Beruflich Dokumente
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AS/NZS 2033:2008 Installation of polyethylene pipe systems
Licensee:
Mr Paul Dale
Date:
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AS/NZS 2033:2008
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AS/NZS 2033:2008
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AS/NZS 2033:2008
This Joint Australian/New Zealand Standard was prepared by Joint Technical
Committee PL-006, Polyolefin Pipe Systems. It was approved on behalf of the
Council of Standards Australia on 10 April 2008 and on behalf of the Council of
Standards New Zealand on 9 April 2008.
This Standard was published on 19 May 2008.
AS/NZS 2033:2008
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Originated as AS 20331977.
Previous edition 1980.
Jointly revised and designated AS/NZS 2033:2008.
Reissued incorporating Amendment No. 1 (October 2008).
Reissued incorporating Amendment No. 2 (June 2009).
COPYRIGHT
Standards Australia/Standards New Zealand
All rights are reserved. No part of this work may be reproduced or copied in any form or by
any means, electronic or mechanical, including photocopying, without the written
permission of the publisher.
Jointly published by Standards Australia, GPO Box 476, Sydney, NSW 2001 and Standards
New Zealand, Private Bag 2439, Wellington 6020
AS/NZS 2033:2008
PREFACE
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This Standard was prepared by the Joint Standards Australia/Standards New Zealand
Committee PL-006, Polyolefin Pipe Systems to supersede AS 20331980.
This Standard incorporates Amendment No. 1 (October 2008) and Amendment No. 2 (June
2009). The changes required by the Amendment are indicated in the text by a marginal bar
and amendment number against the clause, note, table, figure or part thereof affected.
The objective of this Standard is to provide uniform procedures for the installation of
polyethylene (PE) pipe systems for both above and below ground applications.
The objective of this revision is to update the Standard with respect to current practice and
publish it as a joint Australian/New Zealand Standard.
This Standard primarily addresses the installation of polyethylene (PE) pipes and fittings
for plumbing, industrial and irrigation applications and is not intended to replace industry
specific installation codes or regulations.
For plumbing applications, reference should also be made to AS/NZS 3500, Plumbing and
drainage (all parts). For above ground applications using structured wall pipes, reference
should also be made to the manufacturer.
For installations conveying gaseous fluids, reference should be made to AS 5601, Gas
installations and AS 3723, Installation and maintenance of plastics pipe systems for gas, as
appropriate and in New Zealand NZS 5258, Gas distribution.
NOTE: Reference to AS 3723 correct at time of publishing, however, future reference will be
made to AS 4645, Gas distribution networks, Part 3: Plastics pipe systems.
For water supply and sewerage network infrastructure involving the design and installation
of PE pipe systems, reference should be made to Water Services Association of Australia
(WSAA) codes.
For design and installation of buried flexible pipelines, reference should be made to
AS/NZS 2566.1, Buried flexible pipelines Part 1: Structural design and AS/NZS 2566.2,
Buried flexible pipelines, Part 2: Installation or ISO 21138-1.
A bibliography is provided in Appendix A for references that may be used to provide more
detailed explanations or information regarding the installation of PE pipes.
For electrical installations, reference should be made to AS/NZS 3000, Electrical
installations (known as the Australian/New Zealand Wiring Rules).
Australian and New Zealand Standards generally do not
(a)
(b)
(c)
AS/NZS 2033:2008
CONTENTS
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Page
SECTION 1 SCOPE, DEFINITIONS AND MATERIAL REQUIREMENTS
1.1 SCOPE ........................................................................................................................ 5
1.2 NORMATIVE REFERENCES .................................................................................... 5
1.3 DEFINITIONS ............................................................................................................ 6
SECTION 2 PRODUCTS AND MATERIALS
2.1 SCOPE OF SECTION ................................................................................................. 8
2.2 PIPE AND FITTINGS ................................................................................................. 8
2.3 HANGERS AND CLIPS ............................................................................................. 9
2.4 PIPE EMBEDMENT AND TRENCH-FILL MATERIALS ........................................ 9
2.5 TOOLS AND EQUIPMENT ....................................................................................... 9
SECTION 3 GENERAL REQUIREMENTS
3.1 SCOPE OF SECTION ............................................................................................... 10
3.2 TRANSPORT, HANDLING AND STORAGE ......................................................... 10
3.3 PRE-INSTALLATION INSPECTION ...................................................................... 10
3.4 PROTECTION AGAINST DAMAGE ...................................................................... 11
3.5 REPLACEMENT OF METALLIC WATER SUPPLY PIPELINES.......................... 11
3.6 STATIC ELECTRICITY ........................................................................................... 11
3.7 TEMPERATURE CONSIDERATIONS.................................................................... 11
3.8 EFFECT OF WATER HAMMER OR PRESSURE SURGES ................................... 13
SECTION 4 JOINTING METHODS
4.1 SCOPE OF SECTION ............................................................................................... 14
4.2 FUSION JOINTS....................................................................................................... 14
4.3 MECHANICAL COMPRESSION FITTINGS .......................................................... 14
4.4 ELASTOMERIC SEAL JOINTS............................................................................... 14
4.5 FLANGED JOINTS .................................................................................................. 15
4.6 THREADED JOINTS................................................................................................ 15
4.7 REPAIR FITTINGS .................................................................................................. 15
4.8 CONNECTION OF PE PIPES AND FITTINGS TO PIPES AND FITTINGS OF
OTHER MATERIALSOTHER THAN THREADS AND FLANGES ................... 16
4.9 SERVICE CONNECTIONS ...................................................................................... 16
SECTION 5 INSTALLATION OF BURIED PIPES AND FITTINGS
5.1 SCOPE OF SECTION ............................................................................................... 17
5.2 PIPELINE INSTALLATION USING TRENCHLESS TECHNOLOGY................... 17
5.3 PIPE INSTALLATION IN A TRENCH .................................................................... 17
5.4 PIPE INSTALLATION IN AN EMBANKMENT..................................................... 21
SECTION 6 INSTALLATION OF PIPES ABOVE GROUND
6.1 SCOPE OF SECTION ............................................................................................... 22
6.2 INSTALLATION REQUIREMENTS ....................................................................... 22
6.3 SUPPORT OF PIPELINES........................................................................................ 23
6.4 PROVISION FOR EXPANSION ............................................................................. 25
AS/NZS 2033:2008
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Page
SECTION 7 TESTING OF PIPE SYSTEM
7.1 SCOPE OF SECTION ............................................................................................... 30
7.2 TESTING OF PRESSURE PIPE SYSTEMS............................................................. 30
7.3 TESTING OF NON-PRESSURE PIPELINES........................................................... 32
7.4 DEFLECTION TESTING ......................................................................................... 34
7.5 CLOSED CIRCUIT TELEVISION (CCTV) INSPECTION...................................... 34
SECTION 8 COMMISSIONING ........................................................................................... 37
SECTION 9 COMPRESSED GASES
9.1 SCOPE ...................................................................................................................... 36
9.2 CONTENTS IDENTIFICATION .............................................................................. 36
9.3 PRESSURE RATING (PN, SDR) AND TEMPERATURE RERATING .................. 36
9.4 JOINT TYPES........................................................................................................... 37
9.5 CHEMICAL RESISTANCE...................................................................................... 37
9.6 UV RESISTANCE .................................................................................................... 37
9.7 PRECAUTIONS........................................................................................................ 37
APPENDICES
A
BIBLIOGRAPHY...................................................................................................... 38
B
COMMISSIONING GUIDE...................................................................................... 39
AS/NZS 2033:2008
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SECT ION 1
SCOPE, DEF I N I T I ONS
MAT E R I A L RE Q U I RE M E N T S
AND
1.1 SCOPE
This Standard sets out methods for handling, storage, installation, testing and
commissioning of polyethylene (hereinafter referred to as PE) pipelines, above or below
ground, for both pressure and non-pressure applications conveying fluids.
NOTE: Where PE pipelines are to be installed underground the safe installation depths are
calculated by reference to AS/NZS 2566.2.
This Standard applies to PE pipe systems that carry liquids under either pressure or gravity
flow situations and the components of which comply with, but are not limited to, the
following:
(a)
(b)
(c)
(d)
(e)
(f)
(g)
(h)
1646
2698
2698.2
4176
Polyethylene/aluminium and cross-linked polyethylene/aluminium macrocomposite pipe systems for pressure applications
4799
AS/NZS
2566
2566.1
2566.2
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AS/NZS 2033:2008
AS/NZS
2648
2648.1
3500
3500.0
3500.1
3500.5
4020
4129
4130
4327
4401
Plastics piping systems for soil and waste discharge (low and high temperature)
inside buildingsPolyethylene (PE)
4793
4798(Int)
5065
Polyethylene and polypropylene pipes and fittings for drainage and sewerage
applications
ISO/TR
10358
WSAA
PS-318
01
05
NZWWA
1.3 DEFINITIONS
For the purpose of this Standard the definitions in AS/NZS 3500.0 and those below apply.
1.3.1 Embankment and trench zones
Embankment and trench zones as shown in AS/NZS 2566.2.
1.3.2 Fixed point
A point at which axial movement of the pipe or fitting is restrained.
NOTE: For example
(a)
(b)
at junctions and bends except where alternative provision for expansion is made
(see Clause 6.4.3(c)); or
(c)
1.3.3 Permeation
The passage or diffusion of a gas, vapour, liquid or solid through a product without the
product being physically or chemically affected.
* In course of preparation.
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AS/NZS 2033:2008
1.3.4 Shall
Indicates a mandatory requirement.
1.3.5 Should
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Indicates a recommendation, i.e. text that is not a mandatory requirement but given for
guidance.
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AS/NZS 2033:2008
SECT ION
PRODUCTS
AND
MATE R IA L S
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2.2.3 Permeation
Permeation of pipes and fittings by chemicals may be a consideration arising from the fluid
to be transported, or an external influence such as ground contamination.
For PE, as with other materials, including those used for jointing, permeation depends upon
the concentration of the contaminant and its nature.
In instances involving significant levels of contamination, expert advice should be sought.
2.2.4 Elastomeric seals
Elastomeric seals shall comply with the applicable Parts of the AS 1646 series of Standards
and shall be in accordance with the recommendations of the manufacturer of the socketed
pipe or fitting. For drinking and recycled water applications, elastomeric seals shall comply
with AS/NZS 4020.
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AS/NZS 2033:2008
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AS/NZS 2033:2008
SEC T I O N
10
G E N E RA L
RE Q U IRE M E N T S
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be a flat surface free of any sharp stone or projection, which may cause damage or
localized deformation to the pipe; and
(b)
be suitable for the use of the proposed loading and unloading equipment without the
risk of accidental damage to the pipe.
For pipes to AS/NZS 4130 other than plain black pipes, if the total period of exposed
storage outdoors is likely to exceed 24 months, pipes and fittings shall be covered.
Pipes and fittings that are not UV stabilized shall be covered at all times or stored indoors.
Stacking of pipes during storage shall be in accordance with the manufacturers
recommendations.
Joint lubricants shall be stored in sealed containers until ready for use.
3.3 PRE-INSTALLATION INSPECTION
3.3.1 Correct supply
Before installation, pipes and fittings shall be inspected to ensure that they are of the type,
size and classification specified for the installation. Any items that are not according to the
specifications shall be replaced.
3.3.2 Cleanliness
Pipes and fittings shall also be inspected to ensure they are free of obstructions and foreign
materials, which might interfere with the performance of the pipeline, and be cleaned if
necessary.
3.3.3 Fitness for use
The outside surfaces of pipes and fittings shall be visually checked for damage immediately
prior to installation. The allowable damage to the external surface shall be up to 10% of the
wall thickness. Kinks in pipe shall not be installed, re-rounded or repaired by reheating.
Pipe and fitting spigot ends, and spigot ends of cut pipe lengths, shall also be checked for
excessive ovality. Excessively oval pipe and fitting spigots ends may be re-rounded.
Pipes may be cut to remove damaged sections and the remaining sections may be used.
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AS/NZS 2033:2008
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(b)
(c)
the maximum service temperature less 10C for installations where large
unpredictable temperature variations occur up to a maximum of 80C, e.g. aboveground installations such as irrigation systems.
For Items (a) (b) and (c), the maximum allowable operating pressure (MAOP) shall be in
accordance with values in Tables 3.1 and Table 3.2.
NOTE: The values tabled are for materials typically used in Australia and New Zealand.
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AS/NZS 2033:2008
12
TABLE 3.1
MAOP, METRES HEAD
PE 80B
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Temperature
C
PN 3.2
PN 4
PN 6.3
PN 8
PN 10
20
32
40
63
80
100
25
32
40
63
80
30
28
35
55
35
26
32
40
24
45
PN 12.5
PN 16
PN 20
125
160
200
100
125
160
200
70
88
109
140
175
50
64
80
100
128
160
30
47
60
75
94
120
150
22
28
44
56
70
88
112
140
50*
21
26
41
52
65
81
104
130
55*
19
24
38
48
60
75
96
120
* At 50 and 55C the extrapolated performance of the pipe cannot be predicted beyond 36 and 24 years
respectively based on current data.
TABLE 3.2
MAOP, METRES HEAD
PE 100
Temperature
C
A1
PN 3.2
PN 4
PN 6.3
PN 8
20
32
40
63
80
25
32
40
63
30
30
38
35
29
40
PN 10
PN 12.5
PN 16
PN 20
PN 25
100
125
160
200
250
80
100
125
160
200
250
59
75
94
118
150
188
235
36
56
71
89
112
143
179
224
27
34
53
68
84
106
135
169
221
45
25
32
50
64
80
100
127
159
199
50*
24
30
48
60
76
95
121
151
189
55*
23
29
45
57
72
89
115
143
179
* At 50 and 55C the extrapolated performance of the pipe cannot be predicted beyond 36 and 24 years
respectively based on current data.
Across the wall of the pipe, the material temperature taken as the mean of the internal
and external pipe surface temperatures, where a temperature differential exists
between the fluid in the pipe and the external environmental.
(b)
The pressure and temperature condition, where flow is stopped for prolonged periods,
shall also be checked. In this event, fluid temperature and outside temperature may
equalize.
(c)
With respect to time, the average temperature may be considered as the weighted
average of temperatures for the proportion of time spent at each temperature under
operational pressures; it shall be calculated from the following equation:
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AS/NZS 2033:2008
T m = T 1L 1 + T 2L 2 + + Tn L n
where
Tn
NOTE: This approximation is reasonable provided the temperature variations from the mean
do not exceed 10C, which is generally the case for pipes buried at depths 300 mm below
finished surface level.
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Where a pipe is being buried during hot or cold weather, expansion or contraction of the
pipeline may take place as the pipe adjusts to ground temperature during backfilling. In
these cases, where no elastomeric seal joints are included, final connection and backfilling
should not take place until the pipe is at approximately the normal service temperature. In a
system using elastomeric seal joints this precaution may not be necessary.
For above-ground sanitary plumbing and drainage, in most circumstances the greatest
thermal movements will be caused by variations in environmental temperature because the
duration of most waste discharges is short and the temperature response of the material is
slow. Provision for expansion and contraction shall be in accordance with Clause 6.4.
When a downpipe is connected to a stormwater pipe, or otherwise restrained at the
discharge point, provisions shall be made to allow the pipe to expand and contract.
3.8 EFFECT OF WATER HAMMER OR PRESSURE SURGES
Water hammer or pressure surges are a design consideration.
NOTE: Information on surge and fatigue can be found in WSA 01 Polyethylene Pipeline Code
and other documents (see Appendix A) and PIPA POP 10A and 10B, www.pipa.com.au.
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AS/NZS 2033:2008
14
SECT ION
JOI NT I N G
METHODS
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Only trained and certified operators shall carry out fusion jointing. For guidance refer to
http://www.pipa.com.au/Training.html.
4.3 MECHANICAL COMPRESSION FITTINGS
Mechanical compression fittings for the connection of PE pipes shall be used in accordance
with the manufacturers instructions.
4.4 ELASTOMERIC SEAL JOINTS
4.4.1 Application
Only elastomeric seals and lubricants recommended by the pipe or fitting manufacturer
shall be used.
NOTE: Unrestrained elastomeric seal joints for use with PE are applicable only to low or nonpressure applications.
4.4.2 Procedure
The following procedure shall apply to joints where the elastomeric seal is incorporated in
the socket:
NOTE: This procedure does not apply to expansion joints (see Clause 6.4).
(a)
(ii)
(iii) as appropriate, witness mark the pipe at the distance specified by the
manufacturer.
NOTES:
1
A witness mark is normally positioned on the spigot by the manufacturer to show the
optimum insertion depth.
Where spigots and sockets are not made by the same manufacturer reference should be
made to the socket manufacturer for the correct marking depth.
(b)
(c)
Where elastomeric seals are required to be fitted, clean and fit the seal. Check that the
elastomeric seal sits evenly in the housing.
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AS/NZS 2033:2008
(d)
Apply the manufacturers specified lubricant to the end of the spigot and chamfer of
the pipe. Keep the elastomeric seal and its housing free of lubricant, unless otherwise
recommended by the manufacturer.
(e)
Align the pipes so that there is no deflection at the joints, then insert the spigot in the
socket and push it home to the witness mark.
(f)
Hold the socket end firmly during the jointing to prevent previously assembled joints
from moving.
NOTES:
1
Similar procedures apply for making joints where the socket is pushed on to a spigot, e.g.
socketed valves or fittings.
After the joint is made, it may be deflected up to the limit specified by the socket
manufacturer.
4.5.3 Procedure
Manufacturers requirements for alignment and bolt tightening (torque and sequence) shall
be applied to the joints.
4.6 THREADED JOINTS
4.6.1 Application
Only threads produced by the pipe or fitting manufacturer shall be used. Only thread
sealants nominated by the pipe or fitting manufacturer shall be installed.
4.6.2 Procedure
Care shall be taken to avoid over-tightening or damaging joints, and to provide adequate
support to prevent excessive shear forces on threaded joints.
4.7 REPAIR FITTINGS
Various types of repair fittings are available and installation shall be in accordance with the
manufacturers recommendations.
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AS/NZS 2033:2008
16
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SECT ION
AS/NZS 2033:2008
5
I NSTA L L A T I ON O F
P IPES AND F I TT I N GS
B U R IED
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The trench should be kept free of water as far as practicable. Surface water should also be
prevented from entering the trench.
Narrow trenches may be used where the system design permits and person access is not
required.
TABLE 5.1
MINIMUM COVER OVER PIPE
Minimum cover
m
Loading condition
Not subject to vehicular loading
0.30
0.45
0.60
0.75
0.75
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18
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Where the trench depth is such that the minimum cover specified cannot be provided for
pipelines subject to vehicular loading, additional protection may be specified.
Notwithstanding the minimum covers specified in Table 5.1, pipelines shall have sufficient
cover to
(a)
ensure any vehicular loading that is in excess of the loading capability of the pipe is
transferred to the soil strata beyond the pipeline;
(b)
suit the height dimensions (locally) of fittings such as valves and hydrants; and
(c)
Where a pipeline may be subject to abnormal loading during construction, temporary (or
permanent) measures shall be taken to ensure that the pipeline is not overloaded.
5.3.4 Buckling under external load and vacuum
PE pipes and fittings subjected to negative pressure or installed below the water table are
subjected to external loads and may buckle. The pipe class selected in the installation shall
be high enough to ensure stability against
(a)
(b)
Typically consideration shall be given to negative pressures for pipes of SDR greater than
SDR 13.6. In these circumstances advice may be sought from the manufacturer of the pipe.
When grouting is undertaken, the grouting pressures and temperatures should be determined
to ensure that empty pipes do not deflect or buckle beyond acceptable criteria as a result of
grout pressure. Where the contribution of grouting pressure to buckling forces on an empty
pipe is uncertain, grouting should be carried out with the pipe internally pressurized.
5.3.5 Anchorage
For systems with mechanically or fusion restrained joints, anchorage is not usually
necessary. For those without end-load resisting joints, anchorage at changes of direction
and other points of potential pull-out forces shall be provided, e.g. at bends, valves, tees,
etc.
Construction of anchor and thrust blocks shall be in accordance with AS/NZS 2566.1.
When concrete is being placed on a PE pipeline, complete encasement of the pipe shall be
avoided if possible. The maximum encasement shall be 180, unless flexible joints are
provided at each concrete face entered. Where a pipe is completely concrete encased, it
shall be fully wrapped prior to encasement with a compressible material such as geotextile
or polyethylene foam to a nominal thickness of 6 mm.
5.3.6 Encasement in concrete
Where pipes are to be encased in concrete precautions shall be taken to prevent movement,
flotation or deformation of pipes while pouring concrete.
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AS/NZS 2033:2008
Where damage to pressure pipe surfaces could occur as a result of differential movement of
the encased pipe, the pipe and fittings shall be protected.
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NOTES:
1
Encasement in concrete may compromise the inherent flexibility of a PE pipeline and should
only be used in special circumstances. In unstable ground conditions, the use of geotextile to
form a ground beam (as shown in AS/NZS 2566.2) may provide a superior solution.
(b)
(c)
De-watering.
Where trench de-watering is necessary, embedment and fill material shall be placed and
compacted while de-watering systems are operating.
NOTE: PE has a density less than that of water and pipes can float even when full of water.
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20
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Bedding shall be placed and spread so as to provide uniform support for the pipe. Chases
may be provided at sockets, couplings and other appurtenances to achieve uniform support.
The bedding shall not be compacted and the centre of the bedding shall not be walked on
either during or after placement.
The depth of bedding shall be appropriate to the trench floor condition and the diameter and
classification of the pipe. For pipes in clay soils and rock, a graded continuous cushion of
bedding material of minimum thickness 75 mm should be provided at the trench floor.
Where cement mortar is used as bedding, it shall be packed into the space between the
trench floor and the pipe laid in the trench to attain the line, grade and specified minimum
cover over the pipe. Cement mortar-based material shall not be installed as a haunch.
5.3.11 Pipe laying and jointing
Pipes may be jointed at ground level and then lowered into position. If elastomeric seal
joints have been used for jointing, they shall be checked after the pipe is in position to
ensure that the socket is still correctly positioned on the pipe. The manufacturers
instructions shall be adhered to. The pipes may be snaked in the trench to minimize the
effects of thermal movement.
5.3.12 Bending of pipes
For curves of smaller radius, post-formed bends, moulded fittings or purpose-made sockets
shall be used. PE pipes may be bent during pipe laying to allow a pipeline to follow a
curved path.
For profile wall pipes, reference should be made to the manufacturer for bending
requirements.
Generally, a pressure pipeline can be bent without difficulty in the vertical plane to follow
changes in the ground surface. Where it is not possible to bend the pipe by hand, preformed
bends or moulded fittings shall be installed. The form of the trench floor provides support
for the pipes and bending occurs more or less uniformly along the length of the pipes
involved.
Bending in the horizontal plane is more difficult as pipes tend to move in the trench and the
deflection tends to be concentrated in a few places. There is a tendency for excessive loads
and deformation if pipes are not adequately supported. As the structural stiffness of pipes
increases (small SDRs), the forces required to bend a pipe to a designed curvature increase
considerably, and support along the full length of the pipe becomes more important.
The use of pegs or stakes in the trench to define the radius of the designed curve, or to
restrain the pipe during installation, is not permitted. Bending tends to be localized at the
pegs or stakes and, if they are left in the trench when it is filled, highly localized stresses
may cause premature failure of the pipeline.
5.3.13 Pipe embedment
Embedment material shall be placed uniformly along and around the whole length of the
pipe barrel, couplings and other appurtenances in a manner to ensure uniform density of
side support (including haunch support) and overlay without distortion, dislodgment or
damage to the pipeline.
Where a sewer or drain is supported on concrete, overlay material shall not be placed until
the concrete has attained its initial set.
Following pipe placement, the haunch, side support and overlay materials shall be
compacted in layers not greater than 150 mm to uniformly support the pipe.
Compaction equipment or methods that produce horizontal or vertical earth pressures that
may cause damage to, or excessive distortion of, the pipe shall not be employed.
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AS/NZS 2033:2008
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Trenchfill
H min.
(see Table 5.1)
Marking tape
Compacted
overlay
100
min.
100
min.
Compacted pipe
side support
Pipe overlay
150 min.
D
Haunch zone
Bedding
B min.
DIMENSIONS IN MILLIMETRES
AS/NZS 2033:2008
SECT ION
22
I NSTA L L A T I ON
ABOVE GRO UND
O F
P IP ES
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23
AS/NZS 2033:2008
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AS/NZS 2033:2008
24
TABLE 6.1
MAXIMUM SPACING OF SUPPORTS
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Nominal outside
diameter of pipe
Vertical pipes
16
20
25
0.25
0.30
0.35
0.50
0.60
0.70
32
40
50
0.38
0.43
0.45
0.75
0.85
0.90
63
75
90
0.50
0.60
0.67
1.05
1.20
1.35
125
140
160
0.75
0.85
1.00
1.50
1.70
2.00
200
225
250
1.10
1.15
1.25
2.20
2.30
2.50
280
355
1.30
1.50
2.60
3.00
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AS/NZS 2033:2008
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Pipelines shall be supported at, or adjacent to, every bend, including fittings where
pipelines emerge from a wall.
6.4 PROVISION FOR EXPANSION
6.4.1 General
Provision shall be made for thermal movement by fitting expansion joints, unless the
movement can be accommodated by other means as described in Clause 6.4.3. An
expansion joint shall permit an axial movement of the connecting pipe of not less than
10 mm in either direction.
Elastomeric seal joints on pipes may be regarded as expansion joints if recommended as
such by the manufacturer.
6.4.2 Maximum spacing of expansion joints
6.4.2.1 General
The maximum spacing of expansion joints depends upon the maximum temperature
differential expected in service and the magnitude of the axial movement that the selected
expansion joint can accommodate.
NOTE: The thermal expansion or contraction of PE pipe is shown in Clause 3.7.2 and Figure 3.1.
PE pipe systems located within buildings or outside buildings that are out of direct
sunlight and not subject to pipe material temperatures greater than 60C (cold
pipelines) shall be fitted with expansion joints at spacings no greater than 6 m or as
recommended by the manufacturer. Where the length of pipeline between fixed points
is no greater than 1.5 m, provision for thermal movement is not required.
(b)
Water supply and sanitary plumbing pipe systems installed for conveying hot fluids
(e.g. from dishwashers, washing machines, knife sterilizers etc.) or located outside
buildings in direct sunlight, or in roof spaces, so that the pipe material temperature
might exceed 60C (hot pipelines), shall be fitted with expansion joints at spacings
no greater than 4 m. Where the length of pipeline between fixed points is no greater
than 1 m, provision for thermal movement is not required.
at each floor at which fixtures or branch pipes are connected, and shall be
immediately above the highest branch connection; and
(b)
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AS/NZS 2033:2008
26
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Expansion joints may be omitted in the following locations (as illustrated in Figure 6.4):
(a)
Above the highest branch connection on a stack where the stack is free to move
through a weatherproofed sleeve through the roof.
(b)
(c)
Maximum pipe
length
m
Minimum length
of offset leg
ms
40, 50, 63
2.0
3.0
4.0
6.0
0.5
0.6
0.8
1.0
2.0
3.0
4.0
6.0
0.75
1.0
1.1
1.2
140, 160
2.0
3.0
4.0
6.0
1.0
1.1
1.2
1.2
Insert the pipe in the expansion socket to the full depth and mark the pipe.
(b)
Withdraw the pipe a distance equal to the temperature engagement depth and mark
the pipe. The temperature engagement depth shall be determined according to the
average environmental or pipe material temperature at the time of installing the
system.
(c)
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27
AS/NZS 2033:2008
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Expansion joint
a b ove h i g h e s t b r a n c h
c o n n e c ti o n (m ay b e o m i t te d
u n d e r C l a u s e 6 .4. 3 (a))
S li d i n g s u p p o r t
at a ll f l o o r s
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AS/NZS 2033:2008
28
!"#$%
&
& (
FIGURE 6.3 EXPANSION JOINTS AND FIXED POINTS IN GRADED PIPELINES
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AS/NZS 2033:2008
C l a u s e 6.4.3 ( a )
E x pa ns i o n j o i nt o m i t te d w h e re
a l te r n ati ve ex pa ns i o n p rov i d e d
th ro u g h ro of
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C l a u s e 6.4.3 ( c )
E x pa ns i o n j o i nt o m i t te d w h e re
a l te r n ati ve ex pa ns i o n p rov i d e d
by p l a s ti c tra p
C l a u s e 6.4.3 ( c )
E x pa ns i o n j o i nts o m i t te d w h e re
a l te r n ati ve ex pa ns i o n p rov i d e d
l3
l2
l1
L2
L3
L1
C l a u s e 6.4.3 ( c )
E x pa ns i o n j o i nts o m i t te d w h e re
a l te r n ati ve ex pa ns i o n p rov i d e d
l2
l3
l2
L1
C l a u s e 6.4.3 ( c )
E x pa ns i o n j o i nts o m i t te d w h e re
a l te r n ati ve ex pa ns i o n p rov i d e d
L
L EG EN D :
= Pi p e s u p p o r t
= E x pa ns i o n j o i nt
= F i xe d p o i nt
= E x pa ns i o n j o i nt d e l ete d
S e e Ta b l e 6.3 fo r va l u e s of L a n d l
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AS/NZS 2033:2008
SEC T I ON
30
T EST I N G
O F
P IPE
SY ST E M
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(b)
(c)
Presence of air.
(d)
(e)
(f)
(g)
(h)
(i)
Long test sections may incorporate a large number of joints that should be checked for
leakage. The longer the test section the harder it is to locate a leak. Pipes above about DN
250 cause additional effects to further complicate the test process. Where site or production
reasons require longer lengths to be tested, radio links between test operatives to minimize
the test duration should be employed.
The pipeline or system may be tested as a whole or in sections, depending on test pressure
requirements, the length and diameter of the line, the availability of water, and the spacing
between sectioning valves or blanking ends. The pipeline (or section) shall be properly
supported and, if it includes non end load bearing joints, be anchored to prevent the
movement of pipes or fittings during the test.
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AS/NZS 2033:2008
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The test section shall be filled with water, taking care to purge all free air from the section.
Where a motorized positive displacement pump is used for the test, it shall be fitted with an
effective form of pulsation damping. Also, to minimize the risk of potentially damaging
over-pressurization occurring, a pressure relief valve shall be fitted. This relief valve shall
be set correctly and have sufficient capacity to limit any possible pressure rise to a
maximum of 100 kPa above the test pressure.
The pressure shall be monitored at the lowest part of the pipeline or, if that is not possible,
at some other convenient point and the test pressure adjusted to take account of the
elevation difference between the pipelines lowest point and the test rig. The adjustment
shall be made by subtracting 10 kPa for every metre that the rig is elevated above the
lowest part of the line. The source of any leak shall then be ascertained and any defects
repaired. The pipeline shall then be retested.
The pressure test shall be conducted using two pressure measuring instruments that shall
agree within 5% of gauge reading.
7.2.3 Basic pressure test (Visual)
A test pressure of 1.25 times the operating pressure (but not more than 1.25 times the
MAOP of the lowest rated component in the system) shall be applied to the section under
test. The test section shall then be allowed to stand without make-up pressure. Where the
joints are accessible for inspection and there is no evidence of leaks of the test water after
at least 15 minutes under pressure, the section is deemed to have passed the test.
Where the joints are not accessible for inspection and the apparent loss of water is less than
that calculated from the following equation, the section is deemed to have passed the test.
Q 0.14LDH
where
Q
NOTES:
1
The make-up water is not a leakage allowance, but is an allowance to cover the effects of the
test head forcing small quantities of entrapped air into solution. Normally the test should last
for a minimum of 2 h and be concluded within 5 h to 8 h. The make up water requirement
should reduce with time as air goes into solution. Where, after 12 h the make up water still
exceeds the allowable limit, testing should cease and the cause of loss investigated.
It is assumed that if the pipeline passes the test, the anchorages are sound.
Pressure testing against a closed valve should normally only be undertaken when there is no
practicable alternative or when any leakage from the valve can be observed and measured
during the test.
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AS/NZS 2033:2008
32
Variables such as pipe stiffness and soil compaction are irrelevant, as the test result is based
on actual performance during the test. Temperature may be considered constant, as with
other test methods, unless special conditions exist.
7.2.4.2 Test procedure
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Maximum system test pressure (STP) shall be at least 1.25 times the maximum working
pressure of pipeline but not to exceed 1.25 times MAOP of lowest rated pipe/fitting in line.
The pipelines shall be tested as follows:
(a)
Raise pressure to STP, close off main and allow to settle for at least 12 hours. During
this period, pressure will fall as a result of pipe expansion.
(b)
Using water of the same temperature as that in the pipeline (3C) restore and
maintain STP,
(c)
(d)
(ii)
Time: 1 min.
Calculate the water volume added between the second and third hour, V(3h2h) and
the volume added between the fourth and fifth hour, V(5h4h).
(f)
(g)
V all
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AS/NZS 2033:2008
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The pressure shall be maintained without leakage for at least 15 minutes. The source of any
leak shall then be ascertained and any defects repaired. The pipeline shall then be retested.
NOTE: If groundwater is present, the test pressure should be increased to compensate for the
depth of groundwater at a rate of 10 kPa for every 1 m of groundwater depth above the pipe.
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AS/NZS 2033:2008
34
TABLE 7.1
VACUUM AIR TESTING
ACCEPTANCE TIMES FOR 7 kPa PRESSURE CHANGE
Test length, metres
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Pipe size
DN
50
100
150
200
250
300
2
2
3
2
2
3
2
2
3
2
2
5
3
3
6
3
3
6
225
300
375
4
6
7
5
9
14
8
14
22
10
18
29
13
23
36
15
29
43
450
525
600
10
14
18
21
28
37
31
42
55
41
56
73
52
70
92
66
86
106
675
750
900
23
29
41
46
57
83
70
86
124
93
115
165
116
143
207
144
168
243
1000
1050
1200
51
56
73
102
112
147
153
169
220
204
225
294
255
281
367
300
319
460
1500
115
230
344
459
574
700
NOTES:
1
Timing of the test duration shall commence after the 3 minutes initial period.
Test duration times for other combinations of pipe size and test length may be interpolated.
(b)
Only CCTV records of such quality that an accurate assessment of the internal
condition of the pipeline can be made shall be accepted.
(c)
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35
SECT ION
AS/NZS 2033:2008
COMM ISS I ON I NG
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In most instances acceptance testing (see Section 7) of the installation is all that is required.
In the case of more complex projects that may involve supply and installation of equipment,
formal commissioning may be required.
Where commissioning is required, a commissioning plan should be developed to ensure that
the installation is fully operational to the satisfaction of the installation owner. This plan
would normally address
(a)
(b)
pre-commissioning;
(c)
handover;
(d)
sign-off; and
(e)
The installer would generally be required to test and inspect all products, materials,
equipment, installation and workmanship included in the works covered by the project
specification to prove compliance with the specification requirements, and to provide all
equipment, materials, water and power supplies required to carry this out.
Testing includes pre-commissioning, field testing and performance testing of each item of
the whole installation.
NOTE: Further guidance and relevant information is given in Appendix B.
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AS/NZS 2033:2008
36
SECT ION
COMPRESSED
GASES
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9.1 SCOPE
This Section describes some of the special considerations that apply to the use of PE for
compressed air but excluding fuel gas.
When polyethylene pipe systems are used for the conveyance of compressible fluids, such
as compressed air, special considerations apply.
This Section describes some of these.
9.2 CONTENTS IDENTIFICATION
The recommended colour for identification of compressed air systems above ground is blue
in accordance with AS 1345.
This colour identification may be achieved by pipe colour, adhesive labels, or other means.
Hence pipes for the conveyance of compressed air may be black, blue, or some other
colour, provided identification is achieved in accordance with the users specification.
9.3 PRESSURE RATING (PN, SDR) AND TEMPERATURE RERATING
Compressed gas that is under pressure contains substantial stored energy more so than a
liquid under the same pressure. If that energy is released suddenly there is an increased risk
of injury to anyone nearby. For that reason there is a greater factor of safety applied to pipe
for compressed air applications than would be applied to a pipe carrying water at the same
pressure and temperature. Therefore the allowable working pressure of a compressed air
pipeline is less than the PN rating of the pipe.
Accordingly, pipes manufactured specifically for compressed air conveyance are typically
branded as follows:
PE100
SDR 7.4
PN 25
Compressed Air
This means that it is a PN 25 pipe made from PE 100 material but you should only use this
pipe on a compressed air system that has an allowable working pressure that does not
exceed 1600 kPa at an operating temperature that does not exceed 20C.
Tables 9.1 and 9.2 provide recommended relationships between PN rating, SDR,
temperature, and pressure.
TABLE 9.1
MAOP, kPa
PE80B
A2
Classification
of pipe
Standard
dimension
ratio (SDR)
Operating
temperature
20C
Operating
temperature
25C
Operating
temperature
30C
Operating
temperature
35C
Operating
temperature
40C
PN 8
17
500
470
440
400
380
PN 10
13.6
630
600
560
510
480
PN 12.5
11
800
750
700
640
600
PN 16
1000
940
880
800
750
PN 20
7.4
1250
1180
1100
1000
940
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37
AS/NZS 2033:2008
TABLE 9.2
MAOP, kPa
PE100
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A2
Classification
of pipe
Standard
dimension
ratio (SDR)
Operating
temperature
20C
Operating
temperature
25C
Operating
temperature
30C
Operating
temperature
35C
Operating
temperature
40C
PN 10
17
630
620
590
560
530
PN 12.5
13.6
800
780
750
710
670
PN 16
11
1000
990
940
890
840
PN 20
1250
1240
1108
1120
1060
PN 25
7.4
1600
1540
1470
1390
1320
(b)
Correctly stabilized coloured pipes are estimated to be suitable for at least two years
exposure to direct sunlight.
(c)
Black pipes to AS/NZS 4130 are suitable for exposure periods up to 50 years.
9.7 PRECAUTIONS
Compressed air systems contain substantial stored energy, which if released suddenly,
could cause injury. It is recommended that pipe system design, installation and maintenance
be conducted by those with appropriate knowledge and experience. Care is needed to avoid
unplanned overheating of the system. Air compressors will produce air which may be
considerably above ambient temperature. Connection between a piston compressor and
receiver should not be in plastics due to the likelihood of unacceptably high temperatures.
Industry best practice of shielding equipment and pipework from direct heat sources, e.g.
sunlight, should be adopted to prevent excessive heat buildup. It is also recommended that
oil traps be fitted immediately downstream of the compressor.
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AS/NZS 2033:2008
38
APPENDIX A
BIBLIOGRAPHY
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(Informative)
The following listing is not intended to be comprehensive. Links to other relevant sites and
information can be made via the websites shown below.
An Effective Barrier Pipe System for Contaminated Land. M Christodoulou, K Wilson,
M Hunter and J Bowman. Uponor Ltd. Plastic Pipes XIII, Washington DC, October 2006.
Chemical resistance data sheets. Volume 1: Plastics. Shrewsbury, UK. RAPRA Technology
Ltd.
Chemical resistance data sheets. Volume 2: Rubbers. Shrewsbury, UK. RAPRA
Technology Ltd.
Chemical Resistance. Volume 1; Thermoplastics. NY, USA. Plastics Design Library.
ISO/TR 10358, Plastics pipes and fittingsCombined chemical resistance classification
table.
Australasian Society for Trenchless Technology, www.astt.com.au
Plastics Industry Pipe Association of Australia, www.pipa.com.au
Plastics Pipe Institute (PPI), www.plasticpipe.org
Water Services Association of Australia, www.wsaa.asn.au
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39
AS/NZS 2033:2008
APPENDIX B
COMMISSIONING GUIDE
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(Informative)
B1 GENERAL
No pipeline should be placed in service before it has been cleaned of contaminants, before
it has satisfied test requirements and, in the case of water mains, before the quality of water
supplied from the pipeline has met the asset owners standards.
Possible contaminants include
(a)
materials that enter the pipes and fittings during storage and transport;
(b)
construction debris;
(c)
materials introduced during construction, e.g. lubricants used with elastomeric seal
joints;
(d)
(e)
Drinking water lines must be commissioned before going into service to remove any
extraneous matter or toxic materials. Any pipeline that is to carry drinking water must not
be placed in service before the installing engineer is satisfied that the water supplied from
the pipeline will meet the responsible authoritys standards for quality of drinking water.
B2 REMOVAL OF PARTICULATE MATERIALS
Soil and other particulate materials may be removed from a pipeline by flushing. However,
the water velocities required to suspend and remove even sand-sized particles are high
(greater than 2 m/s for 100 mm pipe) and it may not be possible to achieve suitable
velocities in practice. Prolonged flushing at low velocities is not effective.
If high velocity flushing is not possible, consideration should be given to swabbing the
pipeline or using air scouring to ensure particulate contaminants are removed.
B3 WATER QUALITY
B3.1 Disinfection
To enable the conveyed water to meet bacteriological and biological quality standards,
pipelines, including those involved in extensions and repairs, must be disinfected before
use. Disinfection procedures vary depending on the size of the works. Reference should be
made to the responsible authority for details of acceptable disinfection procedures.
B3.2 Materials extracted from the pipe or fittings during service
Drinking water can extract minor amounts of various substances from pipes and fittings in
all materials, including PVC. In most cases the concentration of the extracted material in
the conveyed water is low and of little concern.
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AS/NZS 2033:2008
40
Good manufacturing practice, including compliance with the clauses relating to effect on
water in the relevant pipe or fitting Standards, ensures that there is no long-term effect on
water quality as a result of contact with the pipe or fitting. Short-term increases in the
concentration of potential contaminants have been observed in water conveyed through new
pipelines, particularly where the water is allowed to stand in the pipeline for long periods.
In most cases the concentrations of these contaminants in the conveyed water are well
below the acceptable limits recommended by WHO and other authorities. The responsible
authority should consult with the manufacturers to determine the range of likely
contaminants that might be extracted by drinking water, and the likely level of these
substances in the conveyed water.
Where there is concern about the risk of unacceptably high levels of particular substances
being extracted by water from a new pipeline, consideration should be given to
implementation of an appropriate commissioning procedure to ensure that the levels of
these contaminants are below acceptable limits in water supplied from the pipeline. The
responsible authority should be consulted to determine the commissioning procedure to be
adopted.
B4 COMMISSIONING PROCEDURE AND ACCEPTANCE CRITERIA
Commissioning procedures, including disinfection, and acceptance criteria, should be
specified in the project specification. The asset owner, or party carrying out the works
should be consulted to determine the procedures to be used.
B5 PROCEDURE FOR DRINKING WATER SUPPLY PIPELINES
New and repaired drinking water supply pipelines may be commissioned using the
following procedure:
(a)
(b)
(ii)
Air scouring (that is, where compressed air is injected into the water in the
main to create unsteady flow conditions during the flushing process)generally
not as effective and usually more difficult than swabbing.
(iii) High velocity flushing (e.g. 2.0 m/s to 2.5 m/s for 15 min)not generally
practical or possible for water mains >DN 300.
(c)
(d)
(e)
(f)
(g)
Certify acceptance.
(h)
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41
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AS/NZS 2033:2008
Amendment No. 1 (2008)
CORRECTION
SUMMARY: This Amendment applies to Table 3.2.
Published on 31 October 2008.
AS/NZS 2033:2008
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AS/NZS 2033:2008
42
NOTES
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43
NOTES
AS/NZS 2033:2008
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AS/NZS 2033:2008
44
NOTES
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Standards Australia
Standards Australia is an independent company, limited by guarantee, which prepares and publishes
most of the voluntary technical and commercial standards used in Australia. These standards are
developed through an open process of consultation and consensus, in which all interested parties are
invited to participate. Through a Memorandum of Understanding with the Commonwealth
government, Standards Australia is recognized as Australias peak national standards body.
International Involvement
Standards Australia and Standards New Zealand are responsible for ensuring that the Australian
and New Zealand viewpoints are considered in the formulation of international Standards and that
the latest international experience is incorporated in national and Joint Standards. This role is vital
in assisting local industry to compete in international markets. Both organizations are the national
members of ISO (the International Organization for Standardization) and IEC (the International
Electrotechnical Commission).
www.standards.org.au
www.standards.com.au
www.standards.co.nz
Licensed to Mr Paul Dale on 19 August 2011. 1 user personal user licence only. Storage, distribution or use on network prohibited (10233691).
Administration
Email mail@standards.org.au
Customer Service
Phone 1300 65 46 46
Fax 1300 65 49 49
Email snz@standards.co.nz
Email sales@standards.com.au
Internet www.standards.co.nz
Internet www.standards.org.au
Printed in Australia