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Coestilen

Technical Catalogue

Introduction

Coestilen is the High Density Polyethylene (HDPE)


drainage system. It is exeptinally elastic and resistant to
mechanical stress and vibrations.The programme consists of
pipes
and fittings from 40 mm to 315 mm. It includes
a wide range of joint fittings and connections
to sanitary and sewage systems.
The high molecular weight of PE is
a guarantee against fracture due to
prolonged use. It is also particularly
suited to absorb mechanical stresses
of significant intensity; specifically for
installation in seismic areas. Moreover
it offers excellent resistance to operating
temperatures between 40 and +80C, with the
capacity to handle peaks
of up to 95C.
Coestilen pipes and fittings are compliant with
UNI EN 1519.

Raw Material
Non-Pollutant and 100% Recyclable

Table of contents
1. Field Application

1.1 Advantages

4 Electro Fusion Welding


4.1 Introduction

1.2 Types of installations

20 - 22
20

4.1 - 1 General
4.1 - 2 Welding machines/Tools

2. Material Properties

2-8

4.2 Preparation

2.1 Introduction

4.2 - 1 Welders Technical Features

2.2 Characteristics

4.2 - 2 Fittings/Welders
4.3 Electro Fusion Welding Procedure

2.2 - 1 Physical
2.3 Chemical Resistance

3-8

21

22

4.3 - 1 AT131S

2.3 - 1 COESTILEN Table


2.3 - 2 Chemical Resistance Enquiry

5 Butt Welding
5.1 Introduction

3 Design
3.1 Linear Expansion

9 - 19

5.1 - 1 General

9 - 10

5.1 - 2 Butt Welding Machines/Tools

3.1 -1 Calculation

3.2

5.2 Preparation

3.1 -2 Linear Expansion Table

5.2 - 1 Welders Technical Features

3.1 -3 Example

5.2 - 2 Welding Machines/Tools

Linear Expansion Compensation - by Change


of Direction
11 - 12
3.2 - 1 Calculation

23 - 27
23

24 - 25

5.2 - 3 Pipe/Fittings
5.2 - 4 Heating Time Table
5.3 Butt Welding Procedure

26 - 27

5.3 - 1 AT103S

3.2 - 2 Change of direction Table


3.2 - 3 Example
3.3

Linear Expansion compensation - by


Expansion Sleeve

6 Certificates
13 - 14

3.3 - 1 Calculation
3.3 - 2 Expansion sleeve compensation table
3.3 - 3 Example
3.3 - 4 Installation
3.4 Fixed Points

15

3.4 - 1 Introduction
3.4 - 2 Expansion sleeve fixed points
3.4 - 3 Expansion joints fixed points
3.5 Sliding Points
3.6 Connection Guide
3.6 - 1 HDPE to DWV
3.6 - 2 HDPE to Copper
3.6 - 3 In pipe connection
3.6 - 4 HDPE Slab repair
3.6 - 5 HDPE to thread
3.6 - 6 Push in rubbers adaptors
3.6 - 7 E/ware adaptors

16
17 - 19

28 - 29

1. Field Application
1.1 Advantages
Outstanding elasticity and resistance to mechanical stress and vibrations - ideal for seismic areas.
Outstanding resistance to chemicals, working temperatures between -40C and +80C and to the effects of the weather

Excellent resistance to pressure and accidental pressures surges

1.2 Types of Installations

Coestilen is designed for drainage inside domestic and industrial buildings and for the following fields of application:

Drainage of sanitary fixtures.


Drainage of washing machines
and dishwashers.
Extended drainage of waste
water (large kitchens, laundries,
industrial systems).
Drainage of aggressive fluids in
schools, laboratories and industrial buildings, according to ISO/
TR10358.
Medium and large-sized drain
manifolds.
Application conditions
Maximum temperature of the
fluids piped not under
vacuum: 95C.

Note: It cannot be used for piping drain water containing benzene or benzole (DIN 1986/3, 2.3).

Page 1

2. Material properties
2.1 Introduction

Resistance to temperatures,
It does not break and does not buckle permanently
if water freezes in the pipes, within a temperature
range of 40C and +80C, allowing the handling
of peaks of up to 95C (Surges of steam).
Low thermal conductivity,
it does not tend to form condensate.
Resistance to mechanical stresses.
Coestilen is elastic enough to handle most
external stresses, impacts and deformations.
As long as several specific technical rules are
followed. Coestilen can be buried in concrete.
(sperficic details by request)
Smoothness and abrasion resistance,
thanks to the surface structure that prevents
deposits and incrustations from forming.
Resistance to chemical agents and to organic and
inorganic solvents. It is resistant to detergents and
acids used for unclogging sinks and WC.
Vibration-absorbent,
thanks to its flexibility and elasticity, it is able to
withstand small deformations without breaking
(for example, in the case of buildings settling).
Weld ability,
through a butt welding process or by arc melting.
Resistance to atmospheric agents,
due to the gas black it contains, which helps to
prevent the photo-oxygenation processes due to
the UV rays.

Page 2

2. Material properties
2.2 Characteristics
2.2 - 1 Physical Properties
Properties

Value

Unit of measure

Testing methods

density

954

Kg/m3

ISO 1183 D

melt index 190 C/5Kg

0.5

g/10 Min.

ISO 1133 Cond. 18

gas black content

2.02.5

ASTM D 1603

traction resistance

>20

MPa

ISO/DIS 6259

ultimate elongation

>600

IISO/DIS 6259

expansion coefficient between 20 and


90C

0.18 mm/mC

ASTM D 696

Regression curves

Stress in N/mm2 (kg/cm2)

Diameters, Thickness and Volume

Hours
Duration Time
test under progress
actual testing period

Page 3

mm

cm2

External

Internal

Thickness

Volume per
meter

32

26

5.3

40

34

50

44

15.2

56

50

19.2

63

57

25.4

75

69

37.3

90

83

3,5

54.1

110

101,4

4,3

80.7

125

115,2

4,9

104.2

160

147,6

6,2

171.1

200

187,6

6,2

276.4

250

234,4

7,8

431.5

315

295,4

9,8

685.3

2. Material properties
2.3 Chemical resistance
Due to the special material properties COESTILEN pipes and fitting and generally chemical resistant. To see a full list of
chemicals please view the following web page address:
www.borealisgroup.com/pdf/chemical-resistance/chemical-resistance-hdpe-ld.pdf
If you application has particular need please fill in the below Chemical Resistance Enquiry and forward it to COES.

2.3 -2 Chemical Resistance Enquiry

Enquiry for the chemical resistance of the COESTILEN system

COES Australia
Technical department
495 Tarrgindi Road
Salisbury 4107

PH: 3216 6842


Fax: 3216 6843
E-mail: info@coes.com.au

Installer:

Field of application

Company:

Fluid:

Contact:

Concentration:

Street:

Operating temperature:

City:

Working pressure:

PSI/
bar

Phone:

Service life:

h/d

Fax:
E-mail:

Ambient medium

Bulding project

Ambient Temperature:

Street:

Ambient Pressure:

PSI/
bar

City

Page 4

3. Design
3.1 Linear Expansion
Like all materials Coestilen is subject to expansion and contraction in direct relation to changes of temperature.
COESTILEN expanse due to an increase of temperature, which correspond to lengthening of the pipes.
COESTILEN contracts due to an decrease of temperature, which results in a shorting of the pipes.
The changes of length are directly proportional to the temperature differential and is expressed by the following relation:
(the 0.18 coefficient is rounded up to 0.2 for ease of calculation)

3.1 -1 Calculation
Symbols and Meanings
Symbol

Meaning

Measuring
unit

Linear Expansion

mm

Expansion coefficient Coestilen

mm/mC

Pipe Length

t1

Design Temperature

t2

Maximum Temperature

t3

Minimum Temperature

t1

Temperature Difference
t = t2 - t1

t2

Temperature Difference
t = t1 - t3

Linear Expansion formula


L = Pipe Length x Temperature Difference x
Expansion Coefficient

L = L x t x

3.1 - 2 Linear Thermal Expansion Table


Linear Thermal Expansion (mm)

Pipe Length (m)

Temperature Variation t in C
5

10

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

10

11

12

13

14

15

16

17

18

10

12

14

16

18

20

22

24

26

28

30

32

34

36

12

15

18

21

24

27

30

33

36

39

42

45

48

51

54

12

16

20

24

28

32

36

40

44

48

52

56

60

64

68

72

10

15

20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

12

18

24

30

36

42

48

54

60

66

72

78

84

90

96

102 108

14

21

28

35

42

49

56

63

70

77

84

91

98

105 112 119 126

16

24

32

40

48

56

64

72

80

88

96

104 112 120 128 136 144

18

27

36

45

54

63

72

81

90

99

108 117 126 135 144 153 162

10

10

20

30

40

50

60

70

80

90

100 110 120 130 140 150 160 170 180


110 121 132 143 154 165 176 187 198

11

11

22

33

44

55

66

77

88

99

12

12

24

36

48

60

72

84

96

108 120 132 144 156 168 180 192 204 216

13

13

26

39

52

65

78

91

104 117 130 143 156 169 182 195 208 221 234

14

14

28

42

56

70

84

98

112 126 140 154 168 182 196 210 224 238 252

15

15

30

45

60

75

90

105 120 135 150 165 180 195 210 225 240 255 270

16

16

32

48

64

80

96

112 128 144 160 176 192 208 224 240 256 272 288

17

17

34

51

68

85

102 119 136 153 170 187 204 221 238 255 272 289 306

18

18

36

54

72

90

108 126 144 162 180 198 216 234 252 270 288 306 324
114 133 152 171 190 209 228 247 266 285 304 323 342

19

19

38

57

76

95

20

20

40

60

80

100 120 140 160 180 200 220 240 260 280 300 320 340 360

21

21

42

63

84

105 126 147 168 189 210 231 252 273 294 315 336 357 378

22

22

44

66

88

110 132 154 176 198 220 242 264 286 308 330 352 374 396

23

23

46

69

92

115 138 161 184 207 230 253 276 299 322 345 368 391 414

24

24

48

72

96

120 144 168 192 216 240 264 288 312 336 360 384 408 432

25

25

50

75

100 125 150 175 200 225 250 275 300 325 350 375 400 425 450
Page 5

3. Design
3.1 Linear Expansion/Contraction Example
Fixed Point

Expansion Direction
Sliding Point

Sliding Point

Length of pipe (L)

The Linear expansion formula for COESTILEN can be more simply explained with the following example.
Expansion:
A installation with 10 meter length of pipe, with a
working maximum temperature of 80C, and a design
temperature of 20C

Contraction:
A installation with 10 meter length of pipe, with a
minimum working temperature of 5C, and a design
temperature of 20C

3.1 -3 Example - Expansion


Given and required values
Symbol

Meaning

Value

Measuring
unit

Linear Expansion

mm

Expansion coefficient Coestilen

Pipe Length

10

mm/mC

t1

Design Temperature

20

t2

Maximum Temperature

80

t1

Temperature Difference
t = t2 - t1

60

Step 1 Since our 10 meter pipe will be running hot discharge, we will need
to calculate the Linear Expansion
L = L x t1 x
L = 10m x 60 C x 0.2
L = 120mm

3.1 - 4 Example - Contraction


Given and required values
Symbol

Measuring
unit

Meaning

Value

Linear Expansion

Expansion coefficient Coestilen

Pipe Length

10

t1

Design Temperature

20

t3

Minimum Temperature

t2

Temperature Difference
t = t1 - t3

15

mm
mm/mC

Step 1 Since our 10 meter pipe will be running cold discharge, we will need
to calculate the Linear Contraction.
L = L x t1 x
L = 10m x 15 C x 0.2
L = 30mm
Page 6

3. Design
3.2 Linear expansion compensation by change of direction
In order to prevent the pipes from being subjected to mechanical stresses (axial thrusts), they have to be able to change their
length freely.
This can be obtained by using systems that use the elasticity and flexure of several stretches of pipe direction changes.
Keeping this in mind the change of length is compensated by the elastic deformation to which several stretches of pipes
making up the system may be subjected.
This proves to be particularly advantageous when the geometric configuration of the system allows the elasticity of the
material to be used to full advantage by suitable positioning of the fixed points.

3.2 - 1 Calculation
Symbols and Meanings
Change of direction formula.

Symbol

Meaning

Measuring unit

Ls

Length of the arm

mm

Ls = K x d x L

Extermal diameter of
pipe

mm

Linear expansion

mm

Ls = Material Constant x Square Root of


(External Diameter of pipe x Liner Expansion)

Material constant PP

3.2 - 2 Change of direction table


Calculation of Arm Length Ls (mm)

Linear Thermal expansion L (mm)

Pipe OD
40

50

56

63

75

90

110

125

160

200

250

315

10

200

224

237

251

274

300

332

354

400

447

500

561

20

283

316

335

355

387

424

469

500

566

632

707

794

30

346

387

410

435

474

520

574

612

693

775

866

972

40

400

447

473

502

548

600

663

707

800

894

1000

1122

50

447

500

529

561

612

671

742

791

894

1000

1118

1255

60

490

548

580

615

671

735

812

866

980

1095

1225

1375

70

529

592

626

664

725

794

877

935

1058

1183

1323

1485

80

566

632

669

710

775

849

938

1000

1131

1265

1414

1587

90

600

671

710

753

822

900

995

1061

1200

1342

1500

1684

100

632

707

748

794

866

949

1049

1118

1265

1414

1581

1775

110

663

742

785

832

908

995

1100

1173

1327

1483

1658

1861

120

693

775

820

869

949

1039

1149

1225

1386

1549

1732

1944

130

721

806

853

905

987

1082

1196

1275

1442

1612

1803

2024

140

748

837

885

939

1025

1122

1241

1323

1497

1673

1871

2100

150

775

866

917

972

1061

1162

1285

1369

1549

1732

1936

2174

160

800

894

947

1004

1095

1200

1327

1414

1600

1789

2000

2245

170

825

922

976

1035

1129

1237

1367

1458

1649

1844

2062

2314

180

849

949

1004

1065

1162

1273

1407

1500

1697

1897

2121

2381

190

872

975

1032

1094

1194

1308

1446

1541

1744

1949

2179

2446

200

894

1000

1058

1122

1225

1342

1483

1581

1789

2000

2236

2510

250

1000

1118

1183

1255

1369

1500

1658

1768

2000

2236

2500

2806

Page 7

3. Design
3.2 Linear expansion compensation by change of direction - Example
Fixed Point

Expansion Direction

Ls2 = 389.19 mm

L = 13.77
L = 120

Length of pipe (L)

Expansion Direction

Sliding Point

Pipe A

Ls1 = 1148.91mm

Pipe B

Fixed Point

3.2 - 3 Example
Given and required values
Symbol

Meaning

Value

Measuring
unit

Linear Expansion

mm

Expansion coefficient Coestilen

0.2

mm/mC

Pipe Length

10

t1

Design Temperature

20

t2

Maximum Temperature

80

t1

Temperature Difference
t = t2 -t1

60

Step 1 Since our 10 meter pipe will be running hot


discharge, we will need to calculate the Linear
Expansion
L = L x t1 x
L = 10m x 60 C x 0.2
L = 120mm
Step 2 Knowing that Pipe A will expand by 120mm
we can now work out the length of the arm
(The minimum distance of the first sliding
point)
Ls1 = K x d x L
Ls1 = 10 x 110 x 120
Ls1 = 1148.91 mm

Given and required values


Symbol

Meaning

Ls1
Value

Ls2 Measuring
Value
unit

Ls

Length of the arm

1148

389

mm

External diameter of pipe

110

110

mm

Linear expansion

120

13.7

mm

Material constant PE

10

10

To compensate the expansion of Pipe A the


minimum distance for the sliding point on Pipe
B is 1148.91 mm from the bend

Step 3 The Linear expansion and length of arm will


need to be calculated on Pipe B
L = 1.148m x 60 C x 0.2
L = 13.77
Ls2 = 10 x 110 x 13.77
Ls2 = 389.19 mm
To compensate the expansion of Pipe B the
minimum distance for the sliding point on Pipe
A is 389.19 mm from the bend

Page 8

3. Design
3.3 Linear expansion compensation by Expansion Sleeve
An Expansion Sleeve is a device in which the free end of a pipe
can slide in order to compensate its change of length.
For all diameters from 40mm to 315mm

Expansion

The expansion sleeve is used in:


vertical columns
horizontal backbones/manifolds
Between anchor brackets
Rigid joints
- Where Excessive movement is anticipated

Expansion
Direction
20C
0C Pipe Installation Temperature

3.3 - 1 Calculation
Linear Expansion formula
L = Pipe Length x Temperature Difference x
Expansion Coefficient

L = L x t x

3.3 - 2 Expansion sleeve compensation table

Pipe Length (m)

Maximum Linear expansion compensation by Sleeve Size, Pipe Length and Temperature Variation
Linear Thermal Expansion (mm)
legend
Temperature Variation t in C
5 10 15 20

25

30

35

40

45

50

55

60

65

70

75

80

85

90

40mm to 160mm

10

11

12

13

14

15

16

17

18

200mm to 250mm

10

12

14

16

18

20

22

24

26

28

30

32

34

36

315mm

12

15

18

21

24

27

30

33

36

39

42

45

48

51

54

8 12 16

20

24

28

32

36

40

44

48

52

56

60

64

68

72

85

90

5 10 15 20

25

30

35

40

45

50

55

60

65

70

75

80

6 12 18 24

30

36

42

48

54

60

66

72

78

84

90

96 102 108

7 14 21 28

35

42

49

56

63

70

77

84

91

98 105 112 119 126

8 16 24 32

40

48

56

64

72

80

88

96 104 112 120 128

9 18 27 36

45

54

63

72

81

90

99 108 117 126

10 10 20 30 40

50

60

70

80

90 100 110 120 130

11 11 22 33 44

55

66

77

88

99 110 121

12 12 24 36 48

60

72

84

96 108 120

13 13 26 39 52

65

78

91 104 117 130

14 14 28 42 56

70

84

98 112 126

15 15 30 45 60

75

90 105 120

16 16 32 48 64

80

96 112 128

17 17 34 51 68

85 102 119

18 18 36 54 72
19 19 38 57 76

Installation Depth Indicator (mm)


Socket
Depth

0C

20C

Max L

MD0400

160

80

105

80

90 108 126

MD0500

160

80

105

80

95 114

MD5600

160

80

105

80

20 20 40 60 80 100 120

MD0600

160

80

105

80

21 21 42 63 84 105 126

MD0700

160

80

105

80

22 22 44 66 88 110

MD0900

160

80

105

80

23 23 46 69 92 115

MD1100

160

80

105

80

24 24 48 72 96 120

MD1200

160

80

105

80

25 25 50 75 100 125

MD1600

160

80

105

80

26 26 52 78 104 130

MD2000

240

120

145

120

27 27 54 81 108

MD2500

240

120

145

120

28 28 56 84 112

MD3100

260

130

155

130

29 29 58 87 116

Code

Page 9

3. Design
3.3 Linear expansion compensation by Expansion Sleeve - Example
The Linear compensation expansion by expansion sleeve for COESTILEN can be more simply explained with the following
example.
Expansion:
A installation with 10 meter length of 110mm pipe, with a working maximum temperature of 80C, and a design temperature
of 20C
Fixed Point

L 0C

Fixed Point

Sliding Point

Sliding Point

Length of pipe (L)


A Fixed point must be always be located behind the expansion socket to avoid any movement of the socket in the event of expansion

3.3 - 3 Example
Symbol

Meaning

Value

Measuring
unit

Linear Expansion

mm

Expansion coefficient Coestilen

0.2

mm/mC

Pipe Length

10

t1

Design Temperature

20

t2

Maximum Temperature

80

t1

Temperature Difference
t = t2 -t1

60

Step 1 Since our 10 meter pipe will be running hot


discharge, we will need to calculate the Linear
Expansion
L = L x t1 x
L = 10m x 60 C x 0.2
L = 120mm

Using the table on page 9. The Maximum L that can be compensated with a 110mm Expansion Sleeve is 80mm.
Due to this we will split the run in two and use two Expansion Sleeves to compensate the linear Expansion.

L = 60mm

L = 60mm

5 meters

5 meters

3.3 - 4 Installation
Step 1

Chamfer the pipe end.

Step 2

Mark the correct insertion depth on the pipe


(witness mark), based on installation temperature.

Step 3

Lubricated the pipe end with suitable lubricating


material.
Do not use oil or grease which can damage the
rubber seal.

Step 4

Insert chamfered pipe into expansion sleeve up to


the witness mark.

20C
0C

Page 10

3. Design
3.4 Fixed points

3.4 - 1 Introduction

Fixed points and their execution :


Use of the devices described presumes that the changes of pipe length occur in a way compliant with what is envisaged
during the design stage. It is necessary that you rigidly restrain the ends of the stretches of pipes where you want to
compensate the change of length. This will foster movements in the direction of the foreseen compensation devices.

Compensation Device

Expansion direction

Fixed Point

3.4 - 2 Expansion Sleeve Fixed Points


Coupling flow resistance values

OD

Thrust (N).

Kg

50/63

200

20

75

300

30

90

400

40

110

500

50

125

600

60

160

800

80

200

1100

110

250

1500

150

315

2000

200

The Distance L and thrust force N must be taken in


account, when selecting the diameter of the rod (b) and the
distance between the anchor point and the pipe collar
Thrusts
The stresses the fixed points are subjected to are:
P = thrust exercised by the pipe
p = weight of the pipe and the liquid it contains
In the case of expansion sleeves, the thrust value is the
resistance offered by the sleeve to the flow of the pipe in its
housing.

3.4 - 3 Expansion Joints Fixed Points


Thrusts
The stresses the fixed points are subjected to are:
P = thrust exercised by the pipe
p = weight of the pipe and the liquid it contains

In the case of expansion joints, it is the resistance


offered by the stretch of pipe subjected to elastic
deformation and can be found form relations of this
type:

P = n x L x Ej/H3
Page 11

Expansion direction

The restraints are the fixed points of the system.


Their selection and arrangement must take into account some construction features of the system. Be aware of the probable
existence of structural conditions such as branches and crossing through structures, etc., which may themselves constitute a
fixed point.
Fixed Point

3. Design
3.5 Sliding points
Fixed points must divide the pipe into streches in which contraction or expansion is possible. However without ever
releasing the expansion force on the clips or fittings. Sliding points are used to guide streches of pipe between compansation
devices. The distance between the sliding points, primarily depends if the installation is Horizontal or Vertical.

Fixed Point
Fixed Point

Sliding Point

Sliding Point
Expansion Direction

10 x Pipe OD

10 x Pipe OD

10 x Pipe OD

10 x Pipe OD

Expansion Direction
Fixed Point

Sliding Point

10 x Pipe OD

10 x Pipe OD

Expansion Direction
Sliding Point

Fixed Point

Fixed Point

Sliding Point
Expansion Direction
Fixed Point

Maximum Spacing of Brackets (mm)


Code

Horizontal

Vertical

TS040B

400

600

TS050B

500

750

TS056B

560

840

TS063B

630

945

TS075B

750

1125

TS090B

900

1350

TS110B

1100

1650

TS125B

1250

1875

TS160B

1600

2400

TS200B

2000

3000

TS250B

2500

3750

TS315B

3150

4725

Sliding Point

15 x Pipe OD

Sliding Point

15 x Pipe OD

Fixed Point

Page 12

3. Design
3.6 Connection Guide
3.6 - 1 HDPE to DWV

Size
40
50
65
80
100
150
225
300

DWV
ID
39
51.6
53.6
76.2
104
151.6
236.8
298.2

Insert Coupling

OD
43
56
59
82
110
160
250
315

Size
50
56
75
90
110
160
250
315

To HDPE
ID
44
50
69
83
101.4
147.6
234.4
295.4

GA Rubber

OD
50
56
75
90
110
160
250
315

Fitting

Rubber

MI0500 GA0500
MI5600
MI0600 GA0700
MI0900 GA0900
MI1100
MI1600
MD2500
MD3100
-

DWV Pipe

If needed

Water flow

3.6 - 2 HDPE to Copper

Size
40
50
65
80
90
100

Copper
ID
34.9
47.6
60.3
72.2
84.9
97.6

Insert Coupling

OD
38.1
50.8
63.5
76.2
88.9
101.6
GA Rubber
If needed

Size
50
56
63
75
90
110

To HDPE
ID
44
50
57
69
83
101.4

OD
50
56
63
75
90
110

Fitting

MI0500 GA0500
MI0500
MI0600
MI0700?
MI0900 GA0900
MI1100 GA1100

Copper Pipe

Water flow

Page 13

Rubber

3. Design
3.6 Connection Guide

Water flow

3.6 - 3 In pipe Connection

or

DWV

or

Copper

SPRD1105
Rubber

From
HDPE
110
-

SPRD1156
Rubber

From
HDPE
110
-

HDPE

GA Rubber
If needed

SPRD1106
Rubber

SPRD

110mm HDPE Pipe

SPRD1107
Rubber

To
HDPE
50
-

HDPE
56
-

From
HDPE
110
-

From
HDPE
110
-

DWV
40
GA0500

Copper
40
GA0500

To
DWV

50
-

40
GA5600

50
-

Copper
50
GA5600

HDPE
63
-

To
DWV
-

Copper
65
-

HDPE
75
-

To
DWV
65
GA0700

Copper
65
GA0700

Water flow

3.6 - 4 HDPE Slab Repair

Code

HDPE Pipe

MP0500
MP5600
MP0700
MP0900
MP1100

Electro Fusion
Coupling

MP Coupling

HDPE Pipe

Page 14

From
To
HDPE
mm
mm
50
50
56
56
75
75
90
90
110
110

3. Design
3.6 Connection Guide
3.6 - 5 HDPE to Thread
Code
SP/MI50
SP/MI56
SP/MI75
SP/MI90
SP/MI110

From
HDPE
mm
50
56
75
90
110

To
Thread
Inch
mm
1
40
2
50
2
63
3
75
4
100

Code
SP/FI50
SP/FI56
SP/FI75
SP/FI90
SP/FI110

From
HDPE
mm
50
56
75
90
110

To
Thread
Inch
mm
1
40
2
50
2
63
3
75
4
100

Water flow

Code
PMG0501
PMG0502

To
HDPE
56
56

From
Copper
40

32
50

DWV

HDPE

40

40

Copper Pipe

PMG Rubber

HDPE Pipe

3.6 - 7 E Ware adaptors

Code
SP/EW110
SP/EW160

From
HDPE
110
160

To
E/ware
110
160

Rubber ring not included

Page 15

Water flow

3.6 - 6 Push in Rubber adaptors

4. Electro Fusion Welding


4.1 Introduction

4.1 - 1 General

The Electro Fusion machine works on a simple principle.


An adequately sized electric resistance is built into the body of the sleeve coupling which can connect the fitting to
the electro fusion machine by means of terminal pins.
To perform the weld it is only necessary to connect the terminal pins to the machine and press the Start button.
The current flowing through the resistance (coupling) will develop enough heat to create an excellent fusion
between the sleeve and the pipe.

4.2 - 2 Welding Machines/Tools


The following machines and tools are used to Electro-fuse COESTILEN pipe/fittings

AT131S
40 to 160mm

UT1103
40 to 315mm

UT1172 - UT1173
Leads for UT1103
AT1420
Pipe Marker

AT1431
Pipe Scraper

AT1700
Alcohol Wipes

AT1500
32 - 110mm
Pipe Cutter

AT1430
Trim Knife
Page 16

AT1600
Pipe bevelling tool

4. Electro Fusion Welding


4.2 Preparation
4.2 - 1 Welders Technical Features

AT131S electro fusion machine is suitable for


welding COES electrical couplers in Polyethylene
(PE) from 50 to 160mm
The AT131S welding machines structure is
lightweight, so it is extremely easy to carry
around. It is distinguished by the automatic
setting of the welding parameters, by the selfcompensation of the current supplied (according
to the ambient temperature) and by the selfdiagnosis, in the event of any malfunction that
could occur before or during welding.
The machine features cables with pins, a
transport bag and a manual scraper, most
useful to remove the layer of oxidation from the
pipe (which could undermine the good result of
the welding).

UT1103 electro fusion machine is suitable for


welding COES electrical couplers in HDPE from
50 mm to 315 mm and PPR couplings from 20
mm to 63 mm in PN 25.
The UT1103 is made in compliance with the
current safety standards and Directives. This
welding machines structure is lightweight, so it
is extremely easy to carry around. It is controlled
by a microprocessor that allows the recognition of
three different types of cable with pins, identified
by a code (written on each one of them), which
the operator can confirm by looking at the display.
The main features include self-compensation of
the current supplied (according to the ambient
temperature) and self-diagnosis of any malfunction
that could occur before or during welding.
The machine features a transport bag and a manual
scraper, most useful to remove the layer of oxidation
from the pipe (which could undermine the good
result of the welding).
Not supplied with Leads

4.2 - 2 Fittings / Welders

Item Code
ME0500
ME5600
ME0600
ME0700
ME0900
ME1100
ME1200
ME1600
ME2005
ME2505
ME3105

Pipe Size
Socket
Witness
(mm)
Width (mm) Mark (mm)
50
56
63
75
90
110
125
160
200
250
315

61
61
61
61
61
61
61
61
160
160
160

30
30
30
30
30
30
30
30
79
79
79

Page 17

1. Only use original COESTILEN welding devices


and COESTILEN welding tools.
2. It is essential to comply carefully with the laws
in force regarding safety in the workplace and the
protection of workers health.
3. If the power is supplied by generator sets, we
strongly recommend using a SignWave/Inverter
generator with suitable head room (eg :5 KVA).
4. Power socket subjected to a high sensitivity
differential switch (I = 30mA)
5. Rated power supply voltage = 240V
6. Extension cables. These should be suitable for
the power absorbed by the machine. (Please see
instruction manual of the welding device is use)
7. Machine cables. These should be in good
condition, with no cuts or scratches, and should
not be exposed to chemical agents, the movement
of vehicles over them or mechanical stress.

4. Electro Fusion Welding


4.3 Electro Fusion Welding Procedure

Step 1
Cut Square to centre
line of pipe.
Concentric, i.e., not
oval.

Step 2
Scrape external pipe ends
for a distance approx. 2/3
of the socket length (refer
to E/F socket depth), to
ensure removal of thin
oxidized outer layer, using
an appropriate tool. Pipe
surface should appear
duller in the scraped area.

Step 5
Referring to Socket
depth table, mark
witness mark on pipe

Step 6
Check to make sure
that coupling has not
been damaged.

Step 9
Press the Start
button on the front of
the welder.

Step 10
The welding process
is now automatic and
once complete will be
signalled by the control
box with a visible light

Step 3
Remove burr from
end of pipe

4.3 - 1 AT131S

Step 4
Clean external
surfaces of pipe ends
with alcohol wipes

Step 7
Clean internal surface of E/F
coupling with recommended
cleaner

Step 8
Attach cables from
E/F AT131S to the
socket terminals.

Step 11
A successful weld
is determined
when the indicator
points on the
socket, adjacent to
the terminals, are
clearly visible near
the surface

Step 12
Once the weld
cycle has
commenced, under
no circumstances,
should the electrofusion coupling be
re-used in the event
of a faulty weld.

Disconnect leads from the socket and allow complete cooling before connecting to hydraulic services.
Page 18

5. Butt Welding
5.1 Introduction

5.1 - 1 General

The principal characteristic of COESTILEN and all thermoplastics in general is the possibility to make a
molecular bond by means of butt welding.
Butt welding is the process of heating two components and clamping them together so as to get one single,
structurally continuous piece after solidification.

5.1 - 2 Butt Welding Machines / Tools

AT131S
40 to 160mm

AT1050
90 to 315mm

AT1210
90 to 315mm

AT1430
Trim Knife

AT1420
Pipe Marker

AT1500
32 - 110mm
Pipe Cutter
Page 19

AT1700
Alcohol Wipes

AT1600
Pipe bevelling tool

5. Butt Welding
5. 2 Preparation
5.2 - 1 Welders Technical Features

AT103S manually operated butt welding machine


suitable for PE pipes and fittings.
The machine is comprised of two carriages mounted
on roller bearings, one fixed and the other moveable
on chrome plated slide bars.
As well as moving the trolley, the operating lever
acts on a calibrated scale in order to apply the correct
welding pressure for the PE pipe to be welded.
Electric mill cutter with micro switch control on the
handle
PTFE coated heating mirror
Both mill and heating plate run along a slide bar
Reducing rings for clamps d. 40, 50, 56, 63, 75, 90,
110, 125,mm
Right and left clamps d. 160mm

AT1050 A professional welding machine ideal for


medium sized pipes and sewers up to 315 mm. It
consists of a machine body with pressure regulating
device, a pair of clamps, two lateral supports, an
electrically controlled milling cutter for leveling the
ends of the pipe and/or fitting with a safety micro
switch, an extractable heating plate with automatic
electronic device to control the temperature, a sliding
support, a tip-up metal frame on wheels that acts as
a work bench and protection when transporting the
machine. (Supplied with 200, 250 Inserts and Guides.
Right and left clamps 314mm)

Manual welder featuring a Aluminum


heating plate coated with Teflon and a
practical, heat insulated plastic handle.
Temperature controlled with a fixed
mechanical thermostat.

Page 20

5. Butt Welding
5.2 - 2 Welding Machines/Tools

5.2 Preparation

Only use original COESTILEN welding devices and COESTILEN welding tools.
All welding devices and tools must be free from impurities.
a. Teflon coating on Heatplate has not been damaged.
b. Heat-plate are clean before assembling. (If necessary clean the welding tools with a non
fibrous, coarse tissue and with methylated spirit)
(Burnt particles may lead to an incorrect fusion)
c. Welding machine complies with local regulations.
d. The power supply must coincide with the data on the type plate of the welding device.
e. Extension cables must be selected according to the power input of the welding devices.
Operating temperature of COESTILEN welding devices is at 210C 5.
Correct size insert rings and supports are installed in the jaws.

1.
2.

3.
4.

5.2 - 3 Pipe/Fittings
1.

Pipe
a.
b.
c.
d.

2.

Fittings
a. Clean of any dirt/dust (The use of an alcohol based agent is recommended)
b. Fitting not damaged

Pipe is cut at right angles to the pipe axis.


Pipe axis is free from burrs or cutting debris.
Clean of any dirt/dust (The use of an alcohol based agent is recommended)
Pipe has not been damaged in transit.

5.2 - 4 Heating Time Table

Pipe Dia
(mm)

B
Bead Height
(mm)

T1
Heating Time
(sec)

50
56
63
75
90
110
125
160
200
250
315

0.7
0.7
0.8
0.8
0.9
0.9
1
1.1
1
1.5
1.5

24
24
30
35
42
52
59
74
62
77
97

F1
T2
Heat/Weld Pressure Cooling Time
(kg)
(min)
4.6
4.6
7.5
10
15.5
21.5
28
45
45
88
140

Page 21

5
5
6
6
7
7
8
9
9
11
13

5. Butt Welding
5.3 Butt Welding Procedure
5.3 - 1 AT103S
Step 1. Place the Coestilen pipe and/or fitting in the right side clamp, ensuring correct alignment. Place Coestilen
pipe and/or fitting in left side clamp. When using cut pipe ensure ends are reasonably square and burr-free.

Step 2. Operate the hand lever and move the components together to check end-to-end alignment. If misaligned
loosen one clamp, rotate the component, say, 10 - 20, re-check alignment and then re-tighten the clamp. Retract
the components.

Step 3. Lower the planing tool between the 2 components and with the hand lever, move the carriage up to
the planing face, simultaneously switching on the planer. Maintaining pressure on the planing face with the
components, plane until a continuous ribbon of HDPE is produced from both sides of the planer. Before
switching off the planer retract the carriage with the hand lever.

Page 22

5. Butt Welding
5.3 Butt Welding Procedure
Step 4. Lift the planer from between the components and lower the heater plate into position. Operating the hand
lever move the carriage and bring the components in contact with the heater plate. Apply the heating pressure
(F1), using the pressure measurement gauge on the front face of the machine as a reference, until the required
bead height (B) is achieved.

Step 5. Release the pressure and with the components remaining in contact with the heater plate, allow the heat
soak time to elapse. (F1)

Step 6. At the end of heat soak operate the hand lever to retract the components and lift the heater plate from
position. Quickly reverse the direction of the carriage and bring the heated components together, applying the
applicable weld pressure (F1) and tighten the carriage lock nut. Refer welding chart below, for weld pressure.

Step 8. Allow the weld joint to cool (T2), then loosen the carriage lock nut and remove components from the
machine.

Page 23

6. Certicates

Certificate of Conformity
Level 2
SAI Global hereby grants to:

C.O.E.S Compagnia Edil Sanitaria S.p.A.


the WaterMark Licensee the right to use or arrange the use of the WATERMARK as shown above only in respect of the
goods described and detailed on the product listed identified on www.saiglobal.com which are produced by the WaterMark
Licensee or for the WaterMark Licensee by the manufacturer identified below and which comply with the appropriate
Standard referred to below as from time to time amended. The WaterMark Licence is granted subject to the rules governing
the use of the WATERMARK and the Terms and Conditions for certification. The WaterMark Licensee covenants to comply
with all the Rules and Terms and Conditions.

Evaluated to:
AS/NZS 4401:2006 - Plastics piping systems for soil and waste discharge (low and high
temperature) inside buildings - Polyethylene (PE)
Manufactured by:

COES SpA
Via Genova 13, PIOLTELLO MILANO, Italy
The WATERMARK is a registered certification trademark of Standards Australia Limited (A.C.N. 087 326 690) and is issued
under licence by SAI Global Certification Services Pty Limited (ACN 108 716 669) (SAI Global). This certificate remains
the property of SAI Global and must be returned to SAI Global upon its request. Refer to the Schedule for the list of product
models.
Certificate No.: WMKT21796
Certified Date: 27 May 2009
Issue Date: 29 May 2009
Expiry Date: 26 May 2012

Alex Ezrakhovich - General Manager Certification


For and on behalf of SAI Global

Authorised Local Signatory, SAI Global

SAI Global is Accredited by


the Joint Accreditation System
of Australia and New Zealand.
Acc No. Z1440295AS

To verify that this certificate is current please refer to the SAI Global StandardsMark website: http://StandardsMark.com

Certificate of Conformity
Level 2
SAI Global hereby grants to:

C.O.E.S Compagnia Edil Sanitaria S.p.A.


the WaterMark Licensee the right to use or arrange the use of the WATERMARK as shown above only in respect of the
goods described and detailed on the product listed identified on www.saiglobal.com which are produced by the WaterMark
Licensee or for the WaterMark Licensee by the manufacturer identified below and which comply with the appropriate
Standard referred to below as from time to time amended. The WaterMark Licence is granted subject to the rules governing
the use of the WATERMARK and the Terms and Conditions for certification. The WaterMark Licensee covenants to comply
with all the Rules and Terms and Conditions.

Evaluated to:
AS/NZS 5065:2005 - Polyethylene and polypropylene pipes and fittings for drainage and sewerage
applications
Manufactured by:

C.O.E.S Compagnia Edil Sanitaria S.P.A


Via Genova 13, PIOLTELLO MILANO, Italy
The WATERMARK is a registered certification trademark of Standards Australia Limited (A.C.N. 087 326 690) and is issued
under licence by SAI Global Certification Services Pty Limited (ACN 108 716 669) (SAI Global). This certificate remains
the property of SAI Global and must be returned to SAI Global upon its request. Refer to the Schedule for the list of product
models.
Certificate No.: WMKT00210
Certified Date: 1 December 2007
Issue Date: 17 February 2009
Expiry Date: 16 February 2012

Alex Ezrakhovich - General Manager Certification


For and on behalf of SAI Global

Authorised Local Signatory, SAI Global

SAI Global is Accredited by


the Joint Accreditation System
of Australia and New Zealand.
Acc No. Z1440295AS

To verify that this certificate is current please refer to the SAI Global StandardsMark website: http://StandardsMark.com

Page 24