FRÄNKISCHE AquaPipe system User manual

AquaPipe® system
Installation manual
Transport pipe
Drainage Systems
www.fraenkische.com

1 Incoming material inspection 3
2 Transport to the construction site 3
3 Unloading the lorry 3
4 Storage at the construction site 3
5 Transport to the pipe trench 4
6 Creating the trench 4
7 Installation 4
7.1 Bearing 4
7.2 Installation of pipes and shafts 5
7.2.1 Material inspection 5
7.2.2 Pipe installation 5
7.2.3 Shortening pipes 6
7.2.4 Shaft connections to
AquaTracControl 6
7.2.5 Embedding and backfilling of pipes
and shafts 6
7.2.6 Placing the extension pipe 7
7.2.7 Shortening and cutting the extension pipe 7
8 Placing shaft covers 7
9 Connections to concrete shafts and
wall lead-throughs 8
10 Flexible connections of pipes
to shafts 8
11 Installation of fittings 8
12 Installation of the retrofit
AquaDock connection 8
13 Lateral connections to concrete pipes
and concrete shafts 10
14 Bend radii and coupling connection 10
15 Technical advice –
local technical consultants 11
Table of Contents
General information on using our products and systems:
Information about or assessments of the use and installation of our products and systems is exclusively provided on the basis of the information submitted. We do not assume any liability for
damage caused by incomplete information. If the actual situation deviates from the planned situation or if a new situation occurs or if different or new installation techniques are applied, these
must be agreed upon with FRÄNKISCHE, since these situations or techniques may lead to different conclusions. Notwithstanding the above, the customer is solely responsible for verifying the
suitability of our products and systems for the intended purpose. In addition, we do not assume any liability or responsibility for system characteristics and system functionalities when third-party
products or accessories are used in combination with FRÄNKISCHE systems. We only assume liability if original FRÄNKISCHE products are used. For use in other countries than Germany,
country-specific standards and regulations must also be observed.
The recommendations are based on DINEN1610, DWA-A139 and DWA-A127.
They apply in addition to the following information.
All information provided in this publication is generally up to date at the time of printing. Moreover, this publication was prepared with the greatest possible care. However, we cannot rule out
printing errors or translation mistakes. Furthermore, we reserve the right to change products, specifications and other information, or changes may be necessary due to legal, material or other
technical requirements, which no longer could be considered for this publication. For this reason, we are unable to accept any liability if this is based solely on the information contained in this
publication. Instrumental in connection with information about products or services are always the purchase order, the concrete product purchased and the related documentation or the
information provided by our specialist staff in the specific case.
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Check pipes, pipe components, shafts,
shaft components and accessories upon
delivery to make sure they are labelled
suciently and comply with the require-
ments of the customer. Please observe
Generally transport pipes, pipe compo-
nents, shafts, shaft components and
accessories using appropriate vehicles;
Using excavator and crane:
Generally use hoisting slings (e.g., textile
slings). Do not use chains and ropes.
Avoid dropping, dumping as well as
hitting the pallets, pipes, shafts, shaft
components and accessories hard
against each other.
Using forklifts:
Place pallets on forks crossways; ensure
largest-possible spacing between the
forks.
Do not dump pallets with a jerk on hard
ground. Store the pallets on even ground
that is suciently hard to prevent pallets
and/or base battens from bogging
down.
Pipes and fittings can be stored outside;
the storage period outside should, how-
ever, not exceed one year.
In order to prevent excessive heating
of pipes during summer and damage
from UV exposure due to sustained
direct sunlight, we recommend that
the pipes should be stored in the shade
or covered with brightly coloured, light-
tight tarpaulin.
Observe the following in terms of
storage of pipes and shafts:
1. Store pipes in a way which guarantees
proper even bearing.
2. Do not stack loose pipes higher than
1m. Secure pipe stacks at the sides.
3. You may stack packeted pipe
pallets on top of each other.
Do not stack more than 2 pallets
on top of each other.
4. A maximum of 4 coils of pipe may be
stored on top of each other for Aqua-
Flex. If required, support laterally.
5. Store shafts on their base on even and
solid ground to prevent deformation of
the shafts.
1 Incoming material inspection
2 Transport to the construction site
3 Unloading the lorry
4 Storage at the construction site
the manufacturer’s specifications. Care-
fully examine all parts both upon deliv-
ery and right before installation to make
sure that they are free from damage.
Reject damaged components and note
this down on the delivery note.
load and unload under professional
supervision. Pipes should be largely sup-
ported during transport.
Attach hoisting slings in the middle
of the pallet spaced 3.5m apart. Help
controlling the pallets by hand. Do not
move pallets on the lorry using crowbars
or rods.
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Nominal width Shored trench and unshored
trench (ß > 60 degrees)
Unshored trench (ß <
60 degrees)
DN 150–DN 200 DO+ 0.40m DO+ 0.40m
DN 250–DN 350 DO+ 0.50m DO+ 0.40m
DN 400–DN 600 DO+ 0.70m DO+ 0.40m
DN 800 DO+ 0.85m DO+ 0.40m
7.1 Bearing
Thanks to their low weight, the transport
of individual pipes and accessories up to
a nominal diameter of DN 350 and/or of
shafts to the pipe trench does not
require any special lifting equipment.
Use suitable tools (e.g., wide textile
slings) in connection with lifting equip-
ment for larger nominal diameters. Lift-
ing equipment and fixtures must not
The provisions according to the regula-
tions regarding the installation of sewer
pipes (DINEN1610) apply regarding the
minimum trench width (depending on
nominal width and installation depth).
Please note that too narrow trenches
impede proper installation (compaction
of the embedding area). Trenches that
are too wide increase costs.
Create a small recess in the trench bot-
tom to ensure continuous pipe and shaft
bearing. A trench width of at least
1.30m is required in the shaft area to
allow professional embedding.
Generally adhere to the provisions of
DINEN1610 during installation. The
bedding and backfill materials specified
in the pipe stress calculations must be
installed and compacted to the specified
The bedding area must be level and
free of stones. Create and compact the
bearing with at least 10cm to 15cm
of stoneless, compactable material.
According to the specifications of
DINEN1610, use compactable material
such as soils of the categories G1
(non-cohesive soils – GE, GW, GI, SE,
SW, SI), G2 (slightly cohesive soils –
GU, GT, SU, ST) or G3 (cohesive mixed
soils – silty clay and gravel – GU, GT,
SU, ST). Embed the pipe on the sides
according to the specified bedding
angle. Create a small recess in the bot-
tom around the base area of the shaft
bottom (approx. 8cm) and backfill loose-
ly using backfill material (pipe bedding).
5 Transport to the pipe trench
6 Creating the trench
7 Installation
pose any risk of damaging pipe compo-
nents and/or shafts. Implicitly avoid
hooks, chains, cables or other tools
which could lead to edgy or jerky stress-
es and slip.
If transport is eected in pallets, the
specifications according to Section 3
"Unloading the lorry" apply. Trans-
porting individual pipes using chains
or ropes is forbidden.
standard. This is the only way to make
sure that the resulting deflection equals
the deflection determined through pipe
stress calculations and that the mini-
mum safety standards in the stress and
stability analysis are complied with. We
recommend using pipes with a length of
3m for gradient conditions smaller than
or equal to 0.8%.
Push the shaft with its base into this
bedding. Install the shaft analogously
to the pipe support. Make sure that the
trenches are free from water, e.g.,
stormwater, infiltration water, spring
water or water leaking from pipes, dur-
ing installation. The way of dewatering
must not influence the embedding area
and the pipe system. Take measures to
avoid washout of fines during dewater-
ing. Consider the influence of drainage
measures on groundwater movements
and the stability of the surroundings.
Suciently seal all construction site
drainage after finishing dewatering
measures.
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re 2.
re 3.
re 4.
re 6.
Nominal width Insertion area
marking
DN 150 110 mm
DN 200 148 mm
DN 250 170 mm
DN 300 193 mm
DN 350 170 mm
DN 400 201 mm
DN 500 255 mm
DN 600 270 mm
DN 800 370 mm
Marking table
7.2 Installation of pipes and shafts
Attention
Lubricated pipe ends must
not be placed on the bedding
(risk of embedding material
sticking to the pipe ends).
7.2.1 Material inspection
Before installation, check pipes, pipe
components, shafts, shaft components
and accessories for damage which
7.2.2 Pipe installation
Connect pipes using push-fit couplings.
For this purpose, pipes are delivered
including couplings and sealing rings.
1. Clean the insertion area of the pipe
and the insides of the couplings from
dirt using a rag or similar.
2. Insert the profile sealing rings contin-
uously and without overexpanding
individual spots into the second com-
plete corrugation trough at the spigot.
3. Use a marker to mark the insertion
area according to the marking table.
This is the only way to ensure the
installation of pipes without gaps
(see marking table).
4. Evenly apply a sucient amount
of lubricant to the profile sealing
ring and the inside of the coupling’s
insertion area. Do not use oils and
greases.
5. Right before installation, check
couplings and pipe end again for for-
eign objects and remove if necessary.
Please pay particular attention to
gravel, sand or crushed stones which
could have entered the coupling
during work at the pipe and/or
adheres to lubricated sections.
6. Insert pipes to the limit stop and/or
the marking. Protect the pipe section
using a square timber and distribute
installation forces equally during
installation.
7 Installation
might have occurred during transport
and/or storage. Damaged components
must not be installed.
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7.2.3 Shortening pipes
7.2.4 Shaft connections to AquaTracControl
7.2.5 Embedding and backfilling of pipes and shafts
The provisions of DIN EN 1610 and
DWA-A 139 generally apply. Carry out
backfilling according to design specifica-
tions. It includes side filling, covering
within the embedding area, and main
backfilling. Create the embedding of the
pipe in the embedding area with stone-
less, compactable material. Backfill the
bedding material evenly on both sides of
the pipe above the pipe crown in layers
of approx. 15cm, and compact using
light compaction equipment only or,
if required, even by hand. Further filling
(as of approx. 15cm above the pipe
crown) must be made in layers with con-
stant compaction of the filling material.
Mechanical compaction of main backfill-
ing with light to medium equipment
directly above the pipe should only be
performed starting from a minimum
Cut the pipes to length in the middle of
the corrugation trough and align upright
to the pipe axis using a fine-toothed saw
or other appropriate tools. Remove
edges and irregularities on the cutting
surfaces with a grater, file or another
suitable tool.
Proceed as follows:
1. Clean the insertion area of the pipe
and the insides of the shaft connec-
tions at AquaTracControl from dirt
using a rag or similar.
2. Insert the profile sealing ring continu-
ously and without overexpanding indi-
vidual spots into the first complete
corrugation trough of the AquaPipe
pipe at the spigot (when cutting pipes,
make sure that cuts are in the middle
of the corrugation trough and there is
no damage to the corrugation edge).
3. Evenly apply a sucient amount of
lubricant to the profile sealing ring
and the inside of the shaft connec-
tion. Do not use oils and greases.
4. Right before installation, check the
shaft connection and pipe ends
again for foreign objects and remove
if necessary. Please pay particular
attention to gravel, sand or crushed
stones which could have entered the
insertion area during work at the pipe
and shaft and/or stick to lubricated
sections.
5. Insert pipes to the limit stop. Protect
the pipe section using a square timber
and distribute installation forces
equally during installation.
Please observe the following
The use of heavy construction gear
and vehicles and storing excavated
material in the area over covered
pipes are not admissible unless
relevant load conditions have been
considered in the static calculation.
This holds true particularly for pipe
systems with low depths of cover.
7.2.6 Placing the extension pipe
The extension pipe must be inserted into
the upper area of the shaft base body.
For watertight systems, place the profile
7 Installation
thickness of 30cm above the pipe
crown. Use heavy compaction equip-
ment only starting from a depth of cover
of 1.0m above the pipe crown. Choose
compaction equipment, the number of
compaction runs and the thickness of
layers subject to compaction depending
on the material to be compacted and the
pipe system to be installed. To avoid
load concentration on the pipe, consist-
ent compaction throughout the entire
embedding area must be ensured. In
addition, the pipes must not come in
contact with compaction equipment.
Preferably secure the pipes from lateral
and vertical forces during installation.
Embed the shaft and compact the
bedding material analogously to the
pipe. Insert the extension pipe for this
process (see Section 7.2.6).
sealing ring into the first corrugation
trough of the extension pipe. Evenly
apply a sucient amount of lubricant to
the profile sealing ring and the inside
of the insertion area. Do not use oils
and greases. Afterwards, insert the
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6

AquaTrafficControl with cover for rolling-in in bituminous road surfaces
DOM sealing ring Concrete
support ring
acc. to DIN 4034
Compatible adapter ring
Stoneless,
non-cohesive
material
Extension pipe
DN500
625 mm
Top edge
of terrain
AquaTrafficControl with standard cover 625mm
DOM sealing ring Concrete
support ring
acc. to DIN 4034
Stoneless,
non-cohesive
material
Extension pipe
DN500
625 mm
Top edge
of terrain
Carrier layer
(according to requirements)
Carrier layer
(according to requirements)
7.2.7 Shortening and cutting the extension pipe
Cut the extension pipes to length in the
middle of the corrugation trough using
a fine-toothed saw or a pipe cutter.
Remove edges and irregularities on the
cutting surfaces with a grater, file or
Install standard shaft covers according
to DINEN124, CW610, installation
according to design specifications.
Alternatively, you can also use covers
for rolling-in in bituminous layers. Shaft
covers, concrete support ring, bucket
handle and bucket are not included in
FRÄNKISCHE's scope of delivery and
must be supplied on site. As soon as the
road superstructure is being prepared,
the bearing for the shaft covers must be
created. The shaft cover is integrated
into the road superstructure within the
road. The concrete support ring and the
carrier layer below transfer trac loads
into the soil. There must be no direct
load transfer between the support ring/
carrier layer and the extension pipe.
The bedding must be flat and without
stationary loads and must be compacted
according to the requirements.
The concrete support ring must be
placed centrally without aecting the
bearing. The shaft cover and/or,
Attention
You must not asphalt directly to the
pipe in the area of the bituminous
layers. Using standard equalisation
rings, you can locally adjust this area.
Please observe the following:
The height of the cover of support
ring and frame must be clarified in
connection with the use of a dirt trap.
The dirt trap should not rest directly
on the extension pipe.
7 Installation
8 Placing shaft covers
another suitable tool. Extension pipes
can also be extended using couplings
and sealing rings. For this purpose,
mount the sealing ring into the second
complete corrugation trough at the spig-
ot and install the coupling as described
in Section 7.2.2.
if required, more equalisation rings must
be placed on a 10-mm-thick mortar joint
to prevent stationary loads. If the cover
is outside the road, the bearing for the
cover must be prepared separately from
compactable material. When using sup-
port rings according to DIN4034 Part 1
(and compatible adapter rings for covers
that can be rolled-in) and when using the
DOM sealing ring, extension pipes can
be connected to the cover properly. The
DOM sealing ring must be mounted
onto the last corrugation of the exten-
sion pipe for this purpose. Make sure to
mount it continuously and without over-
expanding individual spots. Evenly apply
a sucient amount of lubricant to the
top of the DOM sealing ring and the
inside of the support rings. Subsequent-
ly, install the concrete support ring over
the DOM sealing ring; make sure that
the sealing lip centrally seals against the
concrete support ring.
7.2.6 Placing the extension pipe (continued)
extension pipe until it reaches the inside
stops of the insertion area only, not
beyond that. The remaining area below
the stops serves as a compensating
area. The extension pipe must be
aligned upright when backfilling. The
shafts can be seen better during the
construction period if the extension
pipes protrude from the planum.
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Only FRÄNKISCHE shaft lining must
be used for the connections of pipes to
shafts or wall lead-throughs.
1. Clean the insertion area of the shaft
lining before installation.
2. Apply a sucient amount of lubricant
to the complete insertion area of the
shaft lining.
3. Insert the profile sealing ring continu-
ously and without overexpanding
A design without joint pieces is possible
with a proper connection of pipes to
concrete shafts and/or AquaTrac-
Control. If, for planning reasons, a flexi-
ble connection is required project-specifi-
cally, this can be done easily on site
Since fittings feature couplings at both
ends, the same procedure applies to
their installation as to the installation
of pipes.
individual spots into the first com-
plete corrugation trough. (When cut-
ting pipes, make sure that cuts are in
the middle of the corrugation trough
and that there is no damage to the
corrugation edge.)
4. Apply a sucient amount of lubricant
to the entire profile sealing ring.
5. Insert the pipe evenly and centrically
into the shaft lining up to the limit
stop.
The AquaDock connection set allows
the watertight and reliable connection of
AquaFlex connection pipes DN 150 and
AquaPipe DN 150 to the AquaPipe
stormwater pipe DN 300, DN 350,
NB
Use the saddle for retrofit connec-
tions of AquaPipe/AquaFlex DN 200
to AquaPipe from DN300. Observe
the appropriate installation instruc-
tions included with each saddle
delivery.
9 Connections to concrete shafts and wall lead-throughs
10 Flexible connections of pipes to shafts
11 Installation of fittings
12 Installation of the retrofit AquaDock® connection
(DINEN1610; 8.7.4). The necessary
short pipes smaller than or equal to
1,000mm can be cut on site. Flexibility
is provided by the standard coupling and
the appropriate sealing rings.
Lubricants and sealing rings are also
required. Install sealing rings into the
second complete corrugation trough
at the spigot.
DN 400, DN 500, and DN 600.
Connections are equally possible for
new installations and existing pipe
systems. AquaDock connection sets are
delivered completely assembled and are
connected to the AquaPipe pipe
according to the following instructions.
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8

2
4
1
3
re 1.
re 3.
re 4.
re 5.
re 6.
NB
If the on-site conditions allow for it,
the hole should be cut outside the
excavation pit before installing the
pipe. The confined space in the trench
may otherwise compromise the quali-
ty of the hole and the tightness of
AquaDock.
1. Cutting a hole
Use an appropriate hole saw (Ø 178.5 ±
0.5mm) incl. pilot drill to cut a hole into
the main pipe. We recommend the hole
saw from our range of products. Make
sure that the drilling is carried out vertical-
ly in relation to the pipe axis.
Important: After drilling the pipe wall
has been completed, the drill must first
be switched o and brought to a com-
plete halt. Then remove the hole saw
from the opening. We recommend using
NB
We recommend using a knife and fine
abrasive paper for removing edges
and cuttings.
2. Removing edges and cuttings
Remove all edges and cuttings from the
hole. Use fine abrasive paper.
Important: Cuttings in the sealing area
may significantly influence tightness.
NB
The sealing ring must rest against the
saddle.
4. Inserting AquaDock
Insert the AquaDock connection set
into the hole such that the support ring
(saddle) rests evenly on the pipe outside
diameter (Fig.4).
5. Tightening screws
Use an installation wrench to initially
tighten the screws 1 and 2 by approx. 5
clockwise rotations (Fig. 5). Then, tight-
en screws 3 and 4 also by 5 clockwise
rotations. Repeat this initially only for 1
and 2 and then for 3 and 4 until the
screw heads rest against the lock ring.
3. Applying lubricant
Make sure that the AquaDock connec-
tion set is free from dirt. Apply a su-
cient amount of lubricant to the outside
of the pressing nozzle (Fig. 3). No lubri-
cant must be applied to the sealing ring.
6. Functional test
Reach through the opening of AquaDock
and check the position of the sealing.
Important: The sealing must rest
evenly snug inside the pipe wall.
12 Installation of the retrofit AquaDock® connection
our drill stand. This makes proper drilling
easy and safe.
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Concrete
cuff
85
70
50
DN
Hole
Do= outside diameter according to DIN 19534 and/or DIN 19537
D
o
Connection
sealing ring
Concrete pipe/concrete
shaft
AquaFlex/AquaPipe
DN 150/DN 200
AquaPipe and/or
AquaFlex
Required
hole diameter Cat. no.
DN 150 186 mm 57687155
DN 200 226 mm 57687205
DN 250 306 mm 57687255
DN 300 341 mm 57687305
DN 400 426 mm 57687405
DN 500 526 mm 57687505
The concrete connection set allows the
retrofit connection to concrete pipes and
concrete shafts. The set includes a con-
nection sealing, an EPDM sealing ring
and a cu.
1. Drilling into the concrete pipe and/or
shaft using a core drill to bore diameter
according to the table. (Drill bit availa-
ble via building material supplier).
2. Insert the connection sealing into
the drill hole without lubricant.
3. If required, cut the cu to the
connection pipe thickness and
taper properly.
4. Apply a sucient amount of lubricant
to the connection sealing ring and
cu end (especially the chamfer) (the
concrete cu has a sucient chamfer
so that no tapering is required).
5. Centrally align the concrete cu
and insert into the sealing.
6. Connection of the sewer pipes
using sealing ring and lubricant
(also observe Section 14).
13 Lateral connections to concrete pipes and concrete shafts
… when installing AquaFlex:
AquaFlex pipes must not fall below a
bend radius of 0.5m during installation.
It is crucial to observe a straight and cen-
tral insertion of the pipe ends when con-
necting with couplings (e.g., AquaDock,
road gully, etc.). Angles of more than
3 degrees are not permitted and may
14 Bend radii and coupling connection ...
lead to leaks. When embedding and
subsequently backfilling, make sure
that the pipe is not pulled out of the
coupling.
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10

Contact
International Sales Director
European Sales Director European Sales
International Sales Technology
Horst Dörr [phone]
[e-mail]
Stefan Weiß [phone]
[e-mail]
Andreas Lang [phone]
[e-mail]
Dinah Nigrowics [phone]
[e-mail]
Klaus Lichtscheidel [phone]
[e-mail]
Jennifer Gernert [phone]
[e-mail]
Julia Möller [phone]
[e-mail]
Carolin Rausch [phone]
[e-mail]
Viktoria Majewski [phone]
[e-mail]
Fax [phone]
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EN.1527/1.03.2020 | Subject to change without notice | 03/2020
FRÄNKISCHE Rohrwerke Gebr. Kirchner GmbH & Co. KG | Hellinger Str. 1 | 97486 Königsberg / Germany
Phone [phone] | Fax [phone] | [e-mail] | www.fraenkische.com