INSTALLATION GUIDELINES FOR JAIN PE PIPES

Laying of Jain HDPE Pipes can be done in two ways

General Cosiderations
2. ASTM D 2774 - Standard Practice for Underground
Jain PE (Polyethylene) piping can be installed underground,
on the surface, supported above ground, marine or submarine.
For the Jain PE piping system to work as designed, the unique
demands of the installation must be taken in to account.
Jain PE pipe is tough, light weight and flexible. Installation
does not usually require high capacity lifting equipment.
a) Above ground installation Pipe support should be designed
to give lateral constraint against movement, while allowing
free movement of pipe in axial direction. Spacings shown
refer to installation at different temperature & pressure rating.
Spacing shall be increased 50% for vertical pipes.
b) Typical Trench Size for under ground installation: Generally
the pipes are buried at depth of 1 meter depending upon
movement of traffic above the ground.

Installation of Thermoplastic pressure piping.

Pipe Embedment
The backfill materials enveloping a buried pipe are given in
the drawing for easy identification and by their function or
location:

Foundation
A foundation is required only when the native trench
bottom does not provide a firm working platform, or the
necessary uniform and stable support for the installed pipe.
If a foundation is installed, bedding is required above the
foundation.

Initial Back fill

This is the critical zone of embedment surrounding the pipe
from the foundation to atleast 150 cm over the pipe. The pipes
ability to support loads and resist deflection is determined by
the quality of its placement. Within this zone are bedding,
haunching, primary and secondary zones.

Minimum Trench width = D + 40 CM.

Minimum sand cushion
a. below pipe = (10+D/10) CM,
b. above pipe = 15 cm
Where D = Outside diameter of pipe in cm.
Underground Installations
Buried installations generally involve trench excavation, placing
pipe in the trench, backfilling around the pipe, then placing
backfill to the required finished grade. Pipe application and
service requirements, size, type, soil conditions, backfill soil
quality, burial depth and joining requirements will all affect
the installation.
The care taken by the installer during installation will
dramatically affect the system performance. In any pipe
installation the selection of pipe material plays only 1%, the
stiffness of the pipe 2%, the depth of installation 17% and
the method of installation role in 80% for the performance
of the system.
Additional information on pipe burial may be found in the
following standards:1. ASTM D 2321 - Standard Practice for Underground
Installation of Thermoplastic pipe for sewers and other
Gravity flow applications.

.18.

Bedding
In addition to bringing the trench bottom to required pipe
bottom grade, the bedding levels out any irregularities and
ensures uniform support along the pipe length. Bedding is
required when a foundation is installed, but a foundation may
not be required to install bedding.

Haunching
The embedment under the pipe haunches supports the pipe
and distributes the load. The quality of the haunching backfill

Primary Initial Backfill

This embedment zone provides primary support against
lateral pipe deformation. It extends from pipe bottom grade
to at least 3/4th of the pipe diameter height, or to at least 6
over the pipe crown if the pipe is installed where the pipe will
be continuously below normal groundwater level.

Secondary Initial Backfill

Embedment material in this zone distributes overhead loads
and isolates the pipe from any adverse effects from placing
final backfill material. Where the ground water level may
rise over the pipe, the secondary initial backfill should be a
continuation of the primary initial backfill.

iv) Carefully remove the oxidized layer on the butts by using

a Scrapper or a Planer.
v) Bring both faces in contact with an electrically Heated
Welding mirror maintained at temperature of 210 5oC.
Fuse the butts by applying a slight pressure of around 0.2 kg/
cm2. The pipe material melts and forms a uniform circular
rim on the periphery of both the pipe faces.
vi) Remove the heating mirror and quickly bring both ends in
contact with enough pressure.
vii) Allow the Joint to Cool to ambient temperature under
pressure.
viii) Open the clamps and remove the pipes from the welding
jack.

Final Backfill
Final backfill is not on an embedment material, however,
it should be free of large rocks, lumps, construction debris,
stones, stumps and any other material with a dimension
greater than 8.

Socket Welding

Jain PE Pipes can be joined in several different ways depending

upon end use requirements.

For smaller diameter PE Pipes, Socket Heat Fusion technique

is adopted. In this technique individual pipe lengths are joined
by heat fusing the outside surface of the pipe to the inside
surface of fitting. It is mainly used for Industrial & Domestic
Plumbing Systems. For this process special equipment is
available that simultaneously heats these two surfaces to
fusion temperature.

For Permanent Joint:

Extrusion Welding

Butt Welding, Socket Welding, Electro Fusion Welding.

This technique is used for welding pipes with large diameters

and wall thicknesses, plates or special parts having odd shapes.
A portable extruder is used to extrude a weld bead of required
size. This molten bead is gently pressed on the surfaces to be
welded which are simultaneously heated to 210 - 220C by
means of hot air gun.

Jointing of Jain PE Pipes

For Mobile (detachable) Joints:

Flanged Joint, Quick Release Joint, Compression Joint, Insert
Joint

Butt Welding
The most widely used method for jointing individual length
of Jain PE Pipe is by heat fusion of the pipe butt ends. This
technique, which precludes the need for specially modified
pipe end or couplers, produces an economical connection
which is as strong and as chemically resistant as the pipe. To
make a reliable and durable butt welded joint, the following
procedure is to be adopted:
i) Clean both ends with a damp cloth to dislodge any foreign
matter or dirt deposited on the pipe.
ii) Hold the pipes firmly with the clamps of a specially
designed Welding Jack.
iii) Bring both the faces to axial alignment by using support
rollers to minimise mismatch of the faces by rotating, if
necessary.
.19.

Electrofusion Joint
In this method the socket of the fitting incorporates an
electrical heating coil. When energised by an electronic
control unit, the coil causes the material around it to melt and
form an expanding pool which comes into contact with the
surface of the pipe. This causes the pipe to melt, leading to
fusion of pipe & socket. Used for Air/Gas Distribution lines.

Flanged Joint
If transition is to be made to another piping material or if
a pipe section capable of disassembly is required, then Jain
PE Pipe Ends (also called Stub-ends) are available that can be
welded to the pipe by means of heat fusion. A metal back up
flange with appropriately sized and spaced bolt holes permits
bolting to standard or specially sized flanges. In order to get

the same may be welded in the factory on predetermined pipe

length so that they arrive at job site ready
to bolt together. (Ref. : Table-10 for flange dimentions).
Table-10: MS Flange Dimensions suitable for Jain PE Stub
Ends
Size

Dia

PCD

Bore
Dia

Thick

Bolt
Hole
Dia

No.of
Bolt
Holes

Systems where quick engagement and disengagement of joints

are required. In this system Jain PE Pipes and fittings are
welded on one side with spigot and on the other side with
socket having a Hydraulic rubber seal inside it. To make a
joint, spigot coupler is pushed in to the socket coupler and
is locked.
Compression Joint
Jains have a range of compression fittings which could adopt to
PLAIN ENDS of PE PIPES. Jains manufacture compression
fittings ranging from 20 mm to 75 mm size suitable for all
O.D. based Pipes which are covered under relevent IS/ISO/
DIN standard for PE Pipes.

63

165

125

64-65

7.0

19.0

75

185

145

76-77

7.0

19.0

90

200

160

91-92

9.5

19.0

110

220

180 112-113

9.5

19.0

Insert Type Joint

125

250

210 127-128

11.0

19.0

140

250

210 142-143

12.5

19.0

160

285

240 162-163

12.5

23.0

180

285

240 183-184

12.5

23.0

200

340

295 203-204

16.0

23.0

This type of joint is used where PE Pipe is to be connected

with another system having metallic fittings such as G.I.
Coupler or Flange. To make this type of Joint, PE Pipe is
heated to a temperature of 120C in oil and then Serrated
Metallic Nipple is inserted into it and secured by Jubilee Clip
to ensure a leak-proof joint. This type of joint is generally used
in borewell application for connecting submersible pump.

225

340

295 228-229

20.0

23.0

250

395

350 253-254

20.0

23.0

12

280

395

350 284-285

20.0

23.0

12

315

445

400 319-320

24.5

23.0

12

PE Sure-Loc Joints

Procedure for Installing PE Stub Flange

Inspect flange faces and ensure that they are clean and
undamaged.
Check that the correct backing flange is supplied.
Check that the correct gasket is available.
Loosely assemble flanges. Ensure that flanges and bolt holes
align and that flange faces are parallel. Ensure that the
gasket is correctly positioned.
Tighten bolts gradually, in sequence, to ensure even loading
around the flange to avoid distortion. Ensure that washers are
used under bolt heads and nuts.
The sequence for 8 and above bolt holes are that the
tightening should be done on bolts opposite to each other
(180).

Quick Release Joint

This type of joint is most commonly used in Sprinkler Irrigation
.20.

Jain Sure-loc joints are the new generation joints which

are aimed at evolving an easy and quick jointing system with
out the need for butt, electrofusion or any type of mechanical
joints. Jain Sure-loc joints are flexible in the sense that they
are detachable. The joint integrity is achieved by rubber ring
sealing. The joint is self restrained and does not require thrust
blocking or anchoring to keep the joint from separating under
pressure. It is an excellent joint for above ground installations
as the joints can take care of the linear expansion and
contraction of the pipe due to temperature variations.

Fittings
In order to facilitate a complete Piping System, Jains offer
a wide range of tailor made fittings to suit the individual
needs.
Above ground supporting:
Support spacing depends upon the allowable deflection
between supports, which in turn depends upon the pipeline,
the fluid it carries and the service temperature. Jains advise
customers that the allowable long-term deflection between
supports should not exceed 1. Recommended support
spacing may be taken from Table-11 given below.

Table-11:Support Spacings for Jain PE Pipes at 23C in m

Size

At rigid connections such as flanges and mechanical joints.

At connections to metal/plastic tapping points or tees.

Pressure Class kg/cm2

At connections to larger pipes, tanks and manholes.

NB

2.5

10

--

--

1.50

1.55

--

1.65

1.75

1.90

1.65

1.80

2.00

2.15

Design Considerations: Liquids in a pipe resist flow due to

two reasons.

1.80

2.00

2.20

2.40

1) due to viscous shear stresses within the liquid and

2.00

2.20

2.40

2.60

2) friction along the pipes internal surface.

2.30

2.50

2.75

2.95

10

2.60

2.80

3.10

3.30

This flow resistance inthe pipe leads to pressure drop or it is

more often called the loss of head due to friction in the pipe.

12

2.80

3.10

3.35

3.60

14

2.90

3.20

3.50

3.80

16

3.10

3.40

3.75

4.05

During installation, the fabricated fittings should be

protected against bending.

For Calculating the Friction loss any formula used should

depend upon four factors 1) ID of pipe, 2) Pipe surface
characteristic, 3) Viscosity of the liquid flowing through &
4) Velocity of the flow.

The support spacing distance may be adjusted using the

multiplication factor given in Table-12 for other service
temperatures.
Table-12:Multiplication factor for different Service
Temperatures
Service Temperature

15C

38C

49C

60C

Multiplication Factor

1.01

0.95

0.85

0.8

Handling of Jain PE Pipes

Jain PE pipes are manufactured from select high quality
raw materials of required grades according to customers
requirement and application. Polyethylene being much
lighter material than Ductile iron, Cast Iron and Reinforced
Concrete. Jain PE pipes do not require heavy handling
equipment normally required for the other pipes. Conveying,
laying and jointing longer lengths of pipes requires very little
manpower and machinery as the weight of Jain PE pipe would
be less than a fifth of DI, CI or PSC pipes of similar sizes.
Jain PE pipes are flexible and at the same time tough and
can be laid on rolling terrains without the use of directional
fittings and reduce cost and time for the user.
Precautions to be taken during Installation
Protection to be given to Jain PE pipes against excessive
bending and shear loads. A few examples are given below:
Where pipes come out from structures such as walls and
casings.
.21.

Three Formulae namely a) Darcy-Weisbach, b) Manning and

c) Colebrook are accepted, as these formulae recognize the
four factors mentioned earlier. However, reliable results can
be obtained with ease for some applications, with empirical
formulae, when used within their limitations.
The Hazen-Williams formula for water is one such empirical
formula for water. This formula for water at 60F / 15.6 C
can be applied to liquids having the same kinetic viscosity of
1.130 centistokes (0.00001211 ft2 /sec). Waters viscosity
varies with temperature, whereby some error can occur at
other temperatures. (Refer Table-13)