit greater than 50%.
50% or more passes No. 200 sieve.

CL Organic silts and organic silty clays of

low plasticity. Liquid limit 50% or less.
CLASS V SOILS

50% or more passes No. 200 sieve.

CH Organic clays of medium to high
plasticity. Liquid limit greater than
50%. 50% or more passes No. 200
sieve.
PT Peat, muck, and other highly organic
soils.

* Soils are as defined in ASTM D 2487, except for Class I

material which is defined in ASTM D 2321.
** In accordance with ASTM D 2487, less than 5% pass No.
200 sieve.
*** In accordance with ASTM D 2487, soils with 5% to 12%
passing No. 200 sieve fall in a borderline classification that
is more characteristic of Class II than of Class III.

28
 Compaction
1. Saturation — If saturation methods are used for compaction,
the following recommendations should be followed:
a. Prevent flotation of the pipeline.
b. Do not use saturation during freezing temperatures.
c. Exercise care to prevent erosion at pipe sides and bottom
caused by water jetting.
d. Apply only enough water to provide complete saturation.
e. Allow each layer to dewater and solidify until it will support
the weight of workers.
2. Compaction equipment
a.Avoid contacting the pipe with compaction equipment.
b.Do not use compaction equipment directly over the pipe
until sufficient backfill has been placed to prevent damag-
ing or disturbing the pipe.

29
 TABLE 3.4
Approximate Guide for Estimated Range of Degree
of Compaction versus Embedment Class and Method of Placement
as Percent of Standard Proctor Density

CLASS OF EMBEDMENT I II III IV

Manufactured Sand & Gravel Mixed-Grain Fine Grain

MATERIAL DESCRIPTION
Granular Materials Soils - Clea Soil

30
Soil

Optimum moisture content __

9 - 12 9 - 18 6 - 30
range limit % of dry weight

Soil Consolidation Met % of Proctor (or Relative) Density Range

Compact by power
95 - 100 95 - 100 95 - 100 90 - 100
tamper or rammer
 Density by portable vibrators 80 - 95 80 - 95 80 - 95 75 - 90

Consolidate by saturation 80 - 95 80 - 95 __ __

Place by hand 60 - 80 __ __ __

31
Tamp by hand __ 60 - 80 60 - 80 60 - 75

Dump 60 - 80 60 - 80 60 - 80 60 - 75

Note: This table serves as an approximate guide defining average Proctor densities attained through
various methods of soil consolidation in different classes of soil. The table is intended to
provide guidance and is not recommended for design use. Actual design values should be
developed by the engineer for specific soils at specific moisture contents.
 Bedding
1. Bedding is required to bring the trench bottom up to grade and
to provide longitudinal support under the pipe. Blocking must
not be used to bring the pipe to grade.
2. Bell holes are necessary at each joint to maintain continuous
support for the pipe.
3. Bedding thickness of 4 to 6 inches of compacted material is
usually adequate.
4. Use of well-graded material is recommended where trench
native soil is fine-grained.

32
 Haunching
1. Haunching provides side support to the pipe. This area is
the most important for controlling pipe deflection.
2. Haunching material should be worked under the sides of the
pipe to ensure side support.
3. Where coarse materials have been used for bedding, the
same materials should be used for haunching.
4. Haunching should extend to the springline of the pipe.

Initial Backfill
1. Initial backfill is placed to protect the pipe from impact damage
during final backfill.
2. Since initial backfill provides little additional structural support,
special compaction is not required.

Final Backfill
1. Material - The material used for final backfill need not be as
carefully selected as material in the embedment zone, but
should not contain boulders, frozen clumps or rubble which
could damage the pipe.
2. Compaction - Under open fields, natural compaction should
be adequate. Under improved surfaces, special compaction
(as specified by the design engineer) is required.

33
Chapter IV

Pipe Assembly
 Gasketed Pipe
PWPipe gasketed pipe is an integrally belled product. All
gaskets are installed at the factory. The joint is engineered to
provide problem-free service for the life of the pipe, but proper
procedures must be followed to ensure its effectiveness.

1. Clean the gasket area. Remove sand, dirt, grease, and

debris. Do not remove gaskets from bells — removal could
cause improper reinstallation.
2. Check the gasket. Make sure the gasket is seated uni-
formly in the groove by running your finger around the inner
edge of the gasket.
3. Clean the spigot. Use a rag to wipe the spigot clean.
4. Lower the pipe into the trench. Lower carefully to avoid
getting dirt into the bell or spigot.
5. Lubricate. Apply lubricant to the bevel of the spigot end
and approximately midway back to the stop line. A thin
layer of lubricant may be applied to the face of the gasket,
but be careful not to get lubricant behind or under the
gasket. WARNING: use only those lubricants supplied by
PWPipe - the use of other lubricants may cause deteriora-
tion of pipe or gasket.
6. Keep lubricated areas clean. If dirt or sand adhere to lubri-
cated areas, clean and re-lubricate.
7. Assemble pipe. Insert the spigot end into the bell until it con-
tacts the gasket uniformly. Straight alignment is essen-
tial for ease of assembly. Apply steady pressure by hand
or by mechanical means (bar and block, come-along, hydrau-
lic jack) until the spigot slips through the gasket. Insert the pipe
until the stop line is flush with the bell end. For some job
conditions and sizes of pipe, use of heavy equipment (such as
a backhoe bucket) may be necessary for assembling the pipe.
When this equipment is used, extra care must be taken be-
cause the installer loses the “feel” of the assembly. Conditions
such as improper spigot alignment, rolled gaskets, or
overinsertion (overbelling) could go unnoticed during assem-
bly because of the large force generated by the equipment.
The following precautions should be followed:
a. Position the spigot carefully in the bell to ensure straight
alignment both horizontally and vertically.
b. Exercise caution to prevent damage of the bell lip due to
rough contact by the equipment.
c. Be careful that the action of the equipment does not move
the pipe out of straight alignment.
d. Do not insert the spigot past the stop line. When the equip-
ment has pushed the spigot far enough to overcome the
initial resistance of the gasket, use a bar and block to finish
pushing the pipe to the stop line. This procedure not only
prevents overinsertion but also identifies rolled (fishmouthed)
gaskets at a time when they can still be easily corrected.

38
8. If undue resistance to pipe insertion is encountered or if the
pipe cannot be inserted to the reference mark, disassemble
the joint and check the position of the gasket.
a. If the gasket has been dislodged from the race, inspect the
pipe and gasket for damage, replace damaged items, clean
the components, and repeat the assembly steps, assuring
straight alignment.
b. If the gasket is still properly positioned, verify proper posi-
tioning of the reference mark. Relocate the mark if it is not
correctly positioned. In general, fittings allow less pipe in-
sertion than do pipe bells. If the pipe still cannot be inserted
properly, call PWPipe for assistance.

39
9. If the pipe must be field-cut, mark the entire circumference of
the pipe to ensure a square cut. The pipe can be cut with a
hacksaw, handsaw, or power handsaw with a steel blade or
abrasive disc.

40
 10. Bevel the cut end using a pipe beveling tool or a por-
table sander or abrasive disc. Round off any sharp
edges on the leading edge of the bevel with a pocket
knife or a file. Mark cut end with an insertion line similar
to uncut pipe.

Bevel requirements may vary with different joint types:

JOINT BEVEL

a. PVC pipe Bell Same as factory bevel

b. PVC push-on fitting Same as factory bevel
c. Other pipe bell/push-on fitting Shorter bevel length
d. Mechanical joint fitting No bevel

41
 Solvent-Cemented Pipe
1. Specifications
Solvent-cemented joints should be made in accordance with
ASTM D 2855 “Standard Recommended Practice for Mak-
ing Solvent-Cemented Joints with Polyvinyl Chloride (PVC)
Pipe and Fittings.” The solvent cement should conform to
ASTM D 2564 “Standard Specification for Solvent Cements
for Polyvinyl Chloride (PVC) Plastic Pipe and Fittings,” and
the primer should conform to ASTM F 656 “Specification for
Primers for Use in Solvent Cement Joints of PVC Plastic Pipe
and Fittings.” The handling of solvent cements should be in
accordance with ASTM F 402 “Standard Recommended
Practice for Safe Handling of Solvent Cements Used for
Joining Thermoplastic Pipe and Fittings.”
2. Basic principles of solvent-cemented joints:
a. The joining surfaces must be clean and dry.
b. The joining surfaces must be softened and made semi-
fluid.
c. Sufficient cement must be applied to fill the gap between
male and female ends.

42
 d. The assembly must be made while the surfaces are still wet
and fluid.
e. Joint strength develops as the cement dries. In the tight part
of the joint, the surfaces will fuse together. In the loose part,
the cement will bond with both surfaces.
f. Completed joints should not be disturbed until they have
cured sufficiently to withstand handling.
3. Selection of Solvent Cement
PVC solvent cements are available in a variety of viscosities
and wet film thicknesses to cover a wide range of pipe sizes,
and for interference-fit joints as well as non-interference joints.
The solvent cement manufacturer’s recommendations should
be followed for selection of proper cement.
4. Storage
PVC solvent cements should be stored in a cool place except
when actually in use at the job site. Cements have a limited
shelf life when not stored in hermetically sealed containers.
(Screw-top containers are not considered to be hermetically
sealed.) Consult the cement manufacturer for specific recom-
mendations on storage conditions and shelf life. The cement is
unsuitable for use if it exhibits an appreciable change from the
original viscosity, or if there is any sign of gelation. Warning:
Do not add solvent or thinners to the cement.
5. Procedure
a. Cutting the Pipe - Cut pipe square with the axis, using a fine-
tooth saw with a miter box or guide. Wood-working blades
may be used. A rotary cutter may be used if the cutting
blades are specifically designed for cutting plastic pipe in
such a way as not to raise a ridge (flare) at the cut end of the
pipe. The use of a standard rotary metal pipe cutter is not
recommended.

43
b. Joint Preparation — Remove all burrs and break the sharp
lead edges.
c. Test Dry Fit of the Joint — The solvent cement joint is de-
signed so that there will generally be interference of pipe
wall with the fitting socket before the pipe is fullly inserted.

Insert the pipe into the fitting and check that the interfer-
ence occurs about 1/3 to 2/3 of the socket depth. Some-
times, when the pipe and fittings are at their tolerance ex-
tremes, it may be possible to fully insert the dry pipe into the
fitting socket until it bottoms. If this occurs, extra care must
be taken to apply sufficient cement to fill the gap between
pipe and fitting in order to obtain a strong leak-free joint.

44
d. Cleaning — Surfaces to be joined must be cleaned and free
of dirt, moisture, oil, and other foreign material.
e. Handling Cement — Keep cement can closed and shaded
when not actually in use. Discard the cement when a
noticeable change in viscosity occurs, when the
cement does not flow freely from the brush, or
when the cement appears lumpy and stringy. Keep
the brush immersed in cement between applications.
f. Application of Primer and Cement — PVC solvent cement is
fast drying and therefore should be applied as quickly as
possible, consistent with good workmanship. It may be
necessary for two workers to perform this operation for larger
sizes of pipe.
First apply primer to the inside surface of the female
end. Use a scrubbing motion to ensure penetration. Repeat
applications as necessary.
Apply primer to the outside surface of the spigot end to
the depth of insertion. Be sure that the entire surface is
softened.
Reapply primer to the inside surface of the female end.
Immediately apply cement to the pipe spigot end.
Apply a light coat of cement to the inside of the socket.
To prevent solvent damage to the pipe, do not apply an
excess of cement and do not apply cement to the pipe/bell
transition.
Apply a second coat of cement to the pipe spigot end.

45
 g. Assembly of Joint — Immediately after applying the last
coat of cement to the pipe, while both the inside socket
surface and the outside surface of the male end of the
pipe are SOFT and WET with solvent cement, forcefully
bottom the male end of the pipe in the socket. Turn the
pipe or fitting 1/4 turn during assembly (but not after the
pipe is bottomed) to distribute the cement evenly. Assem-
bly should be completed within 20 seconds after the last
application of cement.

If there is any sign of drying of the cement surfaces, carefully

recoat the surfaces and assemble. Care should be taken not to
disturb or apply any force to previously assembled joints, which
can be adversely affected by rough handling.

46
After assembly, wipe excess cement from the pipe at the end of
the socket. Any gaps in the cement bead around the pipe
perimeter may indicate a defective assembly.

h. Set Time — Handle the newly assembled joints carefully until

after the set period as follows:

Temperature Range Minimum Set Time

ºF ºC
60 to 100 15 to 40 30 minutes
40 to 60 5 to 15 1 hour
20 to 40 -5 to 5 2 hours
0 - 20 -20 to -5 4 hours

i. Weather Precautions
a. High humidity — Quick application of primer and cement is
essential to minimize condensation of moisture.
b. High temperatures — Temperature of PVC surfaces
should not exceed 110º F (45º C) at the time of assembly.
c. Low temperatures — At temperatures below freezing, sol-
vents penetrate the PVC surfaces more slowly than in warmer
weather. Testing on scrap pipe is recommended.
d. Store cements and primers between 40º F (5º C) and 70º F
(21º C) when not in use.
e. Allow for adequate expansion and contraction with proper
shading methods or with expansion couplings.
6. Installation
After the set period, the pipe may be carefully laid in a prepared
ditch. For temperature considerations see page 71, “Thermal
Expansion and Contraction.”
7. Cure Period
The cure period before testing depends on the specific ce-
ment, the size of the pipe, the ambient temperature, and the
joint tightness. Cure time may vary from minutes to days. Con-
sult cement manufacturer for information.
8. Safe handling of Primers and Solvent Cements
a. Keep solvent cements and primers away from all sources of
ignition.
b. Provide adequate ventilation to reduce fire hazard and to
minimize breathing of vapors.
c. Avoid contact with skin and eyes.
d. Refer to ASTM F 402 for more information.
47
Chapter V

Testing
 General
This chapter gives PWPipe’s recommendations for project
testing, but the final authority on testing requirements is the project
engineer.
Water pipe installations are tested for pressure and leakage.
PWPipe recommends simultaneous pressure and leakage tests.
If the tests are to be done separately, the pressure test should be
done first.
It is good installation practice to test portions of a line as they
are completed. Sections that fail to pass testing should be lo-
cated, repaired, and retested until tests are passed.
Prior to the start of testing, the following steps are required:
1. The pipe to be tested should be backfilled to prevent move-
ment while under test pressures. Where possible, leave
joints uncovered during testing to allow for easier inspec-
tion.
2. At fittings, permanent thrust restraint is required sufficient to
withstand test pressures. If concrete thrust blocks are used,
the concrete must be allowed to cure before testing begins.
3. Test ends are to be capped and braced to withstand forces
developed by test pressures.
 Filling The Line
These precautions should be followed during filling:
1. The line should be filled slowly, with flow velocity not to
exceed 2 fps (0.6 m/sec).
2. If possible the line should be filled at its lowest point.
3. During filling, all air should be expelled through permanent air
vents at all high points. If permanent air vents are not re-
quired, the installer should install corporation stops at all high
points to expel air during intial filling and during pressure
testing.

Pressure and Leakage

Testing (Combined)
1. Purpose — Pressure test: to locate any defects in materials or
workmanship so that repairs may be made; leakage test: to
establish that the section of the line tested will not leak, or that
leakage is within acceptable limits.
2. Test Pressure and Duration — A test pressure of 150% of work-
ing pressure is recommended. In no case shall the test pres-
sure be allowed to exceed the design pressure for the pipe,
appurtenances, or thrust restraints. Test duration should be 2
hours for a combined pressure and leakage test. For additional
test pressure information, see the Technical Bulletin “Test Pres-
sure for C900 / C905”.
3. Method — The system should be raised to specified pressure by
means of a pump connected to the pipe. The test pressure is
maintained by additional pumping (if necessary), and all fit-
tings, valves, and hydrants carefully examined for leakage.

52
4. Allowable Leakage — Leakage is defined as the quantity of
water that must be supplied to maintain pressure within 5 psig
of the specified pressure after the pipe has been filled, vented,
and raised to test pressures. Allowable leakage may be calcu-
lated from:
Design Basis L = ND P
7,400

Where L = allowable leakage (gal/hr)

N = number of joints in the tested line (pipe and fittings)
D = nominal diameter of pipe (in.)
P = average test pressure (psi)

WARNING: DO NOT USE AIR

PRESSURE FOR TESTING PVC
WATER PIPE. INJURY OR DEATH
MAY RESULT DUE TO THE
CATASTROPHIC NATURE OF
PIPE FAILURE SHOULD FAILURE
OCCUR. (RAPID EXPANSION OF
COMPRESSED AIR COULD EXPEL
SHARP FRAGMENTS OF PIPE
MATERIAL AT HIGH VELOCITY.)

53
Chapter VI

Service
Connections
 General
Service connections range in size from 5/8-inch lines for single-
family homes to large lines for fire service or industrial use. Con-
nections may be made by tapping directly into the wall of the pipe,
by tapping through service saddles, or by using tapping sleeves.
Much of the information in this chapter is taken from the Uni-
Bell PVC Pipe Association’s “Tapping Guide for PVC Pressure
Pipe.” Contact PWPipe for a copy of the guide. Another source of
information is a short video made by Uni—Bell titled “Tapping PVC
Pressure Pipe.”
The illustrations used in this chapter depict specific tooling for
the sake of clarity. It is not the intent of PWPipe to promote
specific types of equipment or the equipment of a particular manu-
facturer.
 Direct Tapping
General
Direct tapping involves the tapping of threads into the pipe
wall and the insertion of a corporation stop. Direct tapping is
recommended for PVC water distribution pipe manufactured in
accordance with AWWA C900 in nominal sizes 6 inch through 12
inch (150 mm through 305 mm) in pressure classes 150 (DR I8)
and 200 (DR 14).
Direct tapping is not recommended for 4 inch pressure class
150 or 200 pipe. In these cases, service clamps or saddles should
be used.

Equipment
1. Tapping Machine: Mechanical device used to install the direct
tapped connection into water mains. The tapping machine
may vary in design and operation depending on the specific
machine manufacturer. The machine must operate with a cut-
ting/tapping tool which is classified as a core cutting tool
(either with internal teeth or with double slots) of the shell
design which retains the coupon cut while penetrating the wall
of the water main. The tapping machine shall provide the
 standard ratchet handle on the boring bar. The tapping ma-
chine shall be of a design where cutting and tapping is con-
trolled and accomplished with a feed nut or feed screw and
yoke.

2. Cutting/Tapping Tool: These two combination drill and tap

tools illustrate the recommended features of the cutter. A core
drill is essential. It may be plain or slotted. Slotted core drills
allow an easier cut, but not a faster cut. DO NOT DRILL A
HOLE IN PVC PIPE WITH A TWIST DRILL OR AUGER BIT.
The core drill must retain the plug of material removed from the
pipe wall (the “coupon”). A simple means of removing the cou-
pon from the core drill should be provided. The core drill must
be designed to accommodate walls as heavy as DR 14 (pres-
sure class 200, AWWA C900). Sufficient throat depth is re-
quired. The shank of the cutter must be adaptable to the
tapping machine being used.
The tap must cut AWWA C800 tapered threads. Iron pipe
threads are not recommended for the pipe wall. The depth of
travel of the cutter as the threads are cut must be carefully
adjusted (to ensure the proper insertion of the corporation
stop—with 2-3 threads showing after an insertion torque of 27–
35 ft. lbs. (36.6–47.5 newton meters)).

60
3. Corporation Stop: The corporation stops should be AWWA
tapered with thread complying with AWWA C800 in sizes 5/8,
3/4 and 1 inch. When sizes larger than 1 inch are required,
tapping saddles or sleeves should be used.

Procedures
1. Planning the Direct Tap:
a. Only AWWA C900 Class 150 and 200 PVC pipes 6” (150
mm) through 12” (305 mm) can be direct tapped.
b. Taps up to 1 inch max. can be made directly (i.e. 5/8”, 3/5”
and 1”).
c. Wet taps (pipe filled) or dry taps (pipe empty) are allowed.
Wet taps are preferred.
d. The maximum allowable pressure in the pipe at the time the
wet tap is being completed is the rated pressure class of the
pipe (i.e. DR 18, PC 150; DR 14, PC 200).
e. Corporation stops must have AWWA C800 thread. Iron
pipe threads are not recommended for the pipe wall.
f. Use a combination core drill and tap when tapping direct.
Do not use twist drills designed for tapping hard wall pipes.
g. Recommended temperature limits:
Dry taps: 0º F (-18º C) to 100º F (38º C)
Wet taps: 32º F (0º C) to 90º F (32º C)
These temperatures refer to the temperature of the pipe
itself, which is closely related to air temperature in most
cases.
h. Placement
- Tap no closer than 24 inches (600 mm) from the ends of
the pipe.
- Stagger multiple taps and keep them at least 18 inches
(450 mm) apart lengthwise.
- Avoid tapping into a discolored surface.

61
 i. Tap a curved pipe only if the radius of the bend is 300
times the pipe outside diameter (or more). The offsets
which result from a minimum bending radius of 300 OD
are as given below.

AWWA C900, 20 foot lengths

Nominal
Pipe Size 6” 8” 10” 12”

A (inches) 14.0 11.0 8.5 7.0

j. Do a test tap in the shop before starting field tapping.

– Do a couple of dry bench taps to establish the mark on
the boring bar corresponding to the correct tapping
depth.
– Firmly seat the cutter in the holder of the tapping ma-
chine. Secure it well. Any wobbling or looseness of
either the cutter or the boring bar will cause problems.
– Make a final check of thread compatibility. AWWA
threads are required for both the tap and the corpora-
tion stop.
k. Observe the basic tapping precautions when tapping
pressurized pipes:
– Have a second person close by.
– Wear protective goggles.
– Provide a quick exit from the ditch.
– Cover the pipe area with a protective blanket (without
obstructing machine operation).
– Follow local regulations.

62
 l. When tapping pressurized pipes, the personnel on the
surface should have a clear understanding of the valve
operation necessary to isolate the tapping site, if required
to do so.
WRONG RIGHT

Over-tightening only one Both sides evenly tightened

side may distort wall and using only the wrench
stress pipe. Never use supplied.
wrench extensions.

2. Mounting the Machine:

a. Make sure the outside diameter of the pipe (listed below)
falls within the range of O.D.’s for which the tapping ma-
chine saddle is designed.

Nominal Pipe Size Pipe O.D.

(inches) (inches)
6 6.90
8 9.05
10 11.10
12 13.20

b. The machine should sit on the drilling site firmly, but not in a
way that will set up wall stresses by distorting the pipe. The
actual placement of the tapping machine on the pipe is to
be done in accordance with the recommendations of the
machine manufacturer.

63
 c. Even when taps are being made on the horizontal plane
(the preferred location because it keeps the gooseneck
of the service pipe as far below the frostline as possible),
it is important that the tightening nuts be turned down
evenly on each side.
Follow this procedure:
– Adjust the nuts on the chain hooks so that they are
even with the tops of the threads.
– Position the chain hooks on the machine and loop the
chain links into the hooks snugly.
– Tighten nuts A and B alternately so that the same
number of threads are showing when the machine is
correctly and firmly mounted.
– During the process, make sure the machine remains
correctly seated in the saddle and saddle gasket.
Overtightening on only one side may distort the wall
and set up wall stresses.
d. Wrench extenders should not be used.
3. Cutting the Hole and Tapping the Threads:
a. Since PVC is easy to cut, there is a temptation to overfeed
the cutter because it is comparatively easy to turn the ratchet
handle. The principle is to allow the cutter to work as a
cutter. Rotate the ratchet handle one complete turn for
every 1/8 turn of the feed yoke (approx. 1-in. (25 mm) move-
ment of feed nut to each 1/4 turn of ratchet handle).

RIGHT

Feed lightly — just enough to

keep the cutter engaged.

64
b. The feed rate should be less in cold weather. Judge the
correct feed rate by “finger pull” — the effort should be about
the same used to open a desk drawer. This rule of thumb
applies in any temperature.
c. Upon wall penetration, the upward thrust on the boring bar
(assuming a pressurized pipe) will be about 1 lb.-force per
1 psi of water pressure.
d. Use the feed yoke to engage the first few turns of the
tapping tool in the hole. After this, the tap is self-feeding
and the feed yoke can be disengaged from the boring bar.
e. The “Cast Iron” mark on the boring bar is not a reliable
indicator of how deep to tap. Tapping to the correct depth
is important and should be determined by performing bench
tests in advance and carefully noting the position of the
threaded feed sleeve (relative to the thrust collar or other
datum point) when the corporation stop is correctly inserted.
f. As the tapping tool is reversed out of the hole, re-engage
the feed yoke or hold the boring bar until the tap clears the
threads. Release the bar slowly so as not to damage the
threads, or injure the machine operator.
g. Examine the coupon of PVC after it is knocked out of the
cutter head. A clean edge means good cutting action. A
raised crown means the cutter was fed through too fast.

WRONG RIGHT If the cutter is fed too fast,

a plug of material is
pushed out of the I.D. of
the pipe where the tool
emerges. The condition of
the “coupon” provides a
check of correct tapping
procedures.

At the first sign of a “crown”

on the coupons, the tap-
ping procedure or the con-
dition of the tools should
be re-examined and cor-
rected before more taps
are attempted.

65
4. Inserting the Stop:
a. Attach the E-Z screw plug to the end of the boring bar.
Screw the corporation stop into the E-Z release plug. The
exposed end of the main stop will be the inlet end with
tapered (AWWA) threads. Check to BE SURE THE STOP
IS CLOSED.
b. Apply two spiral wraps of “Teflon” tape clockwise to the
AWWA threads. Other thread lubricants are not recom-
mended. Do not use liquid sealants (even though they may
contain Teflon).
c. Replace the boring bar assembly in the machine and insert
the stop into the main. Use care to start the first few threads
in the hole so that they are not forced or punched. Using
the feed yoke for this operation requires only light finger
pressure on the feed nut while the ratchet handle is rotated.
d. Disengage the feed yoke and remove the ratchet handle
as soon as the stop has firmly engaged the threads in the
pipe wall. Complete the insertion using a torque wrench.
e. Tighten the stop to 27 foot-pounds (36.6 newton meters).
f. Snap the wrench counterclockwise to release the E-Z plug
from the stop. Remove the tapping machine in the usual
way. If there is leaking past the threads, tighten the stop to
35 foot-lbs (47.5 newton meters). At correct insertion, one
to three threads should be visible.
g. If leaking past the threads persists, remove pressure from
the line, unscrew the main stop to clear away cuttings and
replace the stop to 27 foot lbs. (36.6 newton meters), mak-
ing sure the “Teflon” thread lubricant has been restored.

66
5. Direct Dry Tapping: When direct tapping AWWA C900 DR 18
Pressure Class 150 or DR 14 Pressure Class 200 PVC pipe 6”
- 12” that is empty, or not in service, or not yet under pressure,
the procedure given for making wet taps under pressure should
be followed with a few exceptions:
a. Remove the machine from the pipe after the hole has been
drilled and tapped. Carefully remove the cuttings from the
hole before inserting the main stop.
b. Prepare the stop as described in “Inserting the Stop” and
insert it by hand. Caution: Take special care not to
crossthread the fine, “Teflon” wrapped AWWA threads.
c. Tighten the stop to the point where 1–3 threads are showing
at 27 foot-lbs. (36.6 newton meters).

67
 Saddle Tapping
General
The use of saddles to make taps in PVC pressure pipe is
recommended for any size or class of pipe. Service connections
may be made using a service clamp or saddle. Maximum outlet
size recommended with service clamps or saddles is 2 inches (50
mm). When making this type of connection, equipment is used

which attaches to the corporation stop permitting a cutting tool to

be fed through the corporation stop to cut a hole in the pipe. No
tapping of the pipe wall is required since the corporation stop is
threaded into the service clamp.

Equipment
1. Service Clamps or Saddles
a. Service clamps or saddles used for attaching service con-
nections to PVC water pipe should:
– Provide full support around the circumference of the
pipe.
– Provide a bearing area of sufficient width along the
axis of the pipe, 2 inch (50 mm) minimum, insuring that
the pipe will not be distorted when the saddle is tight-

68
 b. Service clamps should not:
– Have lugs that will dig into the pipe when the saddle is
tightened.
– Have a U-bolt type of strap that does not provide suffi-
cient bearing area.
– Have a clamping arrangement that is not fully contoured
to the outside diameter of the pipe.
2. Tapping Machine: A number of tapping machines are avail-
able which will cut through a corporation stop. The tapping
machine may vary in design and operation depending on the
specific machine manufacturer. The machine must operate
with a cutting tool which is classified as a core cutting tool
(either with internal teeth or with double slots) of the shell
design which retains the coupon cut while penetrating the wall
of the water main. The tapping machine shall provide the
standard ratchet handle on the boring bar. The tapping ma-
chine shall be of a design where cutting is controlled and
accomplished with a feed nut or feed screw and yoke.
3. Cutting Tool: It is important that the cutting tool be a shell type
(hole) cutter which will retain the coupon and be designed to
accommodate walls as heavy as DR 14 (pressure class 200,
AWWA C900). Many shell cutters are designed only for thin
walled PVC. Consequently, they do not have sufficient throat
depth to handle the heavier-walled pipe. DO NOT DRILL A
HOLE IN PVC PIPE WITH A TWIST DRILL OR AUGER BIT.
The shank of the cutter must be adaptable to the cutting
machine being used.
4. Corporation Stop: Because the corporation stop is inserted
into the service clamp or saddle, it must have threads which
match that of the clamp or saddle, which may be either IPS OD
or CIPS OD.
The maximum size of corporation stop which may be
used with a service clamp or saddle is 2 inches. If a tap larger
than 2 inches is required, a tapping sleeve and valve are
required.

69
 Procedure
1. Evenly tighten the saddle to the pipe. Do not overtighten the
bolts. (If the bolts are overtightened, stresses will be intro-
duced into the wall of the pipe.) The torque required is gener-
ally approximately 20 ft. lb.
2. Screw the inlet side of the main stop into the saddle threads.
Retain the stop hardware as supplied.
3. Open the main stop.
4. Using the appropriate adapter and gasket, attach the drilling
machine to the main stop outlet threads. Use a machine with
an operator-controlled feed rate. Be sure to follow the ma-
chine manufacturer’s instructions.
5. The use of a core drill is essential. The key to tapping PVC
pipe lies in advancing the feed nut slowly enough to allow the
core drill to cut the pipe rather than forcing it through the pipe
wall.
6. Lower the boring bar to the main and rotate the cutter while
exerting finger-pull on the feed handle. Rotate the ratchet
handle one complete turn for every 1/8 turn of the feed yoke.
7. After the cutter has penetrated the pipe wall, withdraw the
cutter, close the main stop, and remove the drilling machine.
8. After the machine has been removed, tighten the saddle
bolts to ensure that the saddle gasket will seal.

70
 Tapping Sleeve
and Valve
General
Tapping sleeves and valves are used when service connec-
tions larger than 2 inches (50 mm) must be made in PVC water
mains. Tapping sleeves may be used for making large taps under
pressure. The use of tapping sleeves and valves to make taps in
PVC pressure pipe is recommended for any size or class of pipe.
When making this type of connection, equipment is used which
attaches to the valve permitting a cutting tool to be fed through
the valve to cut a hole in the pipe. No tapping of the pipe wall is
required since the valve is attached to the tapping sleeve.

Equipment
1. Tapping Sleeves and Valves:
a. When tapping sleeves are ordered from the manufacturer,
the outside diameter of the pipe being tapped, the size of
the outlet desired and the working pressure (or test pres-
sure, if higher) should be specified to insure that the sleeve
furnished will be satisfactory. Lead-joint sleeves should not
be used.
b. Tapping sleeves should:
– Provide full support around the circumference of the pipe.
c. Tapping sleeves should not:
– Distort the pipe when tightened.
– Have lugs that will dig into the pipe when the sleeve is
tightened.
– Have a clamping arrangement which is not fully contoured
to the outside diameter of the pipe.
d. When ordering tapping valves, dimensions and attaching
mechanisms consistent with the tapping sleeves should be
specified.
2. Cutting Tool: A toothed core cutter which retains the coupon,
similar to those used for other materials, should be used. The

71
 cutter should have sufficient throat depth to cut heavy walled
PVC such as DR 14. DO NOT DRILL A HOLE IN PVC PIPE
WITH A TWIST DRILL OR AUGER BIT.
3. Tapping Machine: A number of tapping machines are avail-
able which will cut through a tapping valve. The tapping
machine may vary in design and operation depending on the
specific machine manufacturer. The tapping machine must
be attached to the valve and must be ordered according to
the valve specified. Tapping equipment can be purchased
or rented from sleeve manufacturers who also furnish instruc-
tions and/or instructors trained in making such taps. (Con-
tractors who specialize in this type of work are also available
in some areas.)

Procedures
1. The tapping sleeve should be assembled on the pipe in
accordance with the manufacturer’s directions, insuring that
no pipe distortion occurs. The tapping valve is then con-
nected to the sleeve.
2. Tapping sleeves should be well supported independently
from the pipe during the tapping. Support used should be left
in place after tapping. Thrust blocks should be used as with
any other fitting or appurtenance.
3. Attach the drilling machine and adaptor to the valve outlet
flange. Position the necessary support blocks. Open the tap-
ping valve, advance the cutter and cut the hole into the main
through the sleeve. Retract the cutter and then close the
tapping valve. Remove the drilling machine and attach the
new line or lateral.

72
Chapter VII
Special
Considerations

73
 Longitudinal
Bending
1. The ability of PVC pipes to bend is a signficant advantage
over rigid pipes.
2. Longitudinal bending may be done deliberately during con-
struction or may be the result of changes that occur in the
pipe-soil system after construction.

3. Gasketed Pipe Joint Deflection: Gasketed PVC pipe joints

allow a small amount of deflection. The maximum allowable
deflection in gasketed PWPipe products is one degree.
4. Pipe Body Longitudinal Bending: The bending radii of PVC
water pipes must be limited to the following:
Pressure Rated Pipes (ASTM D 1785, ASTM D 2241,
AWWA C905, all PIP pipes): 200 times OD or greater.
OD = Pipe outside diameter in inches — divide result by 12
to get bending radius in feet.
5. Bending should be done manually, with a bar if possible. If
mechanical equipment is used, extreme care should be taken
to prevent damage to the pipe and the adjacent joint. Some
large-diameter pipe may be too stiff to be curved.
6. Fittings should be used for radii tighter than those recommended
above.
7. More information can be found in the PWPipe Technical Bul-
letin “Longitudinal Bending of PVC Pipe”. Contact PWPipe for
a copy.

76
 Thermal Expansion
and Contraction

1. All materials expand and contract with changes in tempera-

ture. Linear expansion of pipe in the longitudinal direction is
dependent on:
a. Variation in temperature.
b. Coefficient of thermal expansion of the material. It is im-
portant to note that the rate of thermal expansion and
contraction is not dependent on pipe size or wall thick-
ness.
2. The coefficient of thermal expansion for PVC is 3.0 x 10 -5º
in/in/ F ( 5.4 x 10 -5 mm/mm/ ºC).
3. Allowance for the movement:
a. 0.36 inch of length variation for every 100 feet of pipe for
each 10º F change in temperature.
b. 5.4 mm of length variation for every 10 meters of pipe for
each 10º C change in temperature.

77
4. Gasketed Joints — When gasketed joints are used, thermal
movement is not a significant design factor as long as:
a. Pipe temperatures are kept within accepted limits for PVC
pipe.
b. Joints are properly installed with the pipe spigots inserted
into the bells to the insertion line.

WARNING
WARNING: IF PIPE SPIGOTS ARE INSERTED
PAST THE INSERTION LINE, THERMAL EXPAN-
SION MAY CAUSE SIGNIFICANT STRESSES IN THE
PIPE BELLS.

5. Solvent Cemented Joints — When solvent cemented joints

are used, thermal movement cannot be accommodated in
the pipe joints. The following installation procedures are rec-
ommended (after the joints are properly cured):
a.Small diameter pipes (1/2 inch to 2 1/2 inch) — When
installation temperature is substantially lower than operating
temperature, the pipe should be installed with straight align-
ment and brought up to operating temperature. This proce-
dure will permit expansion of the pipe to be accommodated
by snaking action. When installation temperature is substan-
tially above operating temperature, the pipe should be in-
stalled by snaking in the trench.
b. Large Diameter Pipes (3 inch and larger) — Pipe should be
installed in straight alignment. Before backfill to the extent
that restricts longitudinal movement, the product temperature
should be adjusted to within 15º F (8º C) of operating tem-
perature.
6. Where the operating temperature cannot be closely con-
trolled, the stresses resulting from extreme temperature varia-
tions must be considered in the design. The design engineer
should be consulted for guidance.

78
 Thermal Effects on PVC
Properties
The physical properties of PVC vary with changes in tem-
perature. The rated values for PVC properties are established at
73.4º F (23 C).
1. As temperature decreases below 73.4º F, pipe stiffness and
tensile strength increase while impact strength decreases.
This decrease in impact strength requires that more care be
taken during installation in cold temperatures.
2. Conversely, as temperatures increase, pipe stiffness and
tensile strength decrease while impact strength increases.
Decreases in pipe stiffness require that more care be taken
during installation in hot weather.

79
 Ultraviolet (UV) Radiation
Like most plastics, PVC can experience degradation when
exposed to UV radiation. This degradation occurs only on sur-
faces exposed to the sun and penetrates only about .001 inch
into the pipe wall. The affected areas often turn a yellow color.
When the pipe is no longer exposed to the sun, further degra-
dation does not occur.
Ultraviolet exposure does not significantly affect pipe stiff-
ness or tensile modulus properties. However, there is a measur-
able reduction in values for impact strength.
PVC pipe’s high initial impact strength means that reduc-
tions in impact properties due to UV radiation are of little con-
cern. If good construction practice is followed in unloading,
handling, and installation, pipe breakage due to impact loads
will not be a problem.
See the PWPipe Technical Bulletin “The Effects of Sun-
light Exposure on PVC Pipe and Conduit” for more details.

80
 Appurtenances
1. Valve and fitting weights should not be carried by PVC pipe.
Most valves and fittings may be supported on properly com-
pacted bedding, but in some soil conditions, concrete cradles
may be required for heavy valves.
2. AWWA C900 and C905 pressure pipe is produced in cast-iron
pipe size (CIPS). This means that ductile iron valves and fit-
tings are compatible with CIPS PVC pipe.
3. Similarly, iron pipe size (IPS) PVC pipe is compatible with ap-
purtenances used for steel pipe.

4. Butterfly valves may not function properly on some heavy-

walled PVC pipe because wall thickness may interfere with
disc movement. Special adapters may be required.
5. Most fittings do not allow as much spigot insertion depth as do
pipe bells and couplings. When assembling a PVC pressure
pipe to an iron fitting (push-on or mechanical joint), remove all
but 1/4 inch of the factory made bevel from the spigot end of
the pipe. Bottom the pipe in the bell of the iron fitting.

81
 Thrust Restraint
The large thrust forces exerted in water distribution systems
require thrust restraint designed to resist test pressures as well as
peak operating pressures.
1. When concrete thrust blocks are used, the size and type of
blocking must be based on the maximum thrust force ex-
pected and the load-bearing capacity of the soil.

THRUST BLOCKS

Through line connection, tee Direction change, elbow

2. When mechanical thrust restraint devices are used, they

must be a type that is specifically designed for use with PVC
pipe. The devices should conform to Uni-Bell’s UNI-B-13
“Recommended Performance Specification for Joint Restraint
Devices for Use with PVC Pipe.”

THRUST RESTRAINERS

Through line connection, Direction change, elbow

cross used as tee

82
 Application Precautions

1. Entrapped air — During filling of pipe with water for testing or

operation, air should be allowed to escape through valves or
corporation stops at the high points of the line. Removal of
entrapped air reduces surge pressures (water hammer) in the
line.
2. Pressurized air — PWPipe’s pressure water pipe is not intended
for air pressure testing or service.
WARNING: Do not use PWPipe products for pres-
surized air applications, as injury may result.
3. Safety — All applicable federal, state, and local safety regula-
tions should be followed.

83
 Index
Appurtenances 75

Backfill, final 27
Backfill, initial 27
Backhoe 32
Bedding 20, 21, 26
Bell holes 26
Bending 69
Bevel 35, 75

Compaction 17, 18, 23, 24

Cutting 37, 38
Cutting Tool 38

Dewatering 15
Direct Tapping 53

Embedment 20, 24
Entrapped air 77

Fittings 38, 75, 77

Foundation 20

Gasket 9, 31-40

Handling 5, 10
Haunching 27

Impact 8, 11, 27
Impact Strength 73

Leakage, allowable 47
Leakage testing 45, 46
Lubricant 31, 60
Minimum Cover 19
Moveable trench support 18, 19

Pipe assembly 29–41

Pressurized air 77
Primer 36, 39, 41
Primer storage 51
Prism load 15

Receiving 5, 7
Reference mark 33

Saddles 62-64
Safety 77
Saturation 23
Service connections 49, 51, 62
Soil Clasifications 21
Solvent cement 36
Specifications 3, 9, 36–41
Stop line 32
Storage 5, 9, 37
Stringing 11
Subditch 17
Supported trench 18, 19

Tapping sleeves 65, 66

Testing 41, 43, 45–47
Thermal effects on PVC properties 73
Thermal expansion 71
Thrust restraint 45, 76
Trench width 15–18

Ultraviolet radiation 74
Unloading 5, 8

Valves 65, 66, 75, 77

Warranty 4

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 Corporate Office:
P.O. Box 10049
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(541) 343-0200
FAX (541) 686-9247

CUSTOMER SERVICE
CENTER:
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