Construction of a pipeline from polyethylene pipes. Laying and installation of polyethylene pipelines Installation of pressure pipes made of polyethylene
Due to their high performance qualities pipe products made of polyethylene are widely used in the construction of engineering communications when carrying out renovations in an apartment or during the construction of your own home. The work is simple, so information on how to connect polyethylene pipes with your own hands will not be superfluous.
They are used for laying water supply, sewer, gas and heating communications, both in everyday life and at industrial facilities. To obtain a high-quality result when installing polyethylene pipes, you must adhere to certain rules.
Tool for creating PE pipeline
To install polyethylene pipes with your own hands, you need to prepare the following tools:
- scissors for cutting products;
- soldering equipment;
- gas keys.
The soldering device is equipped with a set of nozzles of different diameters. Instead of scissors, you can use a jigsaw. But still, when cutting pipes, it is more convenient to use scissors, since with their help the edges will be smoother, without burrs and notches.
Installation of a pipeline made of polyethylene pipes is carried out using a gas wrench. To ensure a more reliable connection, a linen seal is used. Tools intended for laying polyethylene pipelines, sold in construction stores. Typically, a soldering iron with attachments is offered to customers complete with scissors.
Preparation for installation work
Before installing PE pipelines, you must:
- Calculate the amount of required building materials depending on the length of the designed communication, the number of turns and corners.
- Before starting work, you need to turn off the water supply and prepare building materials in accordance with the project.
- It is necessary to lay a polyethylene pipeline from the heating boiler if an autonomous heat supply is installed in the house.
- After the dimensions have become known, they begin to connect polyethylene products and solder fittings and metal pipes.
Learning how to use a soldering iron will not be difficult even for a novice home craftsman. But at the same time, many technical points related to the process of assembling polyethylene pipelines must be observed.
Installation by welding
The laying of communications in this way occurs in the following sequence:
- After a piece of pipe of the required size is cut using special scissors, a chamfer is removed from its edge at an angle of 45 degrees. Read how to cut a pipe at 45 degrees so that everything turns out perfectly.
- The prepared section of the product is installed on the soldering iron nozzle, the same is done with the connecting fitting, which is placed on the second nozzle.
- The parts are then heated to a predetermined temperature, usually about 270 degrees, after which they are quickly removed from the attachments and connected.
- Then the docking area should cool down for several minutes. This procedure should not be done forcibly, as this will have a very negative impact on the quality of the seam.
- According to project documentation it is necessary to lay communications, connecting in a certain sequence all PE pipes with fittings and heating radiators. The soldering is completed at the output element near the heating boiler.
- After the system is filled with water, turn on the heating unit. All connections are carefully checked for leaks. If everything is in order, the pressure is set on the boiler and air is released from the radiators.
Connection fittings for polyethylene pipes
If, when laying a pipeline, it is necessary to install polyethylene pipes, fittings are used for this. Let's figure out how to connect polyethylene pipes for water supply so that there are no problems later. These parts are divided into types depending on the chosen method of work:
- welding of products;
- gluing;
- mechanical type threaded connection.
Depending on the pipe laying method used, fittings for polyethylene pipe products are:
- Electric welded, equipped with embedded heating parts. When the wire is heated using electricity to a certain temperature, the polyethylene begins to melt. As a result, a homogeneous dense formation is formed in those places where the transition is made from one section of polyethylene pipe to another. Modern equipment designed for welding polyethylene fittings, allows you to set the required voltage and time to get a high-quality result.
- Compression. They are not much different from the fittings used when installing copper or plastic products. The difference lies in the material from which they are made. This type fittings are easy to use, since their installation does not require special qualifications - the fitting is almost ready for installation.
- Connecting elements for butt welding. For this purpose, Spigot PVC fittings (cast elements) are used. The joining process involves heating the end of the pipes to a viscous-flowing state of the material, and then they are joined under pressure. The connection point, provided that the welding technology is followed, is homogeneous with the pipeline.
- Reductive. These elements are used for the installation of PE pipes of different diameters. They are equipped threaded connection for quality results. Threaded fittings are used to connect polyethylene pipes to metering devices and water distribution equipment.
Thus, correctly selected fittings make it possible to perform high-quality installation of PE pipelines for water and heat supply with your own hands without special training.
Laying and installation of polyethylene pipelines
The company AOS LLC is the official supplier of PE, HDPE pipes, which indicates high quality supplied products.
We have implemented more than 5 0 objects in Russia and Kazakhstan. The geography of supplies of polyethylene pipes is constantly expanding.
Laying methods. Excavation
Choosing a pipeline laying method
The choice of method for laying pipelines should be made on the basis of technical and economic calculations, taking into account the physical and chemical properties of the transported substances, pipe material, operating conditions, climatic features of the construction area, bearing capacity pipeline and material consumption.
External networks made of polyethylene pipes are recommended to be laid underground, because When laying above ground, pipeline protection is required thermal insulation materials to prevent freezing of the transported substance at negative air temperatures and excessive heating of pipe walls when exposed to solar radiation And elevated temperatures air. For external gas supply networks made of polyethylene pipes, only underground installation is permitted.
Polyethylene pipelines can also be laid:
- in buildings (in-shop or internal pipelines) on suspensions, supports and brackets; open or inside furrows, shafts, building structures, in channels;
- outside buildings (inter-shop or external pipelines) on overpasses and supports (in heated or unheated boxes and galleries or without them), in channels (through or non-through) and in the ground (channelless installation).
Technology for laying PE pipelines in trenches
The elasticity of the material and the low weight of PE pipes give them certain advantages over pipes made of “hard” materials such as cast iron and fiberglass. In particular, during the construction of pipelines, individual strands are often welded at the edge of the trench maximum length(from well to well) which are then lowered into the trench, where all that remains is to connect them to the reinforcement or weld several assembly joints.
Since, in this case, the width of the trench can be significantly reduced, this leads to a reduction in the number earthworks, limiting the mass of material supplied for backfilling and the need for its transportation. Although the trench can be as narrow as possible, it must provide the opportunity for high-quality compaction of the soil.
Work on the construction of trenches for PE pipelines is carried out in compliance with normal safety measures.
Trench profile
The profile of the trench for laying PE pipelines is determined by the project. The width is determined based on the conditions for ensuring ease of carrying out installation work. At the level of the horizontal pipeline diameter >710 mm, the trench must correspond to the outer diameter of the pipe + 0.4 m.
Trench bottom
The bottom of the trench must be leveled, without frozen areas, and free of stones and boulders. The boulder excavation sites must be covered with soil compacted to the same density as the foundation soil. In soils prone to displacement or where there is a high probability of leaching groundwater bedding and topping materials must be taken according to measures to keep the soil surrounding the pipe in a compacted state. In particular, the bottom of the trench can be strengthened with geotextile material.
Pipe base
The normal thickness of the bedding layer is 0.1 m. On rocky soil, bedding must be installed. If the bottom of the trench is rocky or there are stones larger than 60 mm in the bottom of the trench, it is necessary to increase the backfill until the bottom of the trench is completely leveled.
For backfilling, sand or gravel is used (maximum grain size 20 mm). In some cases, it is possible to use material with a larger granule size. In any case, the material used for backfilling should not have sharp edges. If the local soil meets these requirements, backfilling is not necessary.
The bedding should be smooth and not compacted. The material filling the depressions formed after the excavation of boulders and other large objects is subject to compaction to the density of the main soil.
Fig.2 Base layer for the pipeline (backfill, pillow, bed)
Pipeline coating
The soil extracted when tearing off a trench can be used to fill the pipe, provided that it does not contain stones (their maximum allowable size is 20 mm, individual stones up to 60 mm can also be left in the soil). If the soil for filling is intended to be compacted, it must be suitable for such an operation. If the extracted soil is not suitable for filling the pipe, then sand or gravel with a fraction size of up to 22 mm or crushed stone with a fraction size of 4-22 mm should be used for this purpose.
Sprinkling should be carried out across the entire width of the trench until a layer with a thickness of at least 0.3 m is obtained above the surface of the pipe (after compaction). The first layer should not exceed half the diameter of the pipe, but not more than 0.2 m. The second layer is poured to the top of the pipe, but also no more than 0.2 m. During sprinkling, the soil must be applied from a minimum height. Do not dump masses of soil directly onto the pipe. Pipeline sprinkling is usually carried out after the installation and acceptance of the pipeline has been completed.
Fig.3 Pipeline coating
Soil compaction
The soil filling, compacted in the sinuses of the pipeline, provides a slight reduction in tensile forces on side walls pipes from internal pressure transported medium. The degree of compaction depends on the purpose of the area above the pipeline and should be determined by the design.
To avoid subsidence of soil over pipelines located under roads, infill compaction of at least 95% of the modified Proctor value is recommended.
For deep trenches (over 4 m) the degree of compaction is 90%. For other cases - 85% or according to the instructions given in the project. Tamping must be done in layers with a thickness of OD to 0.3 m, compacting each layer. The thickness of the compacted layers depends on the equipment and compaction conditions. You must be careful when performing this task. Compaction of the first layer (to the level of the pipe axis) should not lead to its lifting. Tamping must be done simultaneously on both sides of the pipeline to avoid its movement. When adding soil and backfilling the pipeline, care must be taken to ensure that the soil does not contain large inclusions. The soil is compacted directly above the pipe, having previously ensured a distance of at least 0.3 m to its surface.
Final filling of the trench
The final filling of the trench can begin after backfilling the pipeline and compacting the soil.
It is recommended to place warning tape over the pipeline during backfilling. Warning tape must be placed over gas pipelines. To make it easier to identify pipelines in the future, the use of such tape is also recommended on other pipelines.
For backfilling, you can use soil taken out of the trench, or another, according to the project instructions. The diameter of the particles of the material used to fill the trench should not exceed 300 mm. Do not throw stones, rubble with sharp edges or large sizes. The soil should not be frozen or lumpy.
Thickness of compacted layers and number of tamping passes
| Sealing method | Number of passes to achieve the required compaction category according to the Proctor value, % | Maximum thickness of compacted layer, m | Minimum layer of bedding over the top of the pipes before compaction | |||
|---|---|---|---|---|---|---|
| 93 | 88 | gravel, sand | loosened dense clay | loose clay | ||
| Compaction with feet | - | 3 | 0,15 | 0,10 | 0,10 | 0,20 |
| Sealing with hand stamp, weight min. 15 kg | 3 | 1 | 0,15 | 0,10 | 0,10 | 0,20 |
| Compaction with vibrating stamp, weight min. 70 kg | 3 | 1 | 0,10 | 0,15 | ||
| Compaction with vibrating plate, weight min. 50 kg | 4 | 1 | 0,10 | 0,15 | ||
| min. 100 kg | 4 | 1 | 0,15 | 0,15 | ||
| min. 200 kg | 4 | 1 | 0,20 | 0,10 | 0,20 | |
| min. 400 kg | 4 | 1 | 0,30 | 0,15 | 0,30 | |
| min. 600 kg | 4 | 1 | 0,40 | 0,15 | 0,50 | |
Note: coarse-grained materials, such as crushed stone with a fraction size of 8-12 mm, 8-16 mm or pebbles 8-22 mm, are self-compacting materials and when used for backfilling in layers 0.15-0.20 m thick, compaction >93 is ensured % modified Proctor value.
Fig.4 Final filling of the trench
Trenchless technologies for laying PE pipelines
Trenchless technologies allow you to avoid the costs associated with excavating a trench, backfilling it, compacting it with a tamper, etc. There is no need to stop traffic. The costs associated with the production of new surfaces (after filling an open trench), temporary roads, detours, as well as other related costs are practically eliminated.
Laying using horizontal directional drilling in the ground (puncture, mole method)
The horizontal directional drilling method is the most popular and widely used. It is very economical in situations where it is necessary to lay a pipeline under the roadway, and it is not possible to lay it in open trenches. The method makes it possible to lay underground PE pipes with a length of more than 100 m and a diameter of up to 1200 mm or more, with an accuracy of several centimeters.
Rice. 5 Laying using horizontal directional drilling
In the work carried out on laying a pipeline using this method (Fig. 5), three stages can be divided into three stages.
At the first stage, a special drilling rig drills along a given trajectory (from mark A to mark B). In this case, the drill has a smaller diameter than the pipe intended for pulling.
At the second stage, at point B, preparations are made for pulling the pipeline: the drilling head is replaced with a head of larger diameter, and a PE pipe prepared for pulling is attached behind it (polyethylene pipes are used, supplied in coils or welded into a string on site).
At the third stage, the pipeline is directly pulled from mark B to mark A. The drilling rig pulls the PE pipe into the channel prepared at the first stage. In this case, the head comes first, having a slightly larger diameter than the pipe attached behind it.
PE pressure pipe is the most suitable material for installation using horizontal directional drilling. Polyethylene pipes have sufficient flexibility and strength and can withstand significant tensile loads.
As a rule, for trenchless installation there is no need to use any special PE pipes and ordinary pressure PE pipes are used for the corresponding operating pressures.
Gasket by pulling with simultaneous destruction old pipe or without it
The most common trenchless technologies include the “relining” technology, which involves pulling a PE pipe through a worn-out pipeline, both without destruction and with destruction of the latter.
METHODS OF CONNECTING PE PIPES. CONNECTION REQUIREMENTS
The most important requirement for connections is reliability, which is understood as their equal strength to pipes under operating conditions.
Polyethylene pipes are increasingly replacing metal pipelines. This is due to a number of their advantages. Experts attribute the advantages, first of all, to ease of use, low price and durability.
To create, it is not necessary to seek help from specialists. Do-it-yourself connection and installation of polyethylene pipes is discussed in this article.
There are two main methods for installing connections:
- Non-separable, not implying the possibility of repeated disassembly. These include butt welding and connection with electric welded fittings.
- Collapsible, which allow the connection to be adjusted in the future. Steel flanges are used for installation. Instead, you can use compression fittings.
A communication system can be assembled from a large number of interconnected elements various methods. Most often, if the pipeline requires significant strengthening, a non-dismountable method of installation is used. Temporary connections can be made using steel flanges or compression fittings.
How to connect polyethylene pipes
There are several connection methods. This can be done by welding or using couplings. The choice of one or another technique should be made, first of all, on the basis of what kind of connection needs to be made - collapsible or non-demountable.
Electrofusion welding
Initially, it is necessary to prepare two pipes by cleaning their insides, ends and degreasing the outer surface. The pipes should then be coupled together and secured in the positioner. Once this is done, electric heaters need to be connected to the coupling welding equipment.
The process of connecting pipes is carried out automatically. This happens at the moment when current flows to the couplings. Because of this, the polyethylene heats up and melts. As soon as material begins to protrude through the special holes, you should stop supplying electricity to the area. After this, all that remains is to cool the products naturally.
Couplings
In order to connect two polyethylene pipes using couplings, no additional plumbing tools are required. It is enough to have only a wrench with you. On one end you need to put a nut, which was previously removed from the fitting. You can start working only if the pipe has been chamfered at an angle of 45 degrees.
In order to simplify the process of inserting into the fitting, the workpiece can be treated with a soap solution or a special pipe lubricant.
Once the workpieces are placed in the fitting on required length, the nut should be tightened. This process can be done either wrench, or with my own hands. In the first case, you should be as careful as possible. To ensure a tight seal, do not under any circumstances need to tighten the nut.
Butt welding
Welding of polyethylene is carried out using so-called “irons”. Therefore, it is not often used by home craftsmen. Initially, it is necessary to melt the ends of the two products. Then you need to heat them to a certain temperature. There is no need to apply pressure at this stage. Next, you should remove the heating element from welding and quickly connect the two pipes until they lose the resulting thermal energy.
The melting point of polyethylene is 270 degrees Celsius. If they are installed correctly, you can achieve a homogeneous connection, the strength of which will be equal to 80-90% of the strength of the monolith.
The process of upsetting the resulting joint occurs immediately after cooling the products. Temperature loss should occur naturally. Experts do not recommend lowering it forcibly.
Types of detachable fittings
Most split fittings do not require special tool and are well suited for installation at home. The most common are:
- adapters (collet-nut, collet-fitting, collet-collet);
- tees (two collets-nut, two collets-fitting, three collets);
- Eurocones;
- crosses;
- corners;
- water sockets.
They significantly save installation time of polyethylene pipes, ensuring their reliable connection and long-term operation.
Features of installation of cross-linked polyethylene pipes
Cross-linked polyethylene is a special type of material that loses its properties when melted. That's why It is unacceptable to use any type of welding work:
- butt welding;
- electric welded couplings.
When installing communication systems made of cross-linked polyethylene, the connection can only be made using crimp or press fittings.
How to bend and unbend a PE pipe
There are two main ways to bend a polyethylene pipe:
- Using special molding equipment. In this case, you first need to prepare a template from sheet material, such as fiberboard. With its help it will be possible to protect the workpiece from damage. Afterwards, a silicone shell should be made for attaching the deformable product. It is necessary to place a pipe in it, attaching the latter to the fiberboard frame. This structure must subsequently be placed in a molding machine. It needs to be heated and bent, after which it must be completely cooled.
- Using a hair dryer at home. Initially, it is necessary to heat the previously prepared surface using the device. In order for the welding to proceed as evenly as possible, the product must be gradually rotated. After this, the hot workpiece must be placed in the forming frame. Once this is done, you need to carefully bend the pipe, making sure that it loses its shape. When the angle is fixed, the product should be cooled naturally.
If the pipes long time were bent, alignment must be carried out before installation. This can be done either naturally or artificially. The first method can be used if you have time and clear and warm weather. In this case, it is necessary to stretch the products in an area under the sun and fix them with any in an accessible way. After some time they will level out. To speed up this process, you can use hot water And construction hair dryer. Before this, the pipes must be stretched accordingly.
Fasteners
In order for a polyethylene piping system to function reliably, it must be properly secured. This can be done using fasteners:
- hooks providing free fastening;
- clamps for rigid fastening.
Basic rules for using fasteners:
- each individual joint must be fixed;
- if the pipeline sections are straight, fasteners should be used every 10 meters;
- The clamp must be used with rubber gaskets.
To create a free fastening, you can use clamps without rubber gaskets instead of hooks.
Do-it-yourself pipe installation
Self-installation of a polyethylene pipeline can be divided into stages:
- First you need to inspect the fittings. It will not be superfluous to analyze them, allowing you to understand the process of assembling these elements.
- The workpieces should be cut to the previously determined size. To do this you need to use scissors. If they are missing, they can be replaced with a hacksaw. The edge of the products must be perpendicular to the surface.
- The edges must be processed to remove any burrs that have formed. To do this, you can use sandpaper or a round file.
- You must first put a nut on the end of the pipe, then a compression washer and a seal. The rubber ring must remain in the fitting body. Having lubricated the edge of the product, it must be pushed all the way into the connecting element.
- The compression ring must be brought close to the connection and tightened with a nut.
A pipeline made of polyethylene pipes must be attached to the wall or ceiling using special clips or clamps.
Required Tools
To install a pipeline made of polyethylene pipes yourself, you must first prepare the following tools:
- scissors for cutting products;
- soldering equipment;
- gas keys.
Soldering equipment is equipped with several nozzles that differ from each other in diameter. If nozzles are not included in the kit, these devices must be purchased at a hardware store before work.
Drawing and diagrams
Before starting the installation of polyethylene pipes, it is necessary to draw up a drawing or diagram. This can also be a hand-drawn sketch. small size With step by step plan works It should indicate the following:
- lengths of straight sections;
- number of turns;
- number of taps;
- connection types;
- number of couplings used, etc.
The more detailed the pipeline diagram is, the easier it will be to install it in a house or apartment.
Work order step by step
In order to cope with the installation of a pipeline made of polyethylene pipes, it is necessary to follow the work order. It consists of the following steps:
- Drawing up a drawing or diagram.
- Blank necessary tools, devices and materials.
- Creating holes in walls.
- Installation of fasteners.
- Assembly.
- Laying polyethylene pipes.
- Check the system for leaks.
- Final fastening of all elements.
When all the above stages have been completed, you can put the system into operation.
Pipe laying
If laying a pipeline in the ground is required, both trench and trenchless methods can be used. Both options have their own characteristics.
Laying polyethylene pipes in the ground
The trench for polyethylene pipes must be properly prepared. If its bottom is hard and dense, the creation of a “pillow” is required. To do this, it needs to be paved with a thickness of 10 to 15 centimeters. At a distance of 2 meters to manhole it should be compacted.
There should be no stones, frozen lumps of soil or any debris at the bottom of the trench. If the soil is too loose, it needs to be further strengthened. For this you can use geotextiles.
If the soil characteristics are optimal and the bottom of the trench is flat, you can do without laying a “cushion” of sand. In such situations, experts only recommend making a small notch at the base.
Trenchless pipeline laying
If it is impossible to dig a trench due to its intersection with a road, rails or some other obstacle, a trenchless horizontal directional drilling method can be used to lay a pipeline made of polyethylene pipes. In this way, systems up to 100 meters long and up to 630 millimeters wide can be installed underground.
Drilling can be of two types such as:
- Managed. It is done with the help of tunneling machines. They may use flush or pilot soil drilling.
- Uncontrollable. It is produced in two ways: without casing pipes (ramming rocket, displacement or auger drilling) and with casing pipes (drill injection, puncture drilling, impact and ram drilling).
The video shows the drilling process (puncture) for underground pipe laying.
The choice of one or another method of trenchless pipeline laying depends on the capabilities of the customer and the characteristics of the soil.
Common installation mistakes
When installing a pipeline made of polyethylene pipes, novice craftsmen often encounter the following errors:
- Incorrectly measured pipe sizes. As a result, material consumption increases.
- Leaky connection. Most often, this is due to the fact that the pipes were not completely seated in the fitting, and a loose connection was formed.
- Retightening the nuts. They can squeeze out the O-ring, which in turn will lead to a quick leak in the pipeline.
To prevent adverse consequences, you must carefully check your actions at each stage of work.
Do-it-yourself pipeline on video:
Installation of a water supply system from polyethylene pipes is the process of creating a pipeline for an uninterrupted supply of water to a house or site. The assembly of a structure made from this material is simple and even a beginner can do it. About the construction of a water supply system made of polyethylene pipes and its installation we'll talk In this article.
Features of the design of water supply pipes made of polyethylene pipes
A water supply system made of polyethylene pipes is a system consisting of a central main line with branches through which water flows to plumbing fixtures or taps. Separate parts of the structure are welded or connected with special parts - fittings.
Various modifications of polyethylene pipes are used in the water supply system, differing in characteristics and purpose:
| Pipe type | Application |
| PE63 | For cold water with little pressure |
| PE80, PE100 | For cold water under pressure |
| PE-RT | For cold water and short-term hot water |
| PEX | For supplying cold and hot water |
| PEX/AL/PEX | For organizing cold and hot water supply in critical places |
The following types of connectors are used in the design:
- Electric welded fittings. Used for electrofusion welding of workpieces. Products are equipped heating elements made of wire. When it is heated, the plastic melts and fixes the elements.
- Compression fittings. With their help, pipes are fastened manually. The principle of their installation is the same as when installing metal-plastic blanks. The difference is in the material of the connector - they are made of thick polyethylene with a tapered thread.
- Cast spingot fittings. Such parts do not have an electric coil for heating the products. The plastic is melted with a soldering iron. Made in the form of tees, crosses, bushings to obtain branches and turns.
- Reducing fittings. Unlike other connectors, they can be threaded. Often used for attaching lines to radiators, meters and other equipment.
Polyethylene pipes are connected in two ways - collapsible and non-dismountable. The first option includes the assembly of products using special couplings, the second - butt welding.
To create a collapsible connection It is necessary to first attach the couplings to the pipes and then screw them to each other. This joint can withstand 10 atm.
The photo shows polyethylene fittings for pipes
Welding of polyethylene pipes- this is a connection that is formed by mutual penetration in the molten state, followed by cooling of the edges of the workpieces, resulting in the formation of a monolithic structure. It is performed using special equipment for polyethylene products.
There are several types of welding of polyethylene pipes for water supply:
- Electrofusion welding. Indispensable when installing pipes in trenches, narrow wells and other places where it is impossible to weld products using traditional soldering. The method is considered quite expensive due to special fittings. Electrofusion welding is used to connect pipes with a diameter of 1.1-5 cm, with a small amount of work and when inserting branches into the main line.
- Butt welding. The most common method of joining polyethylene pipes. The edges of the workpieces are melted with a special soldering iron, then they are joined under pressure. To weld pipes with a diameter of more than 50 mm, special equipment is used to ensure a high-quality joint.
- Welding using spigot fittings. It is used to connect structures with a diameter of more than 6.3 cm. During the installation process, the ends are heated until they soften, and then connected under pressure.
How to make a water pipe from polyethylene pipes?
You can assemble the water supply different ways, but always in a certain sequence. First, a project is developed and all components of the structure are purchased. Then you can begin construction work.
Preparatory work before installation of polyethylene pipes
At the first stage of installation, it is necessary to develop a water supply system made of polyethylene pipes. On the sketch, show the route from the source to the connection points, indicating the main line and branches. In the diagram, provide for the location of compensators for linear expansion of the structure.
Due to the expansion of plastic, secure the pipes with specially designed clips that allow the lines to move when heated.
The route can be extended open method in special trays or closed in grooves. Determine the dimensions of polyethylene pipes for water supply, the number of fittings and decide how to connect the sections.
The construction market is saturated with polyethylene pipes for water supply, but high-quality products can only be purchased in large construction stores. Check the product carefully:
- There should be no mechanical damage on the workpieces: chips, cracks, nicks.
- Do not buy a cheap product, which may indicate low-quality plastic.
- All the main characteristics of polyethylene pipes for water supply are marked on the surface (diameter, permissible pressure, temperature, purpose).
If you have any doubts about the quality of the product, ask the seller to provide a certificate of conformity.
Installation of polyethylene pipes using spigot fittings
The photo shows the connection of polyethylene pipes for water supply with fittings
To connect sections of polyethylene pipes you will need the following tools:
- Soldering iron for welding sections. It is usually sold complete with nozzles of different diameters.
- Scissors for cutting blanks. With their help, the cut is smooth, no need to additional processing ends.
The sequence of installation of polyethylene pipes for water supply using fittings:
- Slice required amount blanks according to the water supply diagram.
- Make a chamfer at the ends of the products at an angle of 45 degrees.
- Place a soldering iron next to the main line. Install nozzles on it, the diameter of which corresponds to the diameter of the pipe and fitting.
- Place the blanks on the attachments.
- Turn on the device. The optimal heating temperature for polyethylene is 270 degrees. If there is a regulator, it can be set manually. In simpler devices, the settings are already made at the factory.
- After the indicator signal, quickly remove the pipe and fitting from the soldering iron and connect them. Do not touch the joint for several minutes until the plastic hardens. Joints should not be forcibly cooled so as not to reduce the quality of the joint.
- All elements of the route are attached in a similar way.
- Connect the main to the water supply and check each joint for leaks.
The photo shows tools for electrofusion welding of polyethylene pipes
To install polyethylene pipes for water supply with your own hands using electric couplings, you will need the following equipment and materials:
- Welding machine. Its function is to apply voltage to the clutch for a specified period of time. The product is assembled using semiconductors, which provide high efficiency and productivity. The device is equipped with a digital display to control the entered parameters. Some models have a place to connect a scanner, which allows you to enter fitting parameters into the device via a barcode on the connector.
- Positioner. Its purpose is to compensate for the ovality of the pipe that appears when improper storage and transportation of the product.
- Pipe cutter. With its help, the edges of the pipe after cutting are flat and without jagged edges. When using electrofusion welding, it is not recommended to use a knife or hacksaw for such purposes.
- Pipe cleaning liquid. Removes fat and other deposits from the welded surface. Often comes with fittings. Do not clean parts with products not intended for polyethylene.
- Oxide Glue Remover. Designed to remove the top 0.1 mm thick layer of plastic to create a rough surface. The puller can be replaced with an ordinary scraper.
The photo shows the process of electrofusion welding of polyethylene pipes for water supply
Installation of polyethylene pipes for water supply using electrofusion welding is performed in the following sequence:
- Use a pipe cutter to cut the pieces to the dimensions indicated on the plumbing diagram.
- Measure the length of the coupling.
- Use a marker to place a mark on each piece at a distance of half the coupling plus 2 cm from the edge of the pipe.
- Remove the top layer in which the plastic reacted with oxygen.
- Make a chamfer at the end to facilitate the connection between the pipe and the connector.
- Make sure that the product is not oval, otherwise the coupling will not be able to be put on, or a monolithic solder will not work.
- Place a positioner on each pipe and clamp it until it is perfectly round.
- Clean the surfaces of the elements from dust and degrease with a special compound.
- Insert the pipe into the electrofusion fitting half its length. Usually there is a limiter inside that does not allow you to go further. The mating surfaces must touch or be located at a minimum distance from each other.
- Connect the second pipe in the same way.
- Connect the welding terminals to the special connectors.
- Use a scanner to read the barcode on the fitting.
- Connect to helix electrical voltage. Within a short period of time, the polyethylene will soften to the state of viscous sour cream. Diffusion will occur and the two parts will become one. After cooling, the material becomes solid again.
During hardening, it is prohibited to change the configuration of the line.
Compared to other methods, electrofusion welding of polyethylene pipes has the following advantages:
- Reduces the likelihood of performing docking errors.
- The procedure is absolutely safe for others.
- Connects fixed elements.
- The internal diameter of the line does not decrease.
- Possibility of joining workpieces with different diameters and wall thickness.
- Electricity consumption is minimal.
In the photo there is a centralizer and a trimmer for butt welding of polyethylene pipes
It is used when installing polyethylene pipes with a diameter of more than 50 mm.
Prepare the following equipment:
- Centralizer. Consists of two halves, one of them is movable. They allow you to center the pipes. The frame drive for creating pressure can be manual or hydraulic. Manual feed is used for assembling pipes with a diameter of up to 160 mm. The hydraulic unit is equipped with a pressure gauge to monitor the pressure generated by the device.
- Trimmer. A small electric cutting tool with two heads for high-quality processing of pipe ends.
- Heater. A type of soldering iron for melting the edges of workpieces. The simplest device is the “welding mirror”. It is used when welding products without a centralizer and a trimmer for the installation of non-pressure lines.
The photo shows the process of butt welding polyethylene pipes for water supply
The process of butt welding polyethylene pipes for water supply occurs as follows:
- Make sure there is no ovalness at the end of the pipe.
- Measure the thickness of the product at the joint, which should be the same. Fulfilling the condition will ensure maximum strength of the connection after welding.
- Install a centralizer next to the route. Place the pipes in it in a position where you can install a heater between them. Make sure they are aligned.
- Secure the workpieces with clamps, 2 for each pipe. Tighten the rear clamp first. Bring the front one to touch and screw it in with a little force so that ovality does not appear.
- Set the device to soldering pressure. To do this, bleed the air from the device system and re-tighten the valve until the centralizer begins to move.
- Adjust the pressure required for soldering. Usually the value is indicated in the table supplied with the device.
- Clean the pipe connections from dirt, sand and other debris.
- Install a trimmer near the edge of the product. Turn it on and move the workpiece to the machine, which will chamfer the end 2x45. Repeat the operation on the other pipe.
- Bleed the air and move apart the parts of the centerer.
- Move the device until it touches the elements and make sure that their alignment is not disturbed.
- Wash surfaces with alcohol or a special solvent.
- Heat the soldering iron to 270 degrees.
- Before connecting polyethylene pipes for water supply, set the planned soldering time on the device, determined from the table.
- Place the heater tip between the workpieces.
- Move the pipes to the soldering iron and leave until a 1mm thick bead is formed.
- Time your welding. After it expires, remove the soldering iron.
- Very quickly move the products towards each other with a centralizer until they make contact and leave under pressure for 5 seconds.
- Release the pressure and time it to cool down. The plastic must harden naturally, without acceleration, otherwise the strength of the joint will deteriorate.
When installing a water supply system made of polyethylene pipes, follow our recommendations:
- Throughout the entire process, monitor the temperature of the soldering iron, control the heating of the parts being connected, the height of the burr, and the pressure on the joint.
- Carry out work on a flat plane.
- Perform docking if the alignment of the connected elements is maintained. Axial deviation is no more than 10% of the product thickness.
- During the procedure, close the opposite ends of the pipes to prevent drafts from cooling the molten mass.
- Place the products in the centralizer so that the markings on their surface are located along the same line.
- Before the procedure, perform a test operation during which microparticles are removed from the heater. Wipe the surface of the trimmer with a clean cloth before use.
Installation of cross-linked polyethylene pipes for water supply
The photo shows the process of connecting cross-linked polyethylene pipes
Sections of cross-linked polyethylene are connected with threaded fittings. To work, you will need the simplest tools - scissors, wrenches for tightening nuts, and a tape measure.
The process of laying cross-linked polyethylene water pipes goes like this:
- Use scissors to trim the edge of the pipe.
- Bevel the ends at a 45 degree angle.
- Remove the nut and O-ring from the fitting.
- Place the nut on the pipe and then the ring.
- Flare the piece that fits onto the connector.
- Wet the surface with soapy water.
- Slide the O-ring towards the fitting.
- Push the connector onto the pipe until it stops.
- Hold the fitting with one wrench and screw the nut with the other. It will press the ends of the products against each other.
- After assembling the entire line, check for leaks at the joint by supplying water under operating pressure.
The price of installing a water supply system made of polyethylene pipes
When determining the cost of work, many nuances must be taken into account. The price of installing a water supply system made of polyethylene pipes is influenced by the following factors:
- Line length, room area;
- Diameter of polyethylene pipes for water supply;
- Number of connected plumbing fixtures;
- Complexity of the water supply project, special wishes of the customer;
- Lack of convenience during installation work;
- Options for laying the route - hidden or open;
- Location of the object from the place of residence of the master;
- The quality of the material used - you have to spend more time and effort on second-rate products;
- Wiring type;
- A method for attaching pieces of polyethylene pipes to each other;
- Availability of electricity at the work site.
Price construction work can be reduced if expensive equipment is rented. Prices for renting equipment in construction stores are low, but you can use high-quality devices.
Price for installing a water supply system made of polyethylene pipes in Ukraine:
| Operation | Price |
| 105-250 UAH. at the joint | |
| 110-300 UAH. at the joint | |
| 15-40 UAH/p.m. | |
| Pipe fastening | From 12 UAH. dot |
| Ball valve installation | From 30 UAH. dot |
| 70-150 UAH/p.m. |
Price for installing a water supply system made of polyethylene pipes in Russia:
| Operation | Price |
| Butt welding of pipes with a diameter of 63-110 mm | 300-600 rub. at the joint |
| Electrofusion welding with a diameter of 25-110 mm | 300-800 rub. at the joint |
| Installation of a pipeline with a diameter of 20-32 mm | 250-300 rub./p.m. |
| Pipe fastening | From 80 rub. dot |
| Ball valve installation | From 150 rub. dot |
| Grooving to hide pipes in the wall | 350-800 rub/sq.m. |
How to make a water pipe from polyethylene pipes - watch the video:
Installation work on the construction of a pipeline made of polyethylene pipes can be carried out independently from start to finish, saving money and time. If all assembly rules are followed, the design will ensure a reliable water supply for a long time. You can drink it without fear, it will be odorless and taste good.
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Construction of a pipeline from polyethylene pipes
Most of all pipelines laid in cities date back to Soviet times. The deterioration of heating mains, sewerage, gas and water communications reaches 70%, which is due to the material from which the pipes are made. This is steel that is subject to intense corrosion. The construction of gas pipelines from polyethylene pipes is becoming more in demand today. As the service life expires, many accidents occur on various pipelines: pipes break under high pressure, numerous leaks form, which lead to significant water losses. Performance indicators deteriorate: by reducing the cross-section of pipes, their throughput is reduced, the water becomes polluted, and its biological indicators decrease.
Advantages of polyethylene pipes
Pipes made of polyethylene (PE) are a modern alternative to their physically and morally outdated metal predecessors. They have whole line undeniable advantages compared to products made of steel or cast iron.
- No corrosion, which minimizes installation, maintenance and repair costs.
- Ease of use: polyethylene products are easy to cut, so they can be easily adjusted to fit construction site, and in the field when laying pipelines.
- High throughput due to the fact that the inner walls of PE products are smooth.
- Polyethylene pipes have an elastic structure internal walls, on which scale does not form as a result and they are not clogged from the inside by various suspensions contained in the liquid.
- Polyethylene is chemically inert, successfully resists aggressive influences, therefore, it does not require additional special protection.
- Polyethylene is not electrically conductive, so it is not afraid of stray currents that destroy metal pipes.
- The bending radius of a polyethylene pipe can be up to 10 of its outer diameters, depending on temperature, which reduces the cost of connecting parts and facilitates the design and construction of pipelines.
- Polyethylene pipe has high flexibility: the minimum bending radius is 25 pipe diameters at 200°C.
- Significantly less weight compared to metal pipes, which facilitates installation and installation.
- PE pipes are resistant to temperature changes and have high sanitary and hygienic characteristics.
Scheme of deformation of polyethylene pipes depending on the type of soil.
Important note. Freezing of the soil leads to the movement of pipelines into vertical plane. These movements are uneven, resulting in deformations (bending). Predicting these conditions, it is necessary to determine how much the bending radius of a polyethylene pipe depends on the level of temperature reduction. In order to determine the bending radius, it is necessary to make special calculations. Or refer to special tables that indicate the minimum bending radius for a specific type of pipe.
The minimum bending radius of a polyethylene pipe is recommended by the manufacturer for each type and grade of pipe. If it is not possible to obtain the required bending radius, then bends, tees, etc. should be used.
Due to their technological and operational characteristics, polyethylene pipes have received wide application: they are used in the construction of new pipelines and in the repair of old communications that have expired.
Scope of application of polyethylene pipes
Polyethylene products are widely used in modern construction.
They are used in the construction of water supply, sewerage, and gas pipelines. PE pipes are used in pressure and gravity sewers and serve as protective cases for electrical and telephone wires.
Old networks are being reconstructed using polyethylene pipes. Replacement can be carried out with the destruction of worn-out communications, but it is possible to lay new ones in parallel with the old ones, which does not require stopping the water supply to the population and blocking the sewerage system. Reconstruction of wells and other communication and plumbing structures depends on the degree of their deterioration. Partial replacement may be subject to individual parts(neck, shut-off valves etc.), if necessary, is carried out major renovation with complete replacement of pipelines.
Installation of polyethylene pipes for sewerage
Sewage networks are internal and external. Their purpose is to collect and transport sanitary and stormwater waste water, having different chemical composition. Any problems in the sewer system dramatically affect the quality of life.
Elements and assembly for polyethylene pipes internal sewerage
Polyethylene pipes for sewerage began to be produced not so long ago, and today they fully meet high requirements due to their inertness to the effects of mineral acids, alkalis and other aggressive substances. PE sewer pipes have a large throughput due to the absence of internal roughness. When settling in external systems sewer systems use frost-resistant PE pipes. Installation of internal sewerage does not require pipes with such high performance characteristics.
Sewage pipes are attractive to specialists working on the installation of such systems because their installation is much simpler compared to traditional sewer networks. Installation of internal sewer lines when using polyethylene pipes does not require complex special equipment. Small diameter polyethylene pipes are mounted using compression fittings.
Equipment external sewerage produced by butt welding: special welding equipment allows installation, reducing the number of joints up to five times in comparison with metal sewer pipes
Connection of water polyethylene pipes
PE products are connected in three main ways:
- contact butt welding,
- sleeve welding with embedded electric heaters
- installation using compression fittings.
It's also possible plug connection, which is carried out by steel clamping flanges. Installation of pipeline turns and branches is carried out using welded or cast fittings.
Different connection methods are used depending on operating conditions. If there are conditions for placing welding equipment, then butt welding is necessary. Butt welding is used when working with large diameter pipes (from 630 mm).
Limited working space (wells, chambers, trenches) requires electrofusion welding using embedded heaters.
If it is necessary to connect pipes with a diameter of up to 63 mm, compression fittings are used, which creates detachable structures. This connection is easy to operate, has high performance indicators, and does not require complex special equipment. Compound internal systems pipelines are most often carried out in this way. Their installation is accessible even to non-professionals.
Pipe laying
Laying polyethylene pipelines is carried out in two main ways. These are traditional pipe laying in an open trench and trenchless laying - a deep directional drilling method.
Pipelines made of polyethylene with open method laid in a trench, the width of which is determined by the need to create working conditions. Water supply and sewerage equipment requires a trench width 40 cm greater than the outer diameter of the pipeline. These parameters are most often specified in the project. Long polyethylene pipes are often laid in a trench dug using a narrow-section chain excavator. In this case, the width of the trench decreases.
The trench must be properly prepared. Its arrangement depends on the condition of the soil. If the bottom of the trench is hard and dense, then a cushion is needed. The bottom is covered with a layer (about 10-15 cm) of sand or other granular material and leveled. At a distance of 2 meters from the inspection well, the pillow is compacted. There should be no stones or lumps at the bottom frozen soil. When working with loose soil that is at risk of displacement, it is necessary to strengthen the bottom. In such cases, the bottom of the trench is strengthened with geotextiles.
With a flat trench bottom optimal characteristics There is no need for a soil cushion. You can get by with a small excavation of earth at the base of the pipe to its width and replace it with a softer one.
Backfilling the trench
The soil removed during the construction of the trench, which does not contain 20 mm stones, is used for primary filling. It is made along the entire length of the pipe, about 15 cm high from its top. If it is necessary to compact the fill, the soil must meet certain requirements. You can use fine gravel (20-20 mm) or crushed stone (4-44 mm). Soil must not be dumped directly onto the pipeline. The pipeline laid at the bottom of the trench and sprinkled needs to be compacted. The filled soil is compacted in layers of 20 cm on both sides of the pipe so that it does not move. The soil is not compacted directly above the pipe.
Backfilling is done after compaction and a compacted layer of about 30 cm on top of the pipe. The trench can be backfilled with extracted soil; the size of the largest stones is allowed no more than 300 mm. Even with a layer of protective pavement about 30 cm thick, the size of the stones in the soil used for backfilling cannot be more than 60 mm.
Trenchless pipeline laying
In some cases, when pipeline lines intersect with a railway, busy highway, river or other obstacle, laying an open trench is not possible. The reason may also be the need to minimize the cost of digging a trench. This is the basis for using the method of trenchless laying of polyethylene pipelines. The method of trenchless installation of horizontal directional drilling (HDD method) has become widespread.
Horizontal drilling is a special method of installing communications without opening the soil. Work begins at the point where the pipe comes to the surface. The technology guarantees high accuracy of drill placement at the intended location of reaching the surface. The method makes it possible to lay underground pipes with a length of more than 100 m and a diameter of up to 630 mm or more. There are two main methods of horizontal drilling: guided and unguided.
Controlled horizontal drilling is carried out by tunneling machines, through flushing and pilot drilling.
Uncontrolled horizontal drilling is carried out using two methods: 1) without casing (ram drilling, displacement drilling, auger drilling) and 2) with casing (drill injection, puncture drilling, impact drilling, ram drilling).
Horizontal drilling methods and trenchless laying of polyethylene pipes are considered the most modern technology.
To enlarge the well, a special drilling enlargement is used. To improve the drilling, the well is treated with a drilling clay mud, which forms and lubricates the channel itself.
Thus, the characteristics of polyethylene products allow them to be installed and laid using any currently known method, taking into account the restrictions imposed by the minimum permissible radius of their bending.
A pulled or pushed polyethylene pipe is able to repeat the configuration of the old route, which has a radius of curvature of more than 120 diameters of the pipe itself. Metal products practically do not have such a bending radius.
Organization of installation work
Welding is carried out either according to the basic scheme or by the route method. The basic method is used in cases where the facility is located near the welding site, where the pipes are pre-connected and then transported in finished sections to the pipeline route. The length of the section can reach more than 30 m. On site they are welded into a single thread, which must then be carefully laid in a trench so as not to disturb the bending radius. Route welding begins along the trench. Then installation and welding is carried out using mobile welding units. Small diameter pipes can be laid in the trench manually. However, pipelayers or cranes are most often used. The finished thread should be lowered without jerking, evenly, having previously secured it hemp ropes
or soft slings, which should be located at a distance of 5-10 meters from each other. The solid welded thread must be lowered into the trench carefully so that the critical bending radius is not exceeded during installation. You should first wait at least 2 hours after welding the last link.
Disadvantages of polyethylene pipes
Today, domestic underground pipelines have a length of about 2 million km. These are mainly steel pipelines. For example, polyethylene pipes account for about 10% of the total length of gas pipelines. Other networks don't have much either high performance according to this parameter. However, there is a strong tendency that modern pipelines are changing in percentage in favor of polyethylene pipes.
