DVS Technical Codes On Plastics Joining Technologies

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201
ENGLISH EDITION
DVS Technical Codes

on Plastics Joining
Technologies
Welding processes and semi-finished products:

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DVS Technical Codes

on Plastics Joining
Technologies
Elaborated by Working Group W4

„Welding of Plastics“
of the Technical Committee of the
German Welding Society – DVS
Bibliographic information published by Die Deutsche Bibliothek

Die Deutsche Bibliothek lists this publication in the Deutsche Nationalbibliographie;
detailed bibliographic data are available in the Internet at htttp://dnb.ddb.de.
English Edition
Volume 3
ISBN: 978-3-945023-29-7
All rights reserved

 DVS Media GmbH, Düsseldorf ⋅ 4th Edition 2015
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II
Preface
This book contains more than 100 technical codes that deal with the joining of
plastics in the field of piping, containers and apparatus construction as well as
series fabrication. For this third edition, all technical codes that are available in
German have been translated into English. The technical codes were compiled
by working group W4 “Joining of plastics” of the technical committee of the
German Welding Society. The working group is concerned with welding,
adhesive bonding and mechanical joining of plastics. Its field of activity contains
the following topics:
● welding, adhesive bonding and mechanical joining processes

● testing and design calculation of joints and constructions
● practical application of joining processes
● training and examination of qualified personnel
The book is recommended for all those who are looking for practical information
about the various joining processes, required devices and application as well as
quality assurance and testing.
December 2014 Thomas Frank

Chairman of WG W4
„Joining of plastics“
III
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IV
DVS Technical Codes and Bulletins
DVS 1904-1 (2010-02) Adhesive bonding of plastics in domestic installation –
Requirements on plants and personnel ......................................... 1
DVS 1904-2 (2010-02) Adhesive bonding of plastics in domestic installation –
Pipes and fittings – Adhesive bonding operation –
Findings on adhesive-bonded joints .............................................. 2
DVS 2200-1 (2013-11) Joining of plastics – Code letters and abbreviations – Welding
Supplement 1 processes ...................................................................................... 5
DVS 2201-1 (1989-02) Testing of semi-finished products of thermoplastics –
Bases – indications ........................................................................ 9
DVS 2201-1 (2004-10) Testing of semi-finished products made of thermo-
Supplement 1 plastics; Basics – indications – Material and
abbreviation ................................................................................. 13
Supplement 2 plastics; Basics – indications – Directives for creep
rupture curves of pipes ................................................................ 14
Supplement 3 plastics; Basics – indications – Linear thermal expansion
coefficients ................................................................................... 15
Supplement 4 plastics; Basics – indications – Dimension stability of
semi-finished material after heating ............................................. 16
DVS 2201-1 (2006-10) Service life temperature time limits due to thermal
Supplement 5 Draft ageing .......................................................................................... 17
DVS 2201-2 (1985-07) Testing of semi-finished products of thermoplastics:
Weldability – Test methods – Requirements ............................... 18
DVS 2202 (2014-11) Evaluation of imperfections in joints of thermoplastic
Supplement 1 materials to piping parts and panels – heated plate
welding (HS, IR) .......................................................................... 21
DVS 2202 (2012-11) Assessment of defects in joints between thermo-
Supplement 2 plastics on piping parts and panels – Sleeve welding
with an incorporated heating element (HM) ................................. 26
DVS 2202 (2012-11) Assessment of defects in joints between thermo-
Supplement 3 plastics on piping parts and panels – Heated tool
sleeve welding (HD) .................................................................... 31
DVS 2202-1 (2006-07)* Imperfections in thermoplastic welding joints –
Features, descriptions, evaluation ............................................... 35
DVS 2203-1 (2003-01) Testing of welded joints of thermoplastic sheets and
pipes – Test methods – Requirements ........................................ 62
DVS 2203-1 (2010-08) Testing of welded joints between panels and pipes
Supplement 1 made of thermoplastics – Requirements in the tensile
test – Short-time tensile welding factor fz .................................... 64
Supplement 2 made of thermoplastics – Requirements in the tensile
creep test – Tensile creep welding factor fs ................................. 65
V
Supplement 3 made of thermoplastics – Requirements in the
technological bending test – Bending angle / bending
path ................................................................................................ 66
DVS 2203-1 (2008-11)* Testing of welded joints between panels and pipes
Supplement 4 made of thermoplastics – Requirements on shear and
peeling tests for sleeve welding with an incorporated
electric heating element (HM) and heated tool sleeve
welding (HD) on pipes and fittings .............................................. 77
made of thermoplastics – Tensile test ......................................... 80
Supplement 1 made of thermoplastics – Low-temperature tensile test .............. 83
made of thermoplastics – Tensile impact test ............................. 85
DVS 2203-4 (1997-07) Testing of welded joints of thermoplastics plates and
tubes – Tensile creep test ........................................................... 87
Supplement 1 pipes – Tensile creep test – Testing of socket joints ................... 91
Supplement 2 pipes – Tensile creep test – Testing of the resistance
to slow crack growth using the Full Notch Creep Test
(FNCT) ........................................................................................ 93
Supplement 3 Draft made of thermoplastics – Tensile creep-rupture test –
Checking of the demanded tensile creep-rupture
welding factor and of the minimum service life of
welded joints between polyethylenes (PE 80 and
PE 100) ....................................................................................... 95
DVS 2203-5 (1999-08) Testing of welded joints of thermoplastics plates and
tubes – Technological bend test ............................................... 104
DVS 2203-6 (2008-01)* Testing of joints between polymeric materials – Shear
and peeling tests ....................................................................... 107
DVS 2203-6 (2008-01)* Testing of joints between polymeric materials – Torsion
Supplement 1 shear and radial peeling tests for joints executed by
means of sleeve welding with an incorporated electric
heating element and heated tool sleeve welding ...................... 109
DVS 2203-6 (2008-01) Testing of joints between polymeric materials –
Supplement 2 Testing of adhesive-bonded joints in the shear and
peeling tests .............................................................................. 113
DVS 2204-1 (2011-01) Adhesive bonding of thermoplastics ......................................... 116
DVS 2204-4 (2011-12) Adhesive bonding of pipes and piping parts made of
thermoplastics – Polyvinyl chloride (PVC-U) ............................. 127
DVS 2204-5 (2013-03) Adhesive bonding of pipes and fittings made of thermo-
plastics – Chlorinated polyvinyl chloride (PVC-C) ..................... 132
DVS 2205-1 (2015-01) Berechnung von Behältern und Apparaten aus Thermo-
plasten – Kennwerte ................................................................. 137
DVS 2205-1 (2011-11) Calculation of tanks and apparatus made of thermo-
Supplement 1 plastics – Characteristic values of the polyethylene
material group ........................................................................... 142
VI
Supplement 2 plastics – values of the polypropylene material group ............... 154
Supplement 3 plastics – Characteristic values of the polyvinyl chloride
material group ........................................................................... 167
Supplement 4 plastics – Characteristic values of the fluoropolymer
material group ........................................................................... 175
Supplement 5 plastics – Reduction coefficients in the case of a media
influence .................................................................................... 194
Supplement 6 plastics – Welding factors ......................................................... 204
Supplement 7 plastics – Application examples ................................................ 205
Draft plasten – Stehende runde, drucklose Behälter ......................... 208
plastics – Vertical round, non-pressurised tanks ....................... 223
DVS 2205-2 (2003-11)* Calculation of tanks and apparatus made of thermo-
Supplement 1 plastics – Welded stationary tanks in the case of
installation in buildings .............................................................. 236
Supplement 2 Draft plasten – Stehende runde, drucklose Behälter –
Auffangvorrichtungen ................................................................ 244
Supplement 2 plastics – Vertical round non-pressurised tanks –
Collecting devices ..................................................................... 252
Supplement 3 Draft plasten – Stehende runde, drucklose Behälter –
Flachdächer .............................................................................. 260
Supplement 3 plastics – Vertical round, non-pressurised tanks –
Flat roofs ................................................................................... 264
Supplement 4 Draft plastics – Vertical round non-pressurised tanks –
Flat-bottomed tanks in earthquake regions ............................... 268
Flat-bottomed tanks in earthquake regions ............................... 277
Vertical-skirt tanks in earthquake regions ................................. 285
Vertical-skirt tanks in earthquake regions ................................. 292
VII
Supplement 6 Draft plastics – Vertical round, non-pressurised tanks –
Shell construction method ......................................................... 298
Shell construction method ......................................................... 301
Ring-supported conical bottom ................................................. 304
Ring-supported conical bottom ................................................. 311
Example of a ring-supported conical bottom ............................. 318
Example of a ring-supported conical bottom ............................. 321
Parallel-supported sloping base ................................................ 324
Parallel-supported sloping base ................................................ 331
Example of a parallel-supported sloping basen ........................ 338
Example of a parallel-supported sloping basen ........................ 341
DVS 2205-3 (1975-04) Design of thermoplastic tanks and apparatuses –
Welded joints ............................................................................. 344
DVS 2205-4 (1988-11) Calculation of thermoplastic tanks and apparatus –
Flanged joints ............................................................................ 354
Supplement Welded flanges, welded collars – Constructive details ............. 358
Rectangular Tanks .................................................................... 361
Supplement Rectangular tanks, structural details ......................................... 368
DVS 2206-1 (2011-09) Non-destructive tests on tanks, apparatus and piping
made of thermoplastics – Dimensional checking and
visual inspection ........................................................................ 373
DVS 2206-2 (2014-05) Zerstörungsfreie Prüfungen von drucklosen Behältern
Draft und Apparaten aus thermoplastischen Kunststoffen –
Dichtheitsprüfung ...................................................................... 376
VIII
DVS 2206-4 (2011-09) Non-destructive tests on tanks, apparatus and piping
made of thermoplastics – Testing with electrical high
voltage ....................................................................................... 378
DVS 2206-5 (2011-09) Non-destructive tests on piping made of thermo-
plastics – Angle measurement on welded joints
executed by means of sleeve welding with an
incorporated heating element (HM) and heated
tool sleeve welding (HD) ........................................................... 380
DVS 2207-1 (2014-07) Welding of thermoplastics – Heated element welding
Draft of pipes, piping parts and panels made out of
polyethylene .............................................................................. 382
DVS 2207-1 (2005-09)* Welding of thermoplastics – Heated tool welding
of pipes, pipeline components and sheets made
of PE-HD ................................................................................... 397
DVS 2207-1 (2005-12)* Welding of thermoplastics – Heated tool welding
Supplement 1 of pipes made of PE-Xa with pipeline components
made of PE-HD ......................................................................... 411
DVS 2207-1 (2013-08) Heated tool butt welding of pipes and piping parts with
Supplement 2 high wall thicknesses or diameters made of PE ........................ 416
DVS 2207-3 2013-03) Welding of thermoplastics – Hot-gas string-bead welding
Draft and hot-gas welding with the torch separate from the
filler rod of pipes, piping parts and panels – Methods,
requirements ............................................................................. 418
DVS 2207-3 (2005-04)* Welding of thermoplastics – Hot-gas string-bead
welding and hot-gas welding with torch separate
from filler rod of pipes, pipe components and sheets –
Methods, requirements ............................................................. 427
DVS 2207-3 (2013-03) Welding of thermoplastics – Hot gas string-bead and
Supplement 1 Draft fan welding of pipes piping parts and panels –
Welding parameters .................................................................. 436
DVS 2207-3 (2005-04) Welding of thermoplastics – Hot gas string-bead and
Supplement 1 fan welding of pipes, piping parts and panels –
Welding parameters .................................................................. 437
DVS 2207-3 (2013-03) Welding of thermoplastics – Hot-gas string-bead
Supplement 2 Draft welding and hot-gas welding with torch separate from
filler rod of pipes, pipe components and sheets –
Requirements for welding equipment and accessories ............. 438
DVS 2207-3 (2005-04)* Welding of thermoplastics – Hot-gas string-bead
Supplement 2 welding and hot-gas welding with torch separate from
filler rod of pipes, pipe components and sheets –
Requirements for welding equipment and accessories ............. 441
DVS 2207-3 (2013-03) Welding of thermoplastics – Hot gas string-bead
Supplement 3 Draft and fan welding of pipes, piping parts and panels –
Welding of fluoroplastics ........................................................... 443
DVS 2207-4 (2013-03) Welding of thermoplastics – Extrusion welding of pipes,
Draft piping parts and panels – Processes and requirements ............. 447
DVS 2207-4 (2005-04)* Welding of thermoplastics – Extrusion welding of
pipes, piping parts and panels – Processes and
requirements ............................................................................. 458
IX
Supplement 1 Draft piping parts and panels – Welding parameters ......................... 468
Supplement 1 piping parts and panels – Welding parameters ......................... 469
Supplement 2 Draft piping parts and panels – Requirements on the welding
machines and welding devices ................................................. 470
DVS 2207-4 (2005-04)* Welding of thermoplastics – Extrusion welding of
Supplement 2 pipes, piping parts and panels – Requirements on the
welding machines and welding devices .................................... 473
DVS 2207-5 (1993-02) Welding of thermoplastics – Welding of PE casing
pipes – Tubes and tubular components .................................... 476
DVS 2207-5 (1997-07) Welding of thermoplastics – Welding of PE casing
Supplement 1 pipes – Fittings and isolating valves .......................................... 498
DVS 2207-6 (2003-09) Welding of thermoplastics – Non-contact heated tool
butt welding of pipes, pipeline components and
sheets – Methods, equipment, parameters ............................... 504
DVS 2207-11 (2008-08)* Welding of thermoplastics – Heated tool welding of
pipes, piping parts and panels made of PP ............................... 512
pipes, piping parts and panels made of PVC-U ........................ 524
DVS 2207-13 (2012-11) Welding of thermoplastics – Heated tool welding of
pipes, piping parts and panels made of PVC-C ........................ 531
DVS 2207-14 (2009-04) Welding of thermoplastics – Welding by bending
using a heated tool for panels made of PP and PE .................. 538
pipes, piping parts and panels made of PVDF .......................... 543
DVS 2207-16 (2010-07) Welding of thermoplastics – Heated tool welding of
pipes and piping parts made of Polyamide 12 .......................... 553
DVS 2207-25 (1989-10) Welding of thermoplastic – Heated tool butt welding –
Welding of casement sections made from PVC-U .................... 561
DVS 2208-1 (2007-03)* Welding of thermoplastics – Machines and devices
for the heated tool welding of pipes, piping parts and
panels ........................................................................................ 568
DVS 2208-1 (2012-02) Welding of thermoplastics – Tools and devices for the
Supplement 1 heated tool welding of pipes and piping parts ........................... 582
DVS 2210-1 (1997-04) Industrial Pipelines Made of Thermoplastics – Planning
and Execution, Above-Ground Pipe Systems ........................... 584
DVS 2210-1 (2003-04) Industrial piping made of thermoplastics – Design and
Supplement 1 execution, Above-ground pipe systems – Calculation
example ..................................................................................... 618
DVS 2210-1 (2004-07) Industrial piping made of thermoplastics – Design
Supplement 2 and execution, Above-ground pipe systems –
Recommendations for the internal pressure and leak
tests ........................................................................................... 627
X
DVS 2210-1 (2006-05) Industrial piping made of thermoplastics – Design
Supplement 3 and execution, Above-ground pipe systems – Flanged
joints: Description, requirements and assembly ........................ 638
DVS 2210-2 (2007-10) Industrial piping made of thermoplastics – Design,
structure and installation of two-pipe systems .......................... 645
DVS 2210-3 (2014-11) Industrial pipelines made of thermoplastics – Planning
and installation – Underground pipe systems ........................... 671
DVS 2211 (2005-04)* Welding of thermoplastics – Welding fillers – Marking,
requirements and tests .............................................................. 687
DVS 2212-1 (2006-05)* Qualification testing of plastics welders – Qualification
Test Groups I and II – Hot gas welding with the torch
separate from the filler rod (WF), highspeed hot gas
welding (WZ), heated tool butt welding (HS), sleeve
welding with an incorporated electric heating element
(HM), heated tool sleeve welding (HD) and hot gas
extrusion welding (WE) ............................................................. 691
DVS 2212-1 (2006-05)* Qualification testing of plastics welders – Qualification
Supplement 1 Test Groups I and II – Planned monitoring of the
certified plastics welders according to DVS 2212-1 .................. 705
DVS 2212-3 (1994-10) Testing of plastics welders – Examination Group III –
Lining membranes in geotechnical and hydraulic
engineering ............................................................................... 707
DVS 2212-4 (2013-06) Qualification testing of plastics welders; welding of
PE casing pipes – Pipes and piping parts ................................. 723
DVS 2213 (2010-12) Specialist for plastics welding ................................................... 733
DVS 2213 (2010-12) Qualification testing regulations for the qualification
Supplement 1 test to become a specialist for plastics welding ........................ 735
DVS 2215-1 (2010-09) Heated tool welding of mouldings made of thermo-
plastics in series fabrication ...................................................... 737
DVS 2215-2 (1996-11) Hot plate welding of mouldings made of polyolefins
(PE, PP) in volume production .................................................. 748
DVS 2215-3 (1999-04) Hot plate welding of mouldings made from amorphous
thermoplastics in volume production ......................................... 760
DVS 2215-3 (1999-04) Hot plate welding of mouldings made from amorphous
Supplement 1 thermoplastics in volume production – Welding
parameters for amorphous thermoplastics and blends ............. 767
DVS 2216-1 (2007-04)* Ultrasonic welding of plastic series parts – Process
description, machines and devices, influencing
variables, design and quality assurance ................................... 774
DVS 2216-1 (2005-09)* DVS test specimens with an energy director for the
Supplement 1 ultrasonic welding of thermoplastics and testing
conditions .................................................................................. 798
DVS 2216-2 (2012-07) Guide to the project sequence for the joining of
thermoplastics in series fabrication ........................................... 801
DVS 2216-3 (1992-08) Ultrasonic joining of moulded parts and semi-finished
parts of thermoplastic polymers in mass production –
Forming with ultrasonic; staking, swaging and
tamping ..................................................................................... 807
XI
DVS 2216-4 (1992-08) Ultrasonic joining of moulded parts and semi-finished
parts of thermoplastic polymers in mass production –
Insertion of metal parts and other materials with
ultrasonic ................................................................................... 810
DVS 2216-5 (1996-08) Ultrasonic joining of moulded parts produced of
thermoplastic polymers in mass production,
manufacture of horns ................................................................ 812
DVS 2216-6 (2013-12) Ultrasonic joining of mouldings and semi-finished
products made of amorphous thermoplastics in series
fabrication .................................................................................. 819
DVS 2217-1 (1999-03) Vibration welding of mouldings and semi-finished
products made of thermoplastic polymers in series
production ................................................................................. 831
DVS 2217-2 (2002-12) Vibration welding of mouldings and semi-finished
products made of thermoplastic polymers in series
production: Mouldings made of polyamides .............................. 840
DVS 2218-1 (2010-06) Welding of thermoplastics in series fabrication –
Rotational friction welding – Installations, procedures
and characteristics .................................................................... 844
DVS 2218-1 (2013-12) Welding of thermoplastics in series fabrication –
Supplement 1 Draft Rotational friction welding of mouldings made of
polyolefins (PE and PP) ............................................................ 849
DVS 2218-2 (2003-04)* Welding of thermoplastics in series fabrication –
Rotational friction welding of mouldings made of
polyolefins (PE and PP) ............................................................ 852
DVS 2218-3 (2006-04)* Welding of thermoplastics in series fabrication –
Rotational friction welding of mouldings and semi-
finished products made of polyamides (PAs) ............................ 859
DVS 2219-1 (2005-04)* High-frequency joining of thermoplastics in series
fabrication .................................................................................. 864
DVS 2219-2 (2005-04)* Thermocontact welding of thermoplastic films
(polyolefins) ............................................................................... 870
DVS 2220 (2011-05) Qualification testing of plastics laminators and
adhesive bonders – Laminates as well as laminate
and adhesive-bonded joints between GFRPs
(UP-GF and EP-GF) ................................................................... 876
Supplement 1 adhesive bonders – Fabrication of Test Piece I.1/II.1 –
Joint for a pipe nozzle in a panel ............................................... 883
Supplement 2 adhesive bonders – Fabrication of Test Piece II.2 –
Building up a new laminate ....................................................... 885
DVS 2221 (2010-12) Qualification testing of plastics adhesive bonders –
Pipe joints between PVC-U, PVC-C and ABS with
solvent-based adhesives ........................................................... 887
DVS 2225-1 (1991-02) Joining of Lining Membranes made from Polymeric
Materials (Geomembranes) in Geotechnical and
Hydraulic Application – Welding, Bonding by
Adhesives, Vulcanising ............................................................. 894
XII
DVS 2225-2 (1992-08) Joining of lining membranes – Made of polymer
materials in geotechnical and hydraulic engineering –
Site testing ................................................................................ 901
DVS 2225-3 (1997-07) Joining of sealing sheets made of polymeric materials
in earthwork and water engineering – Requirements
on welding machines and welding devices ............................... 911
DVS 2225-4 (2006-12)* Welding of sealing sheets made of polyethylene (PE)
for the sealing of dumps and contaminated sites ...................... 915
DVS 2225-5 (2011-03) Welding of sealing sheets made of thermoplastics in
tunnel construction .................................................................... 934
DVS 2226-1 (2000-09) Testing of fused joints on liners of polymer materials –
Testing procedure, requirements .............................................. 947
Lap shear test ........................................................................... 949
DVS 2226-3 (1997-07) Test of fusions on PE liners – Peeling test ................................ 951
Tensile creep test on PE ............................................................ 953
DVS 2227-1 (2004-08)* Welding of semi-finished products made of high-density
polyethylene (PE-HD) for the sealing of concrete
structures in the field of ground water protection and
for corrosion protection ............................................................. 957
DVS 2230-1 (2003-07) Welding of plastic series parts – Quality assurance
and testing ................................................................................. 977
DVS 2231 (2008-12)* Above-ground tanks, apparatus and piping made of
thermoplastics – Guide to quality assurance ............................ 997
DVS 2240-1 (2005-05)* Thread inserts for the joining of mouldings made of
plastics .................................................................................... 1000
DVS 2241-1 (2003-07)* Direct screwing into mouldings made of plastics .................... 1007
DVS 2241-1 (2007-10)* Examples – Direct screwing of mouldings made of
Supplement 1 plastics and additional elements for thin-walled
components ............................................................................. 1015
DVS 2242-1 (2011-04) Mechanical joining of plastic components –
Snap joints .............................................................................. 1022
DVS 2242-1 (2011-04) Mechanical joining of plastic components –
Supplement 1 Snap joints – Examples ........................................................... 1030
DVS 2280 (2010-12) DVS® foundation course about the processing of semi-
finished products made of thermoplastics ............................... 1036
DVS 2281 (2004-09) DVS® course for plastics welders in Qualification Test
Group I .................................................................................... 1038
Group II ................................................................................... 1040
Group III .................................................................................. 1042
DVS 2284 (2004-09) DVS® course for plastics welders – PE shell pipes;
Preparation for the welder qualification test according
to the DVS® 2212-4 guideline ................................................. 1044
XIII
DVS 2290 (2012-04) DVS® course for plastics laminators and adhesive
bonders ................................................................................... 1046
DVS 2291 (2010-12) DVS® course for plastics adhesive bonders for pipe
joints between PVC-U, PVC-C and ABS with solvent-
based adhesives ..................................................................... 1048
The dates indicate are the publication dates of the German editions.
* Publication date of the English edition differs from the German edition.
XIV
HSK Kunststoff Schweisstechnik GmbH
Extrusionsschweißmaschinen
Manual Welding Extruders
Warmgasschweißgeräte und Schweißextruder

hot air welders and welding extruders
Industrieextruder Plattenschweißmaschine MSW150/200

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table heaters
Umfangreiches Zubehör Verdichter und Vacuumpumpen

Accessories compactors and vacuum pumps
HSK Kunststoff Schweisstechnik GmbH

Zilzkreuz 1 Tel.: +49 (0)2224-9 0175 - 01 E-mail: info@hsk-kunststoff.de
D-53604 Bad Honnef Fax: +49 (0)2224-90175 - 03 Internet: www.hsk-kunststoff.de
Germany
XV
MUNSCH-Handextruder
N E W ! s
e d g e Welder
W s
c l . a c c essorie
in
XVI
FFOU TURE
R THE NEXT GEN ERATI
ONS
HENZE GmbH Josef-Kitz-Straße 9 Tel.: +49 (0) 2241 - 98 19 0 E-Mail: info@henze-gmbh.de

Kunststoffwerk 53840 Troisdorf Fax: +49 (0) 2241 - 98 19 20 Internet: www.henze-gmbh.de
Keeping you connected

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GLOBAL THERMOPL ASTIC SOLUTIONS
XVII
The professional journal for
JOINING PLASTICS
16:17 Seite 1
U1_JP_2_Titel__ 27.05.14
2/20 14
Supported by
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Plastics are today an indispensable part of our
everyday life. During their manufacture and as-
JO IN IN G PL A ST IC S
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FÜGEN VON KUNSTSTO
sembly, ever more significance is being attached
to the joints in this case. www.joining-plastics.info
fen.de
www.fuegen-von-kunststof
JOINING PLASTICS – FÜGEN VON KUNST-
STOFFEN takes account of this development and,
as a bilingual title (German/English), deals exclusi- Das KVT-HGS-Verfahren
vely with the title subject.
Application-oriented specialist articles indicate

the newest developments and the state of the art
for series welding and for the joining of plastics
in pipeline and tank construction and apparatus
engineering. Furthermore, the reader learns eve-
2/14
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rything important from the sections entitled com-

panies, quality management and standardisation,
research and development as well as safety at Telefon: +49 521 / 93 20 7-0,
JOINING PLASTIC S -
hof 18a, 33609 Bielefeld, e

KVT Bielefeld GmbH, Raben de, Web: www.kvt-bielefeld.d
work and environmental protection. Telefax: +49 521 / 93 20 711,
E-Mail: info@kvt-bielefeld.
d Papers
Topics of the Peer-reviewe
Themen der Fachbeiträge organosheet / short-fibre
Composite strength of an
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DVS Media GmbH • Aachener Straße 172 • 40223 Düsseldorf

T +49. (0)2 11. 15 91-159 • F +49. (0)2 11. 15 91-150 • media@dvs-hg.de • www.dvs-media.eu
February 2010
DVS – DEUTSCHER VERBAND Adhesive bonding of plastics

FÜR SCHWEISSEN UND in domestic installation Technical Code
VERWANDTE VERFAHREN E.V. Requirements on plants and personnel DVS 1904-1
The technical code has been created in cooperation with the Central Association for Sanitation, Heating and Air Conditioning (ZVSHK).
It includes requirements on plants and personnel for plants which carry out adhesive bonding work in domestic installation.
With regard to adhesive bonding in domestic installation on pipes and fittings/mouldings made of plastics, attention must be paid to the
stipulations according to the DVS 1904-2 technical code.
Contents: concerning Section 45 of the Skilled Trades Code are specified in

the individually applicable occupational profiles in Section 1.
1 Scope of application
2 Requirements on the plant 3.2 Adhesive bonding personnel
3 Requirements on the adhesive bonding technology personnel Adhesive bonding work in domestic installation may only be carried
3.1 Adhesive bonding supervisor out by specialists who have acquired the skills and knowledge
3.2 Adhesive bonding personnel necessary for this purpose. This is the case if there is proof of a
4 Evaluation of adhesive-bonded joints valid qualification test according to the DVS® 2221 guideline:
5 Literature "Qualification testing of plastics adhesive bonders".
Reprinting and copying, even in the form of excerpts, only with the consent of the publisher
1 Scope of application 4 Evaluation of adhesive-bonded joints

This technical code applies to the quality assurance of adhesive Adhesive-bonded joints are generally assessed by means of a
bonding work on domestic technology installations for the fields
visual inspection. They must satisfy the needs of the component
of drinking water and drainage installations as well as central
in question and must take account of its operational function, e.g.
heating and ventilation installations and to other supply and leak tightness during the test with compressed air, inert gas or
waste disposal installations including the connecting pipes inside water. For indications about the findings on adhesive-bonded
and outside buildings.
joints, see the DVS 1904-2 technical code.
This technical code does not affect any requirements in relevant
legal regulations, e.g. according to the rules of the Pressure
Device Directive (PDD). 5 Literature
The adhesive bonding work on domestic technology installations [1] DVS 1904-2 technical code: "Adhesive bonding of plastics in
which is carried out according to this technical code complies domestic installation, pipes and fittings, adhesive bonding
with the recognised rules of technology. If any special require- processes, findings on adhesive-bonded joints"
ments are set in addition, particular agreements must be made
[2] Regulation of the employers' liability insurance associations,
about these before the order is placed.
BGV A 1: "Principles of prevention"
[3] Technical bulletin of the employers' liability insurance asso-
2 Requirements on the plant ciation of the chemical industry, M 017: "Solvents"
The plants must possess the facilities with which the adhesive [4] Ordinance concerning the occupational profiles according to
bonding work can be performed properly. Attention must be paid Section 45 of the Skilled Trades Code in the latest version
to the regulations and set of rules of employers' liability insurance [5] Skilled Trades Code (HwO): "Act concerning the regulations
associations (BGVR), especially to BGV A1: "Accident preven- for the skilled trades" in the latest version
tion regulation – Principles of prevention", as well as to the tech-
nical bulletins of the employers' liability insurance association of [6] DVS® 2221 guideline: "Qualification testing of plastics adhe-
the chemical industry, especially M 017: "Solvents". Instructions sive bonders"
for the facilities are included in the DVS 1904-2 technical code. Sources of supply:
– DVS technical codes and guidelines:
3 Requirements on the adhesive bonding technology DVS Media GmbH, Aachener Strasse 172, 40223 Düsseldorf,
personnel http://www.dvs-media.info
3.1 Adhesive bonding supervisor – BGVR (regulations and set of rules of employers' liability
insurance associations):
The adhesive bonding supervisor is responsible for the proper Carl Heymanns Verlag, Luxemburger Strasse 449, 50939 Köln
execution and evaluation of adhesive bonding work. The adhe-
sive bonding supervisor in the terms of this technical code is a – Technical bulletins of the employers' liability insurance
foreman trained according to the occupational profiles for the fitters' association of the chemical industry:
and heating fitters' skilled trades, for the tank and apparatus Jedermann-Verlag, Mittelgewannweg 15, 69021 Heidelberg,
fitters' skilled trades, for the furnace and air heating fitters' skilled Internet: www.jedermann.de
trades or, in the case of legal entities, the technical plant manager – Skilled Trades Code (HwO):
subject to comparable prerequisites. For the foreman's training Verlagsanstalt Handwerk GmbH, Auf’m Tetelberg 7,
and qualification testing, requirements according to the ordinances 40221 Düsseldorf
This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of information
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. No
liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.
DVS, Technical Committee, Working Group "Plastics, welding and adhesive bonding"
Orders to: DVS Media GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
1
February 2010
DVS – DEUTSCHER VERBAND

Adhesive bonding of plastics
FÜR SCHWEISSEN UND
in domestic installation
Pipes and fittings – Adhesive bonding operation Technical Code
VERWANDTE VERFAHREN E.V.
Findings on adhesive-bonded joints DVS 1904-2
The technical code has been created in cooperation with the Central Association for Sanitation, Heating and Air Conditioning (ZVSHK).
It includes instructions for the adhesive bonding of plastic pipes and fittings/mouldings which are used in domestic installation. Further-
more, stipulations are made about the findings on adhesive-bonded joints as well as about occupational health and safety and environ-
mental protection.
Requirements on plants and personnel for adhesive bonding in domestic installation are included in the DVS 1904-1 technical code.
Contents: 2.1.2 Fittings/mouldings

According to DIN 8063-1 and DIN 8063-9.
2 Pipes and fittings/mouldings made of plastics 2.2 ABS/ASA/PVC
2.1 PVC-U
2.2 ABS/ASA/PVC 2.2.1 Pipes
2.3 PVC-C According to DIN EN 1455-1 / DIN EN 1565-1 / DIN 19561-10.
2.4 Marking
2.5 Packaging, transport and storage 2.2.2 Fittings/mouldings
3 General quality assurance of the adhesives and the According to DIN EN 1455-1 / DIN EN 1565-1 / DIN 19561-10.
adhesive-bonded joints
4 Manufacture of adhesive-bonded joints 2.3 PVC-C
5 Findings on adhesive-bonded joints
5.1 External condition 2.3.1 Pipes
5.2 Axial condition According to DIN 8079 / DIN 8080 / DIN EN 1566-1 / DIN
5.3 Adhesive bonding depth 19538-10.
5.4 Adhesive ring (groove)
5.5 Leak test 2.3.2 Fittings/mouldings
5.6 Assessment According to DIN EN 1566-1 / DIN 19538-10.
6 Occupational health and safety measures
7 Environmental protection 2.4 Marking
8 Literature
The marking is the task of the manufacturer of the semi-finished
product.
1 Scope of application The processing plant must check the marking and pay attention
to the following:
This technical code applies to adhesive bonding on domestic tech- – manufacturer's symbol
nology installations for the fields of drinking water and drainage
installations as well as central heating and ventilation installa- – product designation
tions and to other supply and waste disposal installations includ- – material
ing the connecting pipes inside and outside buildings. – authorisation symbol, e.g. DVGW certification symbol
This technical code does not affect any requirements in relevant – nominal width
legal regulations, e.g. according to the rules of the Pressure
Device Directive (PDD). – year of manufacture
The adhesive bonding work on domestic technology installations The cleaning agents as well as the adhesives must be provided
which is carried out according to this technical code complies with the following minimum information not only on the correspond-
with the recognised rules of technology. ingly suitable containers but also on the packaging materials:
If any special requirements are set in addition, particular agree- – product designation
ments must be made about these before the order is placed. – intended use
– authorisation symbol, e.g. DVGW certification symbol with
registration number
2 Pipes and fittings/mouldings made of plastics
– address of the manufacturer or the supplier
2.1 PVC-U – hazard symbols and safety instructions
– quantity
2.1.1 Pipes
According to DIN 8061 / DIN 8062, DIN EN 1452-1 to DIN – processing instructions
EN 1452-5 and DIN 19534-3. – filling date
DVS, Technical Committee, Working Group "Plastics, welding and adhesive bonding"
2
Page 2 to DVS 1904-2
2.5 Packaging, transport and storage – The finally assembled piping must be rinsed before the com-
The cleaning agents and the adhesives are filled and delivered in missioning in order to remove the foreign substances located
correspondingly suitable containers. inside it (on this subject, see the technical bulletin from
ZVSHK: "Rinsing, disinfection and commissioning of drinking
The Ordinance Concerning Hazardous Goods on the Road water installations").
(GGVS) must be observed during the transport of the cleaning
agents and the adhesives.
The cleaning agents and the adhesives should be stored in well- 5 Findings on adhesive-bonded joints
ventilated rooms at the room temperature (approx. 20°C). The
products must be protected against heating. Storage tempera- 5.1 External condition
tures ± 0°C must be avoided. The adhesive-bonded joint must be clean. The adhesive is coloured.
The cleaning agents can be kept for an unlimited period if the Any adhesive which runs down the piping or is smeared is easily
stipulated storage conditions are complied with. visible and should therefore be removed immediately.
The adhesives are suitable for service for a limited time because 5.2 Axial condition
of their compositions. If the above conditions are complied with, a
service suitability of min. 12 months after the filling date is guar- In order to obtain an optimum strength of the adhesive-bonded
anteed for as yet unopened and unstarted adhesive tins. joint, the pipes must be pushed into the fitting/moulding with par-
allel axes.
3 General quality assurance of the adhesives and the 5.3 Adhesive bonding depth
adhesive-bonded joints
During the adhesive bonding, the pipe must be pushed in as far
The cleaning agents and the adhesives are subjected to constant as the stop of the fitting/moulding. The notch-free marking (e.g.
quality control according to the existing application standards, using a pencil) must be no longer visible. It is covered by the
guidelines and technical codes. adhesive ring.
Authorisations and test certificates with the proof of the service 5.4 Adhesive ring (groove)
suitability are in the possession of the manufacturer and can be
requested from there. The user can request a works certificate After the adhesive bonding, a uniform adhesive ring (groove) all
according to DIN EN 10204 from the manufacturer. around must be visible between the pipe and the fitting/moulding.
This guarantees a flawless adhesive-bonded joint.
4 Manufacture of adhesive-bonded joints 5.5 Leak test
Only suitable cleaning agents and the adhesive correspondingly The leak test is carried out after the completion of the assembled
suitable for the adhesive-bonded joint are prescribed by the pipe piping. Binding requirements are included in the requirement
system manufacturer and must be used for the manufacture of rules (e.g. the ZVSHK technical bulletin: "Leak tests on drinking
adhesive-bonded joints. Pay attention to the adhesive bonding water installations with compressed air, inert gas or water").
instructions from the pipe system manufacturer! The pipes and
the fittings/mouldings must be dry, grease-free and dirt-free. The 5.6 Assessment
adhesive bonding should only be carried out at processing tem- If the conditions in the above Sections 5.1 to 5.5 are complied
peratures between + 5°C and + 40°C. with, the requirements to be set on a flawless adhesive-bonded
The following general working sequence applies to adhesive joint are satisfied.
bonding but may have differences in the adhesive bonding tech-
nique from system to system. Therefore, the adhesive bonding
instructions of the individual pipe system manufacturers must be 6 Occupational health and safety measures
taken into consideration:
The adhesives contain organic solvents whose properties neces-
– The adhesive bonding faces at the pipe end and of the fitting/ sitate certain occupational health and safety measures during the
moulding are cleaned with clean non-woven paper and with processing.
the cleaning agent prescribed by the pipe system manufac-
turer. The non-woven paper must be used just once. Hazards to the people dealing with these solvents result from:
– The insert depth of the fitting/moulding is marked on the pipe – the combustibility of the solvents
end (for example) with a pencil so that the required adhesive – the irritant effect of individual solvents on the respiratory
application and the complete insertion of the pipe into the organs, the eyes and the skin
fitting/moulding can be checked.
The handling of these products is governed by:
– The cleaned adhesive bonding faces must be dried off before
the adhesive application. – the technical bulletin of the employers' liability insurance asso-
ciation of the chemical industry, M 017: "Solvents"
– A thick adhesive layer is applied to the whole area of the pipe
with the swab or the brush and a thin adhesive layer into the – the Hazardous Substances Ordinance: "Ordinance concerning
fitting/moulding if necessary. the protection from hazardous substances"
– Immediately after the adhesive application, the pipe is pushed The occupational health and safety measures which must be
into the fitting/moulding as far as the stop without any twisting complied with during the handling of these solvents as well as the
or tilting and is fixed. adhesives are listed therein.
– The duration of the rest time of the adhesive-bonded pipe joint The safety data sheets for these products are prescribed by the
is included in the information from the manufacturer. legislator and must be available to the processing plant.
– The adhesive-bonded joint must not be subjected to any The most important occupational health and safety measures
mechanical loads during the rest time. The same applies corre- during work with cleaning agents and adhesives are:
spondingly to the waiting time until the leak test.
– Keep away from ignition sources!
– The covering or the insulation may only be applied to the laid
– Do not smoke!
piping when the adhesive emerging from the adhesive-bonded
joints has set and is dry. – Do not inhale vapours.
3
– Ensure adequate ventilation. [14] DIN EN 1455-1: "Plastic piping systems for the discharge of
waste water (at low and high temperatures) inside the build-
– Avoid any contact with the eyes.
ing structure – Acrylonitrile butadiene styrene (ABS) – Part 1:
– Avoid any contact with the skin. Requirements on pipes, fittings and the piping system"
– Do not let them get into the sewage system. [15] DIN EN 1565-1: "Plastic piping systems for the discharge of
The handling of these substances must be stipulated in suitable waste water (at low and high temperatures) inside the build-
operating instructions. ing structure – Styrene copolymer blends (SAN + PVC) –
Part 1: Requirements on pipes, fittings and the piping sys-
tem"
7 Environmental protection [16] DIN EN 1566-1 "Plastic piping systems for the discharge of
waste water (at low and high temperatures) inside the build-
If any pipes, fittings/mouldings, cleaning agents or adhesives are ing structure – Chlorinated polyvinyl chloride (PVC-C) –
left over, these are reused or are disposed of properly. Part 1: Requirements on pipes, fittings and the piping sys-
tem"
8 Literature [17] DIN 19534-3: "Pipes and fittings made of unplasticised pol-
yvinyl chloride (PVC-U) with a push-on sleeve for waste
[1] DVS 1904-1 technical code: "Adhesive bonding of plastics water ducts and pipes – Part 3: Quality monitoring and con-
in domestic installation – Requirements on plants and per- struction execution"
sonnel" [18] DIN 19538-10: "Pipes and fittings made of chlorinated poly-
[2] DIN EN 10204: "Metallic products – Types of test certifi- vinyl chloride (PVC-C) for hot-water-resistant waste water
cates" pipes (HT) inside buildings – Part 10: Fire behaviour, quality
monitoring and laying instructions"
[3] DIN 8061 (draft standard): "Pipes made of unplasticised
polyvinyl chloride (PVC-U) – General quality requirements [19] DIN 19561-10: "Pipes and fittings made of styrene copoly-
and testing" mers for hot-water-resistant waste water pipes (HT) inside
buildings – Part 10: Fire behaviour, quality monitoring and
[4] DIN 8062 (draft standard): "Pipes made of unplasticised laying instructions"
polyvinyl chloride (PVC-U) – Dimensions"
[20] Technical bulletin of the employers' liability insurance asso-
[5] DIN 8063-1: "Pipe joints and piping parts for pressurised ciation of the chemical industry, M 017: "Solvents"
piping made of unplasticised polyvinyl chloride (PVC-U);
sleeve and double-sleeve elbows, dimensions" [21] Hazardous Substances Ordinance: "Ordinance concerning
the protection from hazardous substances"
[6] DIN 8063-9: "Pipe joints and piping parts for pressurised
piping made of unplasticised polyvinyl chloride (hard PVC); [22] ZVSHK technical bulletin: "Rinsing, disinfection and com-
injection-moulded reducers for adhesive bonding, dimen- missioning of drinking water installations"
sions"
[23] ZVSHK technical bulletin: "Leak tests on drinking water
[7] DIN 8079 (draft standard): "Pipes made of chlorinated poly- installations with compressed air, inert gas or water"
vinyl chloride (PVC-C) – Dimensions"
[8] DIN 8080 (draft standard): "Pipes made of chlorinated poly- Sources of supply:
vinyl chloride (PVC-C) – General quality requirements and DVS technical codes:
tests" DVS Media GmbH, Aachener Strasse 172, 40223 Düsseldorf,
[9] DIN EN 1452-1: "Plastic piping systems for the water sup- http://www.dvs-media.info
ply – Unplasticised polyvinyl chloride (PVC-U) – Part 1: BGVR (regulations and set of rules of employers' liability
General" insurance associations) as well as ordinances:
[10] DIN 1452-2: Plastic piping systems for the water supply – Carl Heymanns Verlag, Luxemburger Strasse 449, 50939 Köln
Unplasticised polyvinyl chloride (PVC-U) – Part 2: Pipes" Technical bulletins of the employers' liability insurance
[11] DIN 1452-3: Plastic piping systems for the water supply – association of the chemical industry:
Unplasticised polyvinyl chloride (PVC-U) – Part 3: Fittings" Jedermann-Verlag, Mittelgewannweg 15, 69021 Heidelberg,
www.jedermann.de
[12] DIN 1452-4: Plastic piping systems for the water supply –
Unplasticised polyvinyl chloride (PVC-U) – Part 4: Valves DIN / DIN EN / DIN EN ISO standards:
and accessories" Beuth Verlag GmbH, Burggrafenstraße 6 in 10772 Berlin
[13] DIN 1452-5: Plastic piping systems for the water supply – ZVSHK technical bulletins:
Unplasticised polyvinyl chloride (PVC-U) – Part 5: Service Central Association for Sanitation, Heating and Air Conditioning,
suitability of the system" Rathausallee 6
4
lizensiert für: SLV Nord gGmbH November/November/Novembre
2013
Fügen von Kunststoffen –

Kurzzeichen und Abkürzungen –
Schweißverfahren Richtlinie
DVS – DEUTSCHER VERBAND Joining of plastics – Technical Code
FÜR SCHWEISSEN UND Code letters and abbreviations – Directive
VERWANDTE VERFAHREN E.V. Welding processes DVS 2200-1
Assemblage des plastiques – Beiblatt 1
abréviations – Supplement 1
procédés de soudage Supplément 1
In dem Beiblatt sind die derzeit möglichen Verfahren für das Schweißen von Kunststoffen, die Kurzzeichen dieser Verfahren und ein
Querverweis auf die Beschreibung des jeweiligen Verfahrens (soweit vorhanden) in den DVS-Richtlinien sowie der Hauptanwendungs-
bereich aufgeführt.
The currently possible processes for the welding of plastics, the code letters of these processes, cross-references to the descriptions of
the respective processes (in so far as these exist) in the DVS technical codes and the main areas of application are listed in the supple-
ment.
Dans ce supplément de directive sont présentés les procédés actuels pour le soudage des plastiques, les abréviations de ces procédés,
une référence sur la description de chaque procédé dans les directives DVS ainsi que les domaines principaux d’application.
Nachdruck und Kopie, auch auszugsweise, nur mit Genehmigung des Herausgebers
Réimpression et copie, même partielle, uniquement avec autorisation de l’éditeur
Diese Veröffentlichung wurde von einer Gruppe erfahrener Fachleute in ehrenamtlicher Gemeinschaftsarbeit erstellt und wird als eine wichtige Erkenntnisquelle zur
Beachtung empfohlen. Der Anwender muss jeweils prüfen, wie weit der Inhalt auf seinen speziellen Fall anwendbar und ob die ihm vorliegende Fassung noch gültig
ist. Eine Haftung des DVS und derjenigen, die an der Ausarbeitung beteiligt waren, ist ausgeschlossen.
is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid.
No liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing up of the document.
Cette publication a été élaborée bénévolement par un groupe d’experts et est recommandée comme base de travail. L’usager doit pour tout cas vérifier l’application
du contenu et si la version présente utilisée est valable. La responsabilité de la DVS et des personnes ayant participé à la rédaction de cette directive ne peut en
aucun cas être engagée.
DVS, Ausschuss für Technik, Arbeitsgruppe „Fügen von Kunststoffen“

DVS, Technical Committee, Working Group "Joining of Plastics"
DVS, comité technique, groupe de travail «Assemblage des plastiques»
Bezug: DVS Media GmbH, Postfach 10 19 65, 40010 Düsseldorf, Telefon (02 11) 15 91- 0, Telefax (02 11) 1591-150
Orders to: DVS Media GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Téléphone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
Référence: DVS Media GmbH, Postfach 10 19 65, 40010 Düsseldorf, Allemagne, Phone: + 49(0)211/1591- 0, Téléfax: + 49(0)211/1591-150
5
6
Kurzzeichen Verfahren Englisch Französisch Beschrieben in1) Anwendungsbereiche
Code letters Processes English French Described in1) Areas of application
Abbréviation Processus Anglais Francais Décrit dans1) Domaine d'application
Schweißen im elektromagnetischen Wechselfeld / Welding in an alternating electromagnetic field / Soudage par ondes électromagnétiques:
EWS Elektromagnetisches Electromagnetic resistance Soudage électromagnétique par Serienschweißen
Widerstandsschweißen welding résistance Series welding
Soudage en série
HF Hochfrequenzschweißen High frequency welding Soudage par hautes fréquences DVS 2219-1 Folienschweißen
Film welding
Soudage de film plastique
MW Mikrowellenschweißen Microwave welding Soudage par micro-ondes Rohrleitungsbau
Pipeline construction
Construction de la tuyauterie
Schweißen durch Wärmeleitung / Welding using heat conduction / Soudage par conduction thermique:
HB Schwenkbiegeschweißen Welding by bending using a Soudage par pliage à la règle DVS 2207-14 Apparate- und Behälterbau
heated tool chauffante Apparatus and tank construction
Construction d'appareils et de réservoirs
HD Heizelementmuffenschweißen Heated tool socket welding Soudage de manchon par DVS 2207-1, -11, -15 Rohrleitungsbau
élément chauffant Pipeline construction
HH Heizkeilschweißen Heated wedge welding Soudage par coin chauffant DVS 2225-1, -4, -5 Bahnenschweißen
Sheet welding
Soudage de films épais
HI Wärmeimpulsschweißen Thermal impulse welding Soudage par impulsions Folien- und Bahnenschweißen
thermiques Film and sheet welding
Seite 2 zu / Page 2 to / Page 2 de la DVS 2200-1 Beiblatt /Supplement /Supplément 1
Soudage de film plastique,

TK Thermokontaktschweißen Thermal contact welding Soudage par contact thermique DVS 2219-2 Folienschweißen
Film welding
HM Heizwendelschweißen Electrofusion welding Soudage par électrofusion DVS 2207-1, -11, -16 Rohrleitungsbau
Pipeline construction
HN Heizelementnutschweißen Heated tool groove welding Soudage en T avec élément Apparate- und Behälterbau
chauffant Apparatus and tank construction
HR Heizelementrollbandschweißen Heated tool band weld sealing Soudage continu par élément Folienschweißen
chauffant agissant directement Film welding
HS Heizelementstumpfschweißen Heated tool butt welding Soudage bout-à-bout par DVS 2207-1, -5, -11, Rohrleitungs-, Apparate- und Behälterbau
élément chauffant -12, -13, -15, -16, -25 Pipeline, apparatus and tank construction
Construction de la tuyauterie,
DVS 2215-1, -2, -3 Serienschweißen
Series welding
Soudage en série
HT Heizelementtrennnahtschweißen Heated tool welding with cutting Soudage au couperet chauffant Folienschweißen
edge Film welding
WNF Wulst- und nutfreies Schweißen Bead and crevise free Soudage sans bourrelet ni Rohrleitungsbau
cavité Pipeline construction
Schweißen durch Strahlung / Welding using radiation / Soudage par rayonnement:
IR Infrarotschweißen Infrared welding Soudage par infrarouges Rohrleitungsbau, Serienschweißen
Pipeline construction and series welding
IR-H Berührungsloses Heizelement- Non-contact heated tool butt Soudage par élément chauffant DVS 2207-6
stumpfschweißen welding bout à bout sans contact Construction de la tuyauterie,
Soudage en série
IR-E Schweißen mit Emittern Welding with emitters Soudage avec émetteur
LE Lichtstrahlextrusionsschweißen Light beam extrusion welding Soudage par extrusion à l’aide Anlagen- und Behälterbau
d’un faisceau lumineux Installation and tank construction
Construction d'équipement
LB Laserstrahlschweißen Laser beam welding Soudage au laser
LB-C Konturschweißen Contour welding Soudage au laser en contournage
LB-S Simultanschweißen Simultaneous welding Soudage au laser en simultané Serienschweißen
DVS 2243 Series welding
LB-QS Quasi-Simultanschweißen Quasi-simultaneous welding Soudage au laser en quasi Soudage en série
simultané
LB-M Maskenschweißen Mask welding Soudage au laser à l’aide d’un
masque
Schweißen durch Bewegung / Welding using movement / Soudage par friction:
FR Rotationsreibschweißen Spin welding Soudage par frictions rotatives DVS 2218-1, -2, -3 Serienschweißen
Series welding
Soudage en série
US Ultraschallschweißen Ultrasonic welding Soudage par ultrasons DVS 2216-1, -2, -3, Serienschweißen
-4, -5, -6 Series welding
Soudage en série
7
8
VIB Vibrationsschweißen Vibration welding Soudage par vibrations
Serienschweißen
VIB-L Lineares Vibrationsschweißen Linear vibration welding Soudage par vibrations linéaires DVS 2217-1, -2 Series welding
Soudage en série
VIB-B Biaxiales Vibrationsschweißen Biaxial vibration welding Soudage par vibrations biaxiales
Schweißen durch Warmgas / Welding using hot gas / Soudage par gaz chaud:
WE Warmgasextrusionsschweißen Hot gas extrusion welding Soudage par extrusion au gaz DVS 2207-4 Apparate- und Behälterbau,
chaud Apparatus and tank construction
WE-con Warmgasextrusionsschweißen, Hot gas extrusion welding, Soudage continu par extrusion
DVS 2225-1, -4, -5 Bahnenschweißen
kontinuierlich continuous au gaz chaud
DVS 2227-1 Sheet welding
WE-dis Warmgasextrusionsschweißen, Hot gas extrusion welding, Soudage discontinu par extrusi- DVS 2207-4 Apparate- und Behälterbau
diskontinuierlich discontinuous on au gaz chaud Apparatus and tank construction
WF Warmgasfächelschweißen Hot gas fan welding Soudage par balayage au gaz DVS 2207-3 Apparate- und Behälterbau
WU Warmgasüberlappschweißen Hot gas lap welding Soudage par recouvrement au DVS 2225-1, -4, -5 Schweißen von Dichtungsbahnen
gaz chaud Welding of sealing sheets
WZ Warmgasziehschweißen Hot gas string-bead welding Soudage avec traction au gaz DVS 2207-3 Apparate- und Behälterbau
1) mit Beiblättern / with supplements /avec suppléments

Erstellungsdatum: 13.12.2001
File-Name: lizensiert für: SLV Nord gGmbH

Letzte Änderung: 18.02.2002
C:\DVS Merkblätter\2201\2201-1\e2201-1.fm
DVS – DEUTSCHER VERBAND Testing of semifinished products Directive D

of thermoplastics DVS 2201-1
FÜR SCHWEISSEN UND V
VERWANDTE VERFAHREN E.V. Bases – indications (February 1989) S 
Contents: Table 1. Materials and letter symbols.
1 Scope Letter symbol material naming

2 Materials and characteristics PE-HD High density polyethylene (high-pressure PE)*
2.1 Mechanical behaviour
2.2 Thermal behaviour PP-B Polypropylene block copolymer
2.3 Ageing behaviour PP-H Polypropylene homopolymer
3 Instructions for the inspection of incoming goods
PP-R Polypropylene random copolymer
3.1 Visual inspection
3.2 Dimensional inspection PVC-C Chlorinated polyvinyl chloride
3.3 Behaviour after storing at a warm temperature PVC-HI Impact-resistant modified polyvinyl chloride
3.4 Further tests
4 Testing and evaluation of performance PVC-U Unplasticized polyvinyl chloride (rigid PVC)*
4.1 Behaviour under mechanical stress PVDF Polyvinylidenefluoride
4.2 Behaviour under thermal stress

4.3 Behaviour under chemical stress * former name
5 Standards and directives
5.1 Standards for materials and semifinished products 2.1 Mechanical behaviour
5.2 Test standards The values of the mechanical properties of the semifinished
5.3 DVS directives products indicated in the standards have been ascertained on
testing pieces according to standardized test methods. These
values represent the minimum requirements on the moulding
1 Scope materials allowing a comparison of the plastics. They are not
necessarily identical since the influences of configuration and
This directive provides the processor of semifinished products of processing have not been considered. The influence of
thermoplastics with instructions and suggestions for testing temperature and time is also very important so that the values
semifinished products when inspecting incoming goods and for indicated do not characterize the performance capability of the
evaluating the quality and performance capability with regard to finished part, nor can they be taken as a basis for the calculation
the welding practice. of a construction.
2.2 Thermal behaviour

2 Materials and characteristics
With regard to the thermal loading capacity it should be taken into
This standard covers the materials listed in table 1 which are consideration that the characteristic values of the thermoplastics
mainly used in the apparatus and piping engineering sector. depend on the temperature. Apart from the change in solidity due
to the temperature, the time influence has also to be taken into
These materials have specific characteristics regarding account.
processing and application technology due to their molecular
structure. These material characteristics have to be considered Thermal expansion and thermal conductivity are important for the
for applications of thermoplastic semifinished products, mainly for construction.
load-bearing components, especially when they are at the same
time subjected to mechanical, thermal and chemical stress. 2.3 Ageing behaviour
The characteristic values of the semifinished products are During the practical application, all materials are exposed to
described in the relevant DIN standards (see section 5.1). The different environmental influences and are subject to changes.
welding fillers are treated in the DVS data sheet 2211. The The influences of light, temperature and media should especially
parameters of the most common thermoplastics for the be mentioned as ageing influences. Consistency and resistance
calculation of the construction can be found in DVS 2205 part 1. vary according to the field of application and the stress. This has
liability can be accepted by the Deutscher Verband für Schweißtechnik e.V. and those participating in the drawing up of the document.
DVS, Technical Committee, Working Group “Plastics, Welding and Bonding”
Orders to: DVS-Verlag GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
9
to be considered when evaluating the performance capability. As The short-term weld factor is determined with the tensile test
to the application, external and internal influences as well as according to DVS directive 2203, part 2.
mechanical stresses have to be taken into account. They can
lead to a reduction or a prolongation of the service life. 4.1.2 Determination of the elastic modulus
The elastic modulus is determined according to DIN 53457 in the
tensile, pressure or bending test according to the case of stress.
3 Instructions for the inspection of incoming goods
4.1.3 Determination of the impact strength
The standards and directives mentioned in sector 5 are to be
considered for the control of the condition on delivery of the The impact strength or the notched impact strength is determined
semifinished products such as pipes, sheets, profiles and fittings. according to DIN 53453 or DIN 53753 in the impact bending test
Further stipulations can be agreed upon between the parties to or according to DIN 53448 in the impact tensile test.
the contract. The strength of the welded joints is determined according to the
Tests according to DVS 2201 part 1 are to be recommended in DVS directive 2203, part 3.
the case of doubts about the identity and/or weldability of the The resistance of the materials to impulsive stresses can be
material. derived from the strength properties.
3.1 Visual inspection 4.1.4 Creep test under internal compression
The semifinished products have to be visually inspected for even The characteristic creep test curves for pipe materials are
colouring and local colour variations, as well as for cleanliness included in the basic standards mentioned in table 2.
and condition of surface. The marking of the semifinished product
has to be recorded. Materials for which no characteristic creep test curves are
available, are tested according to DIN 53759 “Creep test under
3.2 Dimensional inspection internal compression on hollow parts”.
The dimensions of the semifinished product stipulated in the A DIN standard demonstrating the behaviour in the creep test
standards and directives or the technical delivery conditions have under internal compression and for determining the characteristic
to be controled. creep test curves for pipes is in preparation.
The characteristic values for the dimensioning according to the
3.3 Behaviour after storing at a warm temperature corresponding materials, temperatures and application times can
Storing at a warm temperature is recommended and is to be be concluded from these characteristic creep test curves. These
carried out, as far as test temperature and test duration are characteristic creep test curves have been determined under
concerned, according to the relevant standards and directives. multiaxial stress as it most commonly occurs in the components.
The percentage change of length and the surface (colour, shape)
are compared with the indications on hand. Table 2. Basic standards with characteristic creep test curves for
pipes.
3.4 Further tests
Material Basic standards or directives
Apart from these simple material tests, further tests, according to
the field of application, may be necessary when required. PVC-U DIN 8061
PE-HD DIN 8075
4 Testing and evaluation of performance PP DIN 8078
PVC-C DIN 8080
The components produced from the semifinished products have
PVDF DVS 2205, part 1
to be able to resist the mechanical, thermal and chemical
stresses which occur in practical use during the scheduled
service time. As to the evaluation of the performance quality, the 4.1.5 Tensile creep test
following has to be considered: The tensile creep test is carried out according to DIN 53444.
– suitability of the material When evaluating the tensile creep tests, it has to be considered
– construction appropriate for the plastics involved and that they are carried out under uniaxial stress and lead to longer
test times than under multiaxial stresses. This should be taken
– skilled processing especially of welded joints.
into consideration for the dimensioning.
The results of the tests mentioned below and their evaluation
The long-term weld factor is determined according to DVS
make an evaluation of the performance capability of the
directive 2203, part 4. In the light of current knowledge, this factor
semifinished products possible.
resulting from the uniaxial tensile creep test is also valid for
multiaxial stresses.
4.1 Behaviour under mechanical stress
When testing the mechanical properties a distinction should be 4.1.6 Determination of the creep modulus
made between short-term and long-term behaviour. The most
The creep modulus is determined in the tensile creep test
important tests for detecting the mechanical properties are
according to DIN 53444 or in the bending creep test according to
decribed below.
DIN 54852. As to the dimensioning, the creep modulus has to be
Short-term tests serve only to ascertain the initial solidities and to considered in relation to stress, temperature and time.
determine the test conditions for creep tests. The test results of
these short-term tests must not be used for the dimensioning of 4.2 Behaviour under thermal stress
load-bearing components. The results of creep tests have to be
When evaluating the behaviour of thermoplastics under thermal
used for the constructive dimensioning. In this case please refer
stress, the modification of the technical properties has to be
to DVS directive 2205, part 1.
considered. Especially, the dimensional stability, tenacity and
rigidity decrease with increasing temperature. At higher
4.1.1 Tensile test
temperatures accelerated thermal ageing must be reckoned with.
Yield stress, tensile strength, break resistance as well as the Upper limits of the continual use temperature for the individual
corresponding elongations are determined in the tensile test materials, which must not be exceeded, can be determined from
according to DIN 53455. this behaviour.
10
lizensiert für: SLV Nord gGmbH Page 3 to DVS 2201-1
The coefficient of thermal expansion of the thermoplastics is Table 5. Temperature-time limits of thermal ageing.
temperature-dependent and lies considerably over that of metals.
This fact has to be considered for the constructive dimensioning Material Maximum time of influence in years
of components and installations. The values can be found in at a temperature °C
table 3. 20 30 40 50 60 70 80 90 100 120
PVC-U 50 50 50 30 30 – – – – –
Table 3. Linear coefficient of thermal expansion.
PVC-C 50 50 50 30 30 20 20 20 – –
Material Temperature range Coefficient of thermal PE-HD 50 50 50 15 5 1 – – – –
expansion
°C PP 50 50 50 50 50 25 20 10 1 1
1/K ∙10-4
PVDF 50 50 50 50 50 50 35 10 10 5
PVC-U 20 … 60 0.7 … 0.8
PVC-C 20 … 100 0.6 … 0.7
4.3 Behaviour under chemical stress
PE-HD 20 … 80 1.5 … 2.0
PP 20 … 100 1.6 … 1.8 The behaviour under chemical stress depends decisively on
whether the component is at the same time subject to
PVDF 20 … 120 1.2 … 1.8 mechanical stress or not. Higher temperatures normally
The higher values apply to the upper temperature range. accelerate the procedure leading at the same time to a reduction
of the creep strength, see DVS 2205.
4.2.1 Dimensional stability under heat
4.3.1 Immersion test
The dimensional stability under heat decribes the deformation
behaviour of a material under constant stress at increasing An initial estimation of the behaviour under chemical stress is
temperature. Redeformations due to internal stresses and heat possible in the immersion test according to DIN 16888 or DIN
deformations are not considered. 53476. The results thus received allow only a qualitative
evaluation for applications without stresses.
4.2.1.1 Determination of the Vicat softening temperature
The Vicat softening temperature (VST) is determined according (Only part 1 of DIN 16888 for pipes made of polyolefines is
to DIN 53460, procedure B 50. This test is especially suitable for available at the moment. The following parts for other
amorphous thermoplastics. The VST determined with this test thermoplastics are in preparation. Until their publication other
lies generally approx. 15 °C over the maximum continual use plastics can also be tested by analogy according to this standard)
temperature.
The relevant tables are included in:
4.2.1.2 Determination of the dimensional stability temperature – DIN 8075, supplement sheet for PE-HD
This dimensional stability is determined under bending stress – DIN 8078, supplement sheet for PP
according to DIN 53461, procedure B. This test also considers
the creep tendency of the material. The thus determined – DIN 8061, supplement sheet for PVC-U
temperature lies generally approx. 10 °C over the maximum – Material sheets from manufacturers of raw materials and semi-
continual use temperature. finished products
4.2.2 Determination of behaviour when storing at warm 4.3.2 Stress cracking test
temperatures
The redeformation of the semifinished products resulting from Stress cracking tests according to DIN 53449 parts 1 to 3 can be
internal stresses due to processing is determined with the tests carried out for estimating the behaviour under chemical and at
mentioned below. The carrying-out of the tests is described in the the same time mechanical stress.
standards for semifinished products indicated in table 4.
4.3.3 Determination of chemical resistance factors
The dimensional stability of hot-formed parts can be checked in a
practical test. In this case a test temperature has to be chosen The chemical resistance factors (fcr-factor) decribe in figures the
that lies 10 °C over the provided maximum continual use influence of chemical media on the creep behaviour in
temperature, the test period is 24 hours. comparison with the influence of water at the same temperature.
Fcr-factors are determined according to DIN 16889 in the creep
Table 4. Behaviour of semifinished products when storing at warm test under internal compression.
temperature.
(Only part 1 of this standard for pipes made of polyolefines is
Material Pipes Sheets available at the moment. The following parts for other
PVC-U DIN 8061 DIN 16927 thermoplastics are in preparation. Until their publication, other
plastics can also be tested by analogy according to this
PVC-C DIN 8080 (DIN 16927) standard.)
PE-HD DIN 8075 (DIN 16925)
Corresponding details can be found in the DVS directive 2205
PP DIN 8078 (DIN 16971) part 1.
PVDF DVS 2205 part 1 (DIN 16971) (The there indicated values are reciprocal values of the fcr-factors
( ): These standards can be applied by analogy. The test conditi- and can be inserted directly in the calculation as reduction
ons have to be brought into line with the characteristic values factors.)
of these materials or with DVS 2211.
4.2.3 Thermal ageing 5 Standards and directives

The thermal ageing depends on temperature, time of influence,
medium and its oxygen content. The temperature-time limits The most important standards and directives which are of interest
indicated in table 5 can be achieved at the usual stabilisation of in this connection are mentioned below. A knowledge of them is a
the moulding materials. prerequisite.
11
5.1 Standards for materials and semifinished products Part 1 Sheets made of rigid polyvinylchloride (rigid PVC)
of normal impact resistance; technical delivery
Moulding compounds conditions
DIN 7748 Unplasticized polyvinylchloride (PVC-U) – Part 2 Sheets made of ridid polyvinylchloride (rigid PVC)
moulding compounds of raised impact resistance, of high impact resi-
stance; technical delivery conditions
Part 1 Classification and naming
DIN 16971 Extruded sheets made of polypropylene (PP);
Part 2 Determination of properties technical delivery conditions
DIN 16774 Polypropylene (PP)-moulding compounds
Part 1 Classification and naming 5.2 Test standards
Part 2 Determination of properties DIN 16888 Evaluation of the chemical resistance of pipes
DIN 16776 Polyethylene (PE)-moulding compounds made of thermoplastics;
Part 1 Classification and naming Part 1 pipes made of polyolefines
Part 2 Determination of properties DIN 16889 Determination of chemical resistance factors on
pipes made of thermoplastics;
Part 1 pipes made of polyolefines
Pipes
DIN 53444 Tensile creep test
Pipes DIN 53448 Impact tensile test
DIN 8061 Pipes made of unplasticized polyvinylchloride; DIN 53449 Evaluation of stress cracking (ESC) –
general quality requirements
Part 1 Ball and pin impression procedure
DIN 8061 Chemical resistance of pipes and pipeline
Suppl. sheet 1 sections made of PVC-U Part 2 Tensile creep test procedure
DIN 8062 Pipes made of unplasticized polyvinylchloride; Part 3 Bending stripe procedure
dimensions DIN 53453 Impact bending test
DIN 8074 Pipes made of high-density polyethylene (PE- DIN 54455 Tensile strength
HD); dimensions DIN 53457 Determination of the modulus of elasticity in
DIN 8075 Pipes made of high-density polyethylene (PE- tensile strength, compression and bending test
HD); DIN 53460 Determination of Vicat-softening temperature of
general quality requirements, testing non-hardenable plastics
DIN 8075 Chemical resistance of pipes and pipeline DIN 53461 Determination of the dimensional stability tempe-
Suppl. sheet 1 sections made of PE-HD rature
DIN 8077 Pipes made of polypropylene (PP); dimensions DIN 53476 Determination of the behaviour to liquids
DIN 8078 Pipes made of polypropylene (PP) type 1 and DIN 53753 Impact bending test on test pieces with hole or
type 2; general quality requirements, testing double-V-notches
DIN 8078 Chemical resistance of pipes and pipeline DIN 53759 Creep test under internal compression on hollow
Suppl. sheet 1 sections made of PP parts
DIN 8080 Pipes made of chlorinated polyvinylchloride DIN 54852 Bending creep test with three-point and four-
(PVC-C); general quality requirements, testing point charge
Solid rods / profiles 5.3 DVS directives

DIN 16941 Extruded thermoplastic profiles; general tole- DVS 2201 Testing of semifinished products of thermoplatics;
rances for dimensions, section and position weldability;
DIN 16980 Round thermoplastic rods; dimensions Part 2 test methods; requirements
DIN 16985 Semifinished products made of thermoplastics; DVS 2203 Testing of welded joints of thermoplastics –
technical delivery conditions Part 2 Tensile strength
DIN 16986 Flat rods made of thermoplastics; dimensions Part 3 Impact tensile test
Part 4 Tensile creep test
Plates / sheets DVS 2205 Calculation of containers and apparatus made of
DIN 16925 Extruded sheets made of high-density poly- thermoplastics;
ethylene (PE-HD); technical delivery conditions Part 1 characteristic values
DIN 16927 Sheets made of unplasticized polyvinylchloride; DVS 2211 Filler materials for thermoplastics; scope; desig-
technical delivery conditions nation; requirements; tests
12
File: D:\Eigene Dateien\Kunden\DVS\Ri+Me\2201\2201-1\1-2201-1.fm

Erstellt am: 25.07.2004
Zuletzt geändert am: 02.08.2004
Oktober/October 2004
Prüfen von Halbzeug aus Thermoplasten;

Grundlagen – Hinweise
DVS – DEUTSCHER VERBAND Werkstoffe und Kurzzeichen Richtlinie
FÜR SCHWEISSEN UND Testing of semi-finished products Guideline
VERWANDTE VERFAHREN E.V. made of thermoplastics; DVS 2201-1
Basics – indications Beiblatt 1
Material and abbreviation Supplement 1
Kurzzeichen / Abbreviation Werkstoffbezeichnung / Material

PE-HD (PE 100, PE 80, PE 63)* Polyethylen hoher Dichte (PE hart)** / Polyethylene high density (PE rigid)**
PE-X Polyethylen vernetzt / Polyethylene crosslinked
PE-EL Polyethylen elektrisch leitfähig / Polyethylene electrically conductive
PP-B Polypropylen-Block-Copolymerisat / Polypropylene block copolymer
PP-H Polypropylen-Homopolymerisat / Polypropylene homopolymer
PP-R Polypropylen-Random-Copolymerisat / Polypropylene random copolymer
ABS Acrylnitrit-Butadien-Styrol / Acrylonitrile-butadiene-styrene
PVC-C Polyvinylchlorid chloriert / Polyvinyl chloride chlorinated

PVC-HI Polyvinylchlorid hoch schlagzäh / Polyvinyl chloride high impact resistant

PVC-RI Polyvinylchlorid erhöht schlagzäh / Polyvinyl chloride raised impact resistant
PVC-NI Polyvinylchlorid normal schlagzäh / Polyvinyl chloride normal impact resistant
PVC-U Polyvinylchlorid weichmacherfrei (PVC hart)** / Polyvinyl chloride unplasticised (PVC rigid)**
PVDF Polyvinylidenfluorid / Polyvinylidene fluoride
PVDF-C Typ 1 Polyvinylidenfluorid-Copolymer Typ 1 / Polyvinylidene fluoride copolymer type 1
ECTFE Ethylen-Chlortrifluorethylen / Ethylene-chlorotrifluoroethylene
ETFE Ethylen-Tetrafluorethylen / Ethylene-tetrafluoroethylene
THV Ethylen-Tetrafluorethylen-Copolymer / Ethylene-tetrafluoroethylene copolymer
MFA Tetrafluorethylen/Perfluormethylvinylether / Tetrafluoroethylene-perfluoromethylether
FEP Tetrafluorethylen/Perfluorvinylether Copolymerisat / Tetrafluoroethylene-hexafluoropropylene
PFA Perfluoralkoxy-Copolymer / Tetrafluoroethylene-perfluoropropylether
PTFE-M Polytetrafluorethylen-Copolymer / Polytetrafluoroethylene copolymer
PTFE Polytetrafluorethylen / Polytetrafluoroethylene
* Die Zahlen kennzeichnen die Festigkeitsklasse. / The numbers mark the strength class.
** alte Bezeichnung / earlier used term

Bezug: Verlag für Schweißen und verwandte Verfahren DVS-Verlag GmbH, Postfach 10 19 65, 40010 Düsseldorf, Telefon (02 11) 15 91- 0, Telefax (02 11) 15 91-150
Orders to: DVS-Verlag GmbH, P. O. Box 10 19 65, D-40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Telefax: + 49(0)211/1591-150
13
Erstellt am:
Zuletzt geändert am:
25.07.2004
02.08.2004

DVS – DEUTSCHER VERBAND Richtlinien mit Zeitstandkennlinien für Rohre Richtlinie
Directives for creep rupture curves of pipes Supplement 2
Werkstoff Grundnormen bzw. Richtlinien

Material Fundamental standards or directives
PVC-U DIN 8061
PE-HD DIN 8075
PP DIN 8078
ABS DIN EN ISO 15493
PVC-C DIN 8080
PVDF DVS 2205-1
PVDF-C Typ 1 –*
PVDF-C Typ 2 –*
PVDF-C Typ 3 –*
ECTFE DVS 2205-1**
ETFE –*
THV –*
MFA DVS 2205-1**
FEP –*
PFA DVS 2205-1**
PTFE-M DVS 2205-1**
PTFE DVS 2205-1**
* Keine Daten verfügbar für selbsttragende Konstruktionen. / No data available for self supporting structures.
** in Vorbereitung / in preparation
Anmerkung / Note:
Materialtyp Einheit PVDF-C Typ 1/Type 1 PVDF-C Typ 2/Type 2 PVDF-C Typ 3/Type 3
Material type Unit
Schmelzpunkt °C 158 – 160 140 – 145 132 – 138
Melting point
E-Modul MPa 950 – 1150 600 – 700 360 – 440
Flexural modulus

14
Erstellt am:
25.07.2004
02.08.2004

DVS – DEUTSCHER VERBAND Lineare Wärmeausdehnungskoeffizienten Richtlinie
Linear thermal expansion coefficients Supplement 3
Werkstoff Temperaturbereich Wärmeausdehnungskoeffizient

Material Temperature range Thermal expansion coefficient
°C 1/K · 10-4 mm/mK
PVC-U 20...60 0,7...0,8 0,07...0,08
PVC-C 20...100 0,6...0,7 0,06...0,07
PE-HD 20...80 1,5...2,0 0,15...0,20
PP 20...100 1,6...1,8 0,16...0,18
ABS 20…60 ~1,0 ~0,10
PVDF 20...140 1,2...1,8 0,12...0,18
PVDF-C Typ 1 20...130 1,4...1,8 0,14...0,18

PVDF-C Typ 2 20...120 1,4...1,8 0,14...0,18
PVDF-C Typ 3 20...120 1,5...1,8 0,15...0,18
ECTFE 20...150 0,9...1,8 0,09...0,18
ETFE 30...150 1,1...1,8 0,11...0,18
THV 20...150 2,0...2,4 0,20...0,24
MFA 20...200 1,0...2,2 0,10...0,22
FEP 20...200 1,4...2,6 0,14...0,26
PFA 20...200 1,2...2,0 0,12...0,20
PTFE-M 20...200 1,0...1,3 0,10...0,13
PTFE 20...200 1,0...1,5 0,10...0,15
Genauere Angaben zur Berechnung enthält DVS 2205-1 Beiblatt 5 (in Vorbereitung).
Detailed data for calculation are given in DVS 2205-1 Supplement 5 (in preparation).
Hinweis: Zwischen Wärmeausdehnungskoeffizient und Temperatur für den angegebenen Temperaturbereich besteht im allgemeinen
kein linearer Zusammenhang.
Remark: Within the specific temperature range the thermal expansion coefficient may follow a non linear function.

15

Erstellt am: 25.07.2004
Zuletzt geändert am: 02.08.2004

DVS – DEUTSCHER VERBAND Halbzeugverhalten bei Warmlagerung Richtlinie
Dimension stability of semi-finished material after heating Supplement 4
Werkstoff Rohre Tafeln

Material Pipes Sheets
PVC-U DIN 8061 DIN 16927 / ISO 11833-1
PVC-C DIN 8080 (DIN 16927)
PE-HD DIN 8075 DIN EN ISO 14632
[extrudierte Platten/extruded sheets]
DIN EN ISO 15527
[gepresste Platten/compression molded sheets]
PP DIN 8078 DIN EN ISO 15013
ABS DIN EN ISO 15493 -

PVDF ISO 10931 DIN EN ISO 15014

PVDF-C Typ 1 – DIN EN ISO 15014
ECTFE – –
ETFE – –
THV – –
MFA – –
FEP – –
PFA – –
PTFE-M ISO 13000 ISO 13000
PTFE ISO 13000 ISO 13000
( ) Diese Normen können sinngemäß angewendet werden. Die Versuchsbedingungen sind den Kenndaten dieser Werkstoffe bzw. DVS 2212 anzupas-
sen.
These standards can be applied in a general manner. The test conditions are to be adapted to the characteristics of these materials or to DVS 2212.

16
Bearbeiter: Osenberg
File: D:\Eigene Daten\Kunden\DVS\Ri+Me\2201\2201-1\2201-1b5.fm
Erstellt am:
01.08.2006
07.11.2011
Entwurf/Draft Oktober/October 2006
DVS – DEUTSCHER VERBAND Temperatur-Zeit-Grenzen der Wärmealterung

FÜR SCHWEISSEN UND Service life temperature time limits Richtlinie/Directive
VERWANDTE VERFAHREN E.V. due to thermal ageing DVS 2201-1
Beiblatt/Supplement 5
Einsprüche bis 31. Januar 2006 / Comments until January 31, 2006
Dieser Entwurf wird der Öffentlichkeit zur Prüfung und Stellungnahme vorgelegt. Ergänzungs- oder Änderungsvorschläge werden
erbeten an den DVS e.V., Postfach 10 19 65, 40010 Düsseldorf.
This draft is presented to the public for examination and comments. Proposals for additions or modifications should be sent to DVS
e.V., P.O. Box 10 19 65, D-40010 Düsseldorf, Germany, before the date mentioned above.
Maximale Einsatztemperatur in °C nach Einsatzdauer in Jahren1)

Werkstoff Maximum service temperature in °C in accordance of service time in years1)
Material
1 Jahr 5 Jahre 10 Jahre 20 Jahre 25 Jahre 50 Jahre 100 Jahre
PVC-U2) 60 60 60 60 60 40
A
PVC-C 90 60 40
PE 80 60 55 50 45 40 35
B
PP 120 100 90 80 70 60
PVDF2) 140 140 140 130 120 100
PVDF-C Typ 12) 130 120 100
PVDF-C Typ 22) 120 100
C
PVDF-C Typ 32) 100
ECTFE2) 140 130 120
ETFE2) 140 130 120
PTFE 260 150
PTFE-M 260 150
D PFA 260 150
FEP 200 150
MFA 260 150
THV3)
1) Chemische Einflüsse, außer Wasser, sind in der Tabelle nicht berücksichtigt. / Chemical influences, except water, are not covered in the table.
2) Erfahrungswerte / Empirical values
3) Keine Daten verfügbar. / No data available.
A Die Temperatur-Zeit-Grenze wird im wesentlichen durch Phänomene des Glasübergangs bestimmt. /

The service life time temperature limit is mainly governed by effects related to the glass transition.
B Die Temperatur-Zeit-Grenze wird im wesentlichen durch Phänomene der Thermooxydation bestimmt. /
The service life time temperature limit is mainly governed by effects related to thermooxydation.
C Die Temperatur-Zeit-Grenze wird im wesentlichen durch Phänomene im kristallinen Gefüge bei Annäherung an den Schmelz-
punkt bestimmt. /
The service life time temperature limit is mainly governed by effects related to crystallinity upon approaching the melting point.
D Keine thermische Alterung bekannt bei Anwendungstemperaturen, die unterhalb der in der Tabelle angegebenen Werte liegen. /
No thermal ageing is known below values shown in the table.
Bezug: Verlag für Schweißen und verwandte Verfahren DVS-Verlag GmbH, Postfach 10 19 65, 40010 Düsseldorf, Telefon (02 11) 15 91- 0, Telefax (02 11) 1591-150
17
File-Name: e2201t2.fm
DVS – DEUTSCHER VERBAND Testing of semi-finished products of Direction D

FÜR SCHWEISSEN UND thermoplastics: Weldability DVS 2201-2
V
VERWANDTE VERFAHREN E.V. Test methods – Requirements (July 1985) S 
Dimensions in mm
Contents: welding partners. The allocation of the material characteristics is

done appropriately with the help of known reference specimens
1 Scope or by turning to the relevant literature (1 ... 3) where also more
2 Testing of welding partners detailed identification tests are described. The following simple
2.1 Check of identity tests may be employed.
2.2 Check of surface
3 Testing of weldability 2.1.1 Comparison of densities
3.1 Tear-off test in hot-gas welding It is established by immersion in water whether the test piece
3.2 Stretch test in hot-gas welding floats or sinks, Table 1.
3.3 Adhesion test in heated tool butt welding
3.4 Adhesion test in extrusion welding Table 1. Classification into density groups.
4 Relevant standards and DVS directions
5 Literature floating sinking

(density < 1 g/cm3) (density > 1 g/cm3)
1 Scope polyethylene PE polyvinyl chloride PVC

polypropylene PP polyvinylidene fluoride PVDF
This Direction provides the processor of semi-finished products
of thermoplastics with references to the informative checking of 2.1.2 Comparison of combustibility
the weldability of a given combination of semi-finished products
One edge of a test piece is held into a small flame (e. g. cigarette
(pipes, plates, sections, mouldings) with one another or with filler
lighter, match). The following features are to be noted, Table 2:
material. It is the object of these checks to prevent in particular
any mix-ups of the materials and to recognize changes in the – Ignitability
welding behaviour of the partners brought about by: – Combustion behaviour
– Melting or dripping behaviour
– Transport and intermediate storage (for example loss of mar-
– Smoke development
king, contamination)
– Smell of fume
– Internal stress conditions through the effects of processing or
Fumes may constitute a health hazard. For this reason care
operation (for example hot-formed structural parts or impermis-
should be taken in the smell test that, by fanning away the fumes,
sibly high residual stresses)
only small amounts are taken.
– Ageing through the effects of environment and operation (for
example mechanical stress, influence of heat and media), es- Table 2. Assessment criteria in the combustion test.
pecially if repair welding is to be carried out, etc.
The tests described do not provide evidence of the quality of the Material Characteristics
semi-finished products. Similarly they give no information on the PE ignitable, continues to burn steadily outside the
quality of the welded joints produced with the welding partners. flame, forms burning drips, slight smoke
Proof of the weldability with regard to the quality of the welding development, paraffinic smell (candle)
work is possible according to DVS 2203. The required welding PP as PE, but with added smell and stronger smoke
test pieces can be produced, tested and evaluated according to development, especially in not readily flammable
DVS 2212. materials
The quality of the semi-finished products used should be PVC not readily ignitable, goes out outside the flame,
assessed according to the relevant DIN standards and/or the strong grey smoke development, pungent
corresponding terms of delivery of the manufacturers and the hydrochloric smell
above-mentioned DVS directions; with regard to the welding filler
PVDF not readily ignitable, goes out outside the flame,
materials reference is made to DVS 2211.
very sooty, pungent, hydrofluoric smell.
2 Testing of welding partners The material characteristics described may alter owing to
modifying agents, filling materials, flame-retardants etc.
2.1 Check of identity
2.2 Check of surface
In cases of doubt in respect of the similarity of composition of the
welding partners, checks establishing their identity have to be A surface check is necessary in particular in cases of repair
carried out. An informative determination of the type of welding at the face or where semi-finished products have been
thermoplastics is possible by a comparative check of some stored in an unsatisfactory manner. It is done through inspection
material characteristics in simple tests described in the following. in adequate lighting, possibly with the help of a manifying glass
They may be carried out on small samples taken from the with approx. five times magnification. This will show whether
18
visible changes owing to effects of the environment or operation The remaining marked welding rods are welded directly adjoining
have occurred. the rods already welded on with increased stretching, Figure 2.
All welding rods should touch each other and the specimen
If changes or discolorations, fine cracks, pores etc. are
welded on previously should be heated again to welding
recognizable, the surface has to be scraped by suitable means
temperature. The weld filler is considered suitable if the minimum
(e. g. blunt scraper) in the welding area down to the sound base
values for the stretching indicated in Table 3 are attained and the
material. This allows to establish how deep into the material
weld bead so stretched does not tear when a further weld bend is
these changes extend.
welded on directly next to it. The period between the individual
If there are signs of far-reaching damage, or if further defects in welds should be ≤ 1 min.
the cross-section of the semi-finished product are suspected, a
cross-sectional check, possibly with the inclusion of further tests,
is required.
3 Testing of weldability
The mastery and application of the principles of welding

according to DIN 16960 as well as the execution of the welding
by trained and, if necessary, qualified welders according to DVS
2212 is assumed.
The following tests are to be carried out on the surface prepared Figure 2. Stretching test.
for welding. This applies in particular to any changes in the
material described under 2.2. The tests described in the following Table 3. Minimum values for the stretching of the weld filler in hot-
are based on many years of experience in the welding gas welding with torch separate from filler rod (WF).
engineering of thermoplastics.
Material Streching in %
PE-HD 30
PP-H 20
plate direction
PP-C 20
PVC-C 90
PVC-HI 90
PvC-U 90
PVDF 20
3.3 Adhesion test in heated tool butt welding (HS)

After the preparation of the welding faces two test pieces of
Figure 1. Tear-off test.
approx. 100 mm length and 20 to 50 mm width, or corresponding
to a welding area of 2 cm2, are welded together. The
3.1 Tear-off test in hot-gas welding (WF/WZ) recommended values for the welding conditions can be found in
Table 4. For materials not included there the appropriate data
After suitable preparation of the faces to be welded, filler material given by the manufacturers of the semi-finished products are to
according to DVS 2211 is welded onto the base material be used.
corresponding to DIN 16960. As shown in Figure 1 three weld
beads – wire or section – are welded on over a length of approx.
Table 4. Welding conditions for the adhesion test (recommended
50 mm so that on each test piece a free end of approx. 50 mm
values).
remains.
– 3 s after withdrawal of the welding equipment it is endeavoured Material Temperature Preheating Contact pressure
by pulling at the free end vertically to the surface of the base Heated tool time (N) approx.
material to tear off the first weld filler from the base material, oC s Preheating Welding
– on the second specimen the tear-off is done after 10 s, and PE-HD 210 45 15 30
– on the third specimen after complete cooling, i. e. not sooner PP-H 210 45 15 30
than 10 minutes after the welding. PP-C 210 45 15 30
PVC-C 240 35 15 50
The weldability is considered adequate if only the filler tears, that PVC-HI 220 35 25 50
is to say if in the 1st and 2nd specimen it can be detached over a PVC-U 230 35 25 50
length of max. 15 mm. In the 3rd test piece there must be no PVDF 240 30 15 30
separation between weld filler and base material.
3.2 Stretch test in hot-gas welding (WF) In the case of PE, PP and PVDF it is endeavoured, after a
cooling period, manually to separate the joint vertically to the
For the testing of the suitability of the weld filler material
joining plane. For PVC the test piece is bent manually over
measured lengths of 50 mm are marked, for example by pencil,
180°C directly following the welding process. Weldability exists if
on some welding rods. The first welding rod is welded onto the
the weld does not fail or, in the case of polyolefins, if a stretching
surface of the base material by the hot-gas process with torch
of the joining zone is possible.
separate from filler whilst it is subjected to uniform stretching.
The stretching ε achieved is determined from the distance of the
3.4 Adhesion test in extrusion welding (WE)
two measuring marks:
This method serves to ascertain the weldability of weld filler and
ln – lo base material. The test is carried out as follows: A weld is
ε = -------------- ⋅ 100 (%)
lo extruded onto the abutting surface of two plates, Figure 3. For
this purpose a special shoe without "lug" is used. Directly prior to
lo = marked measured length = 50 mm welding the surface is prepared by cutting (e. g. with a scraper)
ln = distance of measured length after welding beyond the weld region.
19
welding shoe 4 Relevant standards and DVS directions

welding deposit welding direction
DIN 1910 Welding: definitions, classification of welding pro-
Part 1 cesses.
DIN 1910 Welding of plastics: processes
Part 3
DIN 16960 Welding of thermoplastic materials, general direc-
Part 1 tions
Figure 3. Making of weld test piece. DVS 2201 Testing of semi-finished products of thermoplastics:
Part 1 fundamental principles – references
A piece of approx. 200 mm length is welded. After cooling strips DVS 2203 Testing of welded joints of thermoplastics: test
of a width of approx. 6 mm are cut from the centre of the weld Part 1 methods – requirements
and bent over the unwelded joint of the weld junction. Figure 4.
The fracture must pass through the weld. The joined faces must DVS 2208 Welding ot thermoplastics: machines and equipment
not detach themselves (shearing off joined part surface ↔ Part 1 for heated tool butt welding
welding deposit). DVS 2208 Welding of thermoplastics: machines and equipment
Part 2 for hot-gas welding
zones of preparation DVS 2209 Welding of thermoplastics: extrusion welding, pro-
welding deposit direction of bending Part 1 cesses – features
DVS 2211 Fillers for thermoplastics: marking, requirements,
testing
DVS 2212 Testing of welders for welding plastics
5 Literature
Figure 4. Test of adhesion.
[1] Saechtling, H. J.: Plastics identification table (Kunststoff-
Bestimmungstafel.) Carl Hanser Verlag, München 1979.
[2] Krause, A., and A. Lange: Methods of plastics identification
(Kunststoff-Bestimmungsmöglichkeiten). Carl Hanser Ver-
lag, München 1979.
[3] Braun, D.: Identification of plastics (Erkennen von Kunst-
stoffen). Carl Hanser Verlag, München 1978.
20
November 2014

Evaluation of imperfections
FÜR SCHWEISSEN UND
in joints of thermoplastic materials Technical Code
to piping parts and panels – DVS 2202
heated plate welding (HS, IR) Supplement 1
Contents:
1 Scope
2 Characteristics and evaluation of heated plate welding joints
(HS, IR)
1 Scope
This supplement contains the evaluation of heated plate (HS-, IR-)

welded joints in pipeline and plant construction, which have been
welded in accordance with e.g. Guideline DVS 2207-1 (PE),
Guideline DVS 2207-11 (PP), Guideline DVS 2207-12 (PVC-U)
or Guideline DVS 2207-15 (PVDF). Where appropriate this
guideline can also be applied to other materials (e.g. PB).
Guideline DVS 2202-1 of 07-2006 is currently being revised. The

welding processes will in future be divided into process-specific
supplement sheets.
– Supplement 1:
Heated plate welding, including contactless (HS, IR)
– Supplement 2:
Sleeve welding with incorporated electric heating element
(HM)
– Supplement 3:
Heated element sleeve welding (HD)
– Supplement 4:
Hot-gas welding with torch separate from filler rod and hot-gas
string bead welding (WF/WZ)
– Supplement 5:
Hot gas extrusion welding (WE)
Guideline DVS 2202 Supplement 1 supersedes sections 7.3
(Table 1) and 7.8 (Table 6) of Guideline DVS 2202-1 in their en-
tirety.
Both destructive and non-destructive testing are used. The tests
used to evaluate the welding result are listed in the following table.
21
22
2 Characteristics and evaluation of heated plate welded joints (HS and IR)
Cons. Quality level

Characteristic Description Test method
no. I II
Visual test result of the joint
1 Cracks Cracks running longitudinally or perpendicular to the Visual Not permitted Not permitted
seam
They may be present:
– in the base metal
Page 2 to DVS 2202 Supplement 1
– in the seam
2 Bulges Bulges k < 0 caused by e.g.: Visual Not permitted k < 0 Not permitted k < 0
– inadequate joining pressure
– insufficient cooling time
– change in position of the clamped workpiece during
the welding operation
3 Notches or grooves Notches or grooves in the base metal, longitudinal or Visual Localised permissible, if Localised permissible, if
perpendicular to the seam, and that run into the weld tapers out and notch base tapers out and notch base
area, caused by e.g.: is not sharp-edged is not sharp-edged
– clamping tool ∆s ≤ 0.1 s ∆s ≤ 0.1 s
– improper transport
– error during weld preparation
Cons. Quality level
no. I II
4 Misalignment in the joining plane The joint surfaces are offset to each other or different Misalignment measuring Permissible, if Permissible, if
thicknesses have not been evened out. device e ≤ 0.1 s e ≤ 0.2 s
– depending on the material and the thickness, max. 5 mm
the seam quality may suffer adverse effects
5 Stretching / constriction of the heat- Caused by e.g.: Visual Not permitted Not permitted
affected zone – an impermissible introduction of force during the
cooling phase
(does not apply to pipe-end incidence)
6 Shape of weld bead Due to the variety of materials and material types as Visual The result depends on the The result depends on
well as the number of possible weld bead formations, evaluation of the reference the evaluation of the
it is impossible to define uniform evaluation criteria. weld reference weld
No conclusions can be drawn on the long-term
behaviour of the seam based on the shape of the
weld bead.
It is recommended to produce and evaluate reference
welds.
7a Volume of weld bead Welding parameters may be wrong: Visual The result depends on The result depends on
is obviously too little/too much the evaluation of the the evaluation of the
– carry out a comparison weld
reference weld reference weld
(check welding parameters)
It is recommended to produce and evaluate reference
welds.
7b Uneven weld bead Different weld beads formations, in part or across the Visual Permissible, if Permissible, if
entire seam length/across all seams: B1 ≥ B2 B2  0.7 B1 B2  0.6 B1
B1 B2
– tilting of the heating element
– non-angular joining plane

– joining partners with different MFRs
23
24
Cons. Quality level
no. I II
8a Bubbles in bead surface Thermal damage caused by: Visual Not permitted Not permitted
– excessively high heat input
(e.g. due to high heating element temperature)
8b Bubbles in bead surface – due to humidity Visual Permissible, if the require- Permissible, if the require-
– due to material Additional inspection to ments of cons. no. 10 ments of cons. no. 10
Guideline DVS 2203-5 have been met. have been met.

Bubbles in the bead surface caused by PVC-U or C
and Not permitted, if evalua- Not permitted, if evalua-
materials have no impact on the quality of the welded
tion to Guideline DVS tion to Guideline DVS
joint. Evaluation to Guideline
2203-1 Supplement 3 has 2203-1 Supplement 3 has
DVS 2203-1 Supplement 3
not been met. not been met.
necessary
It is recommended to It is recommended to
produce and check produce and check
reference welds reference welds
Internal test result of the joint

9 Lack of fusion No or incomplete fusion on the joint surfaces, in part Visual Not permitted Not permitted
or across the entire weld cross-section, with/without
bubbles or nodules caused by e.g.:
– humidity
– contaminated joint surface
– oxidised joint surface
– excessively long change-over time
– incorrect heating element temperature
– insufficient joining force
10 Cavities Large number of dispersed or localised individual Visual Small individual cavities Small individual cavities
e.g. blowholes/pores blowholes/pores or inclusions caused by e.g.: permitted, if or lines of cavities
– steam formation during welding ∆s ≤ 0.05 s permitted, if
(water, solvent, cleaning agent, etc.) ∆s ≤ 0.15 s
– insufficient joining pressure
– insufficient cooling time
Note: Depending on the material and thickness, Additional inspection to Not permitted, if evalua- Not permitted, if evalua-
unavoidable shrinkage blowholes can occur in Guideline DVS 2203-2 tion to Guideline DVS tion to Guideline DVS
materials with a high crystallinity, e.g. PP, PVDF. and 2203-1 Supplement 1 has 2203-1 Supplement 1 has
not been met not been met

Evaluation to Guideline
necessary
Cons. Quality level
no. I II
11 Foreign matter inclusions E.g.: Visual Not permitted Not permitted
– contaminated heating element
– soiled joint surfaces
25
November 2012

Assessment of defects in joints between
FÜR SCHWEISSEN UND
thermoplastics on piping parts and panels – Technical Code
Sleeve welding with an DVS 2202
incorporated heating element (HM) Supplement 2
Contents:
1 Area of application
2 Characteristics and assessment of welded joints executed by
means of sleeve welding with an incorporated heating element
(HM)
This supplement includes the assessment of welded joints executed

by means of sleeve welding with an incorporated heating element
(HM) (including tapping valves) in pipeline construction (e.g. gas,
water, waste water, industrial, domestic plumbing and geothermal
piping systems) which were welded, for example, according to the
DVS 2207-1 technical code (PE-HD), the DVS 2207-11 technical

code (PP) or the DVS 2207-15 technical code (PVDF). The specified
assessment criteria are based on experience up to a diameter of
630 mm.
The DVS 2202-1 technical code (July 2006) is being revised at
present. In future, the welding processes will be divided into process-
related supplements:
– Supplement 1:
Heated tool butt welding including non-contact processes
(HS and IR)
– Supplement 2:
Sleeve welding with an incorporated heating element (HM)
– Supplement 3:
Heated tool sleeve welding (HD)
– Supplement 4:
Hot gas fan and string-bead welding (WF and WZ)
– Supplement 5:
The entire scope of Section 7.5 (Table 3) of the DVS 2202-1
technical code is being replaced with the publication of the
DVS 2202 technical code, Supplement 2.
Non-destructive and destructives tests and inspections are utilised.
The tests and inspections used for the evaluation of the welding
execution are listed in the following table.
26
2 Characteristics and assessment of welded joints executed by means of sleeve welding with an incorporated heating element (HM)
Cons. Characteristics Description Testing and inspection Assessment group

no. according to
I II
External findings of the joint
2.1 Insertion depth Insertion depth not or incorrectly scribed Visual Impermissible Impermissible
2.2 Melt emergence Weld material emerging locally or all around, on Visual Impermissible if melt Impermissible if melt
one or both sides of the fitting, e.g. due to: emerges beyond the fitting emerges beyond the fitting
– excessive welding energy body body
– excessive welding time
– immediately repeated welding operation
– excessive gap
– device defects
– twisting
Note:
Due to the system, there may be melt flow
visible from the outside between the pipe and
the fitting. However, the melt should not emerge
from the fitting body.
2.3 Pipe surface processing There is no visible machining extending beyond Visual Impermissible if no Impermissible if no
the fitting body corresponding machining corresponding machining
is recognisable is recognisable
The visible machining is: Visual Impermissible if the Impermissible if the
– irregular Additional testing and requirements according to requirements according to
– insufficient (chip thickness) inspection necessary the DVS 2203-1 technical the DVS 2203-1 technical
– not continuous according to the DVS code, Supplement 4 are code, Supplement 4 are
– not present 2203-6 technical code, not satisfied not satisfied
– excessive (undersize pipe) Supplement 1 and
– impermissible (manual scraping in the case assessment according to
of PE-X) the DVS 2203-1 techni-
cal code, Supplement 4
2.4 Angular deviation Pipe welded into the fitting diagonally on one or "Angle determination" Impermissible if e  1° Impermissible if e  2°
both sides, e.g. due to: according to the DVS (PE, PE-Xa, PB, PA and PP) (PE, PE-Xa, PB, PA and PP)
– alignment error 2206-5 technical code
– change in the position during the welding
Note:
The angular deviation is a defect which may

entail other defects (e.g. twisting (3.7) and melt
emergence (3.2)).
The assessment of the angular deviation is not
applicable to ring coil goods.
27
28
no. according to I II
Internal findings on the joint
2.5 Twisting Angular deviation with displacement of the hea- Additional testing and Impermissible if the Impermissible if the
ter spiral and the melt with or without separa- inspection necessary requirements according to requirements according to
tions in the joining plane and increased material according to the DVS the DVS 2203-1 technical the DVS 2203-1 technical
flow, e.g. due to: 2203-6 technical code, code, Supplement 4 are code, Supplement 4 are
– non-flush pipe ends Supplement 1 and not satisfied not satisfied
– inadequate curvature radii in the case of ring assessment according to
coils the DVS 2203-1 techni-
– bending moment on the sleeve cal code, Supplement 4
– movement during the welding
2.6 Incomplete pipe insertion Pipe ends offset or not touching each other or e.g. with a calliper gauge Impermissible if the existing Impermissible if the existing
a) the stop on one or both sides in the sleeve and insertion length deviates insertion length deviates
melt emergence on the inside or outside, e.g. from the stipulated insertion from the stipulated insertion
due to: length by > 5 % of the length by > 5 % of the
nominal diameter of the nominal diameter of the
a: insufficient pipe insertion on both sides / one
pipe (as from  400: max. pipe (as from  400: max.
side (no adequate coverage in the joining
20 mm) 20 mm)
plane)
For special structures For special structures
b: unequal pipe insertion
deviating from these stipu- deviating from these stipu-
b) c: pipe end not cut off at a right angle lations, attention must be lations, attention must be
paid to the information from paid to the information from
the manufacturer the manufacturer
c)
2.7 Pipe sagging Defects with possible melt emergence and Visual Impermissible if the pipe Impermissible if the pipe
change in the position of the spirals due to: Additional testing and sagging protrudes into the sagging protrudes into the
– excessive sagging of the pipe ends inspection necessary welding region and if the welding region and if the
according to the DVS requirements according to requirements according to
2203-6 technical code, the DVS 2203-1 technical the DVS 2203-1 technical
Supplement 1 and code, Supplement 4 are code, Supplement 4 are
assessment according to not satisfied not satisfied
the DVS 2203-1 techni-

cal code, Supplement 4
no. according to
I II
2.8 Lack of fusion due to shape inaccuracy Channel formation locally, over large axial areas Additional testing and Impermissible if the Impermissible if the
or radially around the circumference, e.g. due to: inspection necessary requirements according to requirements according to
– notches and/or grooves in the pipe surface according to the DVS the DVS 2203-1 technical the DVS 2203-1 technical
– deviating diameter tolerance 2203-6 technical code, code, Supplement 4 are code, Supplement 4 are
(e.g. undersize pipe) Supplement 1 and not satisfied not satisfied
– incorrect machining assessment according to
– mechanical damage the DVS 2203-1 techni-
– flaking cal code, Supplement 4
2.9 Lack of fusion due to insufficient material Incomplete joint locally or over large areas with Testing and inspection Impermissible if the Impermissible if the
locking or without separation in the joining plane, e.g. necessary according to requirements according to requirements according to
due to: the DVS 2203-6 techni- the DVS 2203-1 technical the DVS 2203-1 technical
– insufficient welding energy cal code, Supplement 1 code, Supplement 4 are code, Supplement 4 are
(e.g. premature welding termination) and assessment accor- not satisfied not satisfied
– moisture ding to the DVS 2203-1
– contaminated surface technical code, Supple-
– impermissible material combinations ment 4
2.10 Displaced heater spirals Heater spirals wave-shaped, non-uniform, If required, additional Impermissible if the Impermissible if the
piled-up or located in a displaced position in the testing and inspection requirements according to requirements according to
welding plane, e.g. due to: necessary according to the DVS 2203-1 technical the DVS 2203-1 technical
– weld overheating the DVS 2203-6 techni- code, Supplement 4 are code, Supplement 4 are
– soiled welding faces cal code, Supplement 1 not satisfied not satisfied
– twisting and assessment accor-
Impermissible if melt emer- Impermissible if melt emer-
– exceeded tolerances of the joining parts ding to the DVS 2203-1
ges beyond the fitting body / ges beyond the fitting body /
– pipe cut off diagonally technical code, Supple-
pipe end pipe end
– sagging pipe ends ment 4
Note:
Due to the system, the heater spirals may be
displaced.
Attention must be paid to the geometry of the
heater spirals.
2.11 Impermissible SDR class of the pipe Wall thickness of the pipe outside the SDR Visual / measurement Impermissible Impermissible
range stipulated by the fitting manufacturer
2.12 Voids (e.g. pores or shrinkage cavities) – excessive gap Testing and inspection Impermissible if the Impermissible if the
– shrinkage necessary according to requirements according to requirements according to
– moisture (water, cleaning agent ...) the DVS 2203-6 techni- the DVS 2203-1 technical the DVS 2203-1 technical
– air inclusion cal code, Supplement 1 code, Supplement 4 are code, Supplement 4 are
– overheating and assessment accor- not satisfied not satisfied
Note: ding to the DVS 2203-1
technical code, Supple-
Due to the system, voids may form, in particular, ment 4
in the case of diameters > 250 mm.
29
30
2.13 Foreign substance inclusions Axial separations or detachments locally or over Testing and inspection Impermissible if the Impermissible if the
large areas, e.g. due to: necessary according to requirements according to requirements according to
the DVS 2203-6 techni- the DVS 2203-1 technical the DVS 2203-1 technical
– contaminated surfaces
cal code, Supplement 1 code, Supplement 4 are code, Supplement 4 are
(e.g. dirt, grease, dust ...)
and assessment accor- not satisfied not satisfied
ding to the DVS 2203-1
ment 4
Additional tests and inspections in the case of saddle fittings for sleeve welding with an incorporated heating element
2.14 Lack of fusion due to insufficient positive Due to insufficient axial or radial positive locking Testing and inspection Impermissible if the Impermissible if the
locking in the welding plane in the case of a clamped saddle, e.g. due to: necessary according to requirements according to requirements according to
the DVS 2203-6 techni- the DVS 2203-1 technical the DVS 2203-1 technical
– no or incorrect positioning of the clamping tool
cal code, Supplement 1 code, Supplement 4 are code, Supplement 4 are
– incorrect use of the clamping jig of the saddle
and assessment accor- not satisfied not satisfied
– tapping before the welding
– tapping before the end of the cooling time
ment 4
2.15 Lack of fusion due to insufficient material Insufficient welding locally or over large areas, Testing and inspection Impermissible if the Impermissible if the
locking in the welding plane (pipe) as a e.g. due to: necessary according to requirements according to requirements according to
result of shape defects – deformed pipe the DVS 2203-6 techni- the DVS 2203-1 technical the DVS 2203-1 technical
– ovality cal code, Supplement 1 code, Supplement 4 are code, Supplement 4 are
– pipe curvature (ring coil) and assessment accor- not satisfied not satisfied
ment 4
November 2012
DVS – DEUTSCHER VERBAND Assessment of defects in joints between

FÜR SCHWEISSEN UND thermoplastics on piping parts and panels – Technical Code
VERWANDTE VERFAHREN E.V. Heated tool sleeve welding (HD) DVS 2202
Supplement 3
Contents:
2 Characteristics and assessment of welded joints executed by
means of heated tool sleeve welding (HD)
This supplement includes the assessment of welded joints executed

by means of heated tool sleeve welding (HD) in pipeline construction
(e.g. water, waste water, industrial, domestic plumbing and geo-
thermal piping systems) which were welded, for example, according
to the DVS 2207-1 technical code (PE-HD), the DVS 2207-11
technical code (PP) or the DVS 2207-15 technical code (PVDF).
Analogously, this technical code can also be applied to other ma-

terials (e.g. PB). The specified assessment criteria are based on
experience up to a diameter of 125 mm.
The DVS 2202-1 technical code (July 2006) is being revised at
present. In future, the welding processes will be divided into process-
related supplements.
– Supplement 1:
Heated tool butt welding including non-contact processes
(HS and IR)
– Supplement 2:
Sleeve welding with an incorporated heating element (HM)
– Supplement 3:
Heated tool sleeve welding (HD)
– Supplement 4:
Hot gas fan and string-bead welding (WF and WZ)
– Supplement 5:
The entire scope of Section 7.4 (Table 2) of the DVS 2202-1
technical code is being replaced with the publication of the
DVS 2202 technical code, Supplement 3.
Non-destructive and destructive tests and inspections are uti-
lised. The tests and inspections used for the evaluation of the
welding execution are listed in the following table.
31
32
2 Characteristics and assessment of welded joints executed by means of heated tool sleeve welding (HD)

no. according to
I II
External findings of the joint
2.1 Defective weld bead formation Different bead formation (b) or non-existent Visual Impermissible if the Impermissible if the
bead on one or both sides (a) (in part or around requirements according to requirements according to
a b Additional testing and inspec-
the entire weld circumference) due to: the DVS 2203-1 technical the DVS 2203-1 technical
tion necessary according to
code, Supplement 4 are not code, Supplement 4 are not
– excessive heated tool temperature (b) the DVS 2203-6 technical
satisfied satisfied
– excessive preheating time (b) code, Supplement 1 and
– diameter of the pipe, the sleeve or the heated assessment according to the
tool outside the permissible tolerances (a and b) DVS 2203-1 technical code,
– inadequate heated tool temperature (a) Supplement 4
– inadequate preheating time (a)
– inadequate fixing time
– tilted/twisted insertion (a)
– deformation due to improper clamping
2.2 Simple bead formation due to: Additional testing and inspec- Impermissible if the Impermissible if the
– inadequate preheating time tion necessary according to requirements according to requirements according to
– inadequate heated tool temperature the DVS 2203-6 technical the DVS 2203-1 technical the DVS 2203-1 technical
– impermissible tolerances of the pipe, the code, Supplement 1 and code, Supplement 4 are not code, Supplement 4 are not
fitting or the heated tool assessment according to the satisfied satisfied
– unequal temperatures of the joining members DVS 2203-1 technical code,
Supplement 4
2.3 High melt emergence, e.g. due to: Additional testing and inspec- Impermissible if the Impermissible if the
tion necessary according to requirements according to requirements according to
– excessive heated tool temperature
the DVS 2203-6 technical the DVS 2203-1 technical the DVS 2203-1 technical
– excessive preheating time
code, Supplement 1 and code, Supplement 4 are not code, Supplement 4 are not
– incorrect movement of the joining parts, e.g.
assessment according to the satisfied satisfied
due to deficient fixing
DVS 2203-1 technical code,
– impermissible tolerances
Supplement 4
2.4 Angular deviation (shape defect) Pipe welded into the sleeve diagonally on one "Angle determination" accor- Impermissible if e  1° Impermissible if e  2°
or both sides with or without slight twisting, e.g. ding to the DVS 2206-5 tech-
due to: nical code
– setting-up errors
– deficient manual welding
Note:
The angular deviation is a defect which may
entail other defects (e.g. twisting (...) and melt
emergence (...)).
For the assessment of the angular deviation,

the pipe curvature must be taken into conside-
ration in the case of ring coil goods.
Internal findings of the joint
2.5 Incomplete pipe insertion For example, due to: Length measuring device Impermissible Impermissible
– inadequate preheating times
– pipe ends not at a right angle
– inadequate heated tool temperature
– axial movement during the cooling time
– excessive changeover time
– impermissible tolerances of the pipe, the
fitting or the heated tool
2.6 Lack of fusion due to insufficient Channel formation locally, over large axial areas Additional testing and inspec- Impermissible if the Impermissible if the
positive locking or around the circumference, e.g. due to: tion necessary according to requirements according to requirements according to
– notches in the pipe surface
– diameter of the pipe, the sleeve or the heated
tool outside the permissible tolerances
– incorrect machining
Supplement 4
– pipe not flush in the sleeve
– deformation due to improper clamping
2.7 Lack of fusion due to insufficient Incomplete welding locally or over large areas Additional testing and inspec- Impermissible if the Impermissible if the
material locking with separation in the joining plane, e.g. due to: tion necessary according to requirements according to requirements according to
– excessive pipe insertion
– thermal damage
– contaminated joining faces
– incorrect material combination
Supplement 4
– residues on the heated tool
2.8 Constricted pipe cross-section For example, due to: Visual Impermissible if the Impermissible if the
Additional testing and inspec- permissible insertion permissible insertion
– excessive pipe insertion during the heating or
tion necessary according to depth is exceeded depth is exceeded
the joining
– welding of pipes/sleeves with inadequate wall the DVS 2203-6 technical Impermissible if the Impermissible if the
thicknesses code, Supplement 1 and requirements according to requirements according to
– excessive preheating time assessment according to the the DVS 2203-1 technical the DVS 2203-1 technical
– axial movement during the cooling time DVS 2203-1 technical code, code, Supplement 4 are not code, Supplement 4 are not
– excessive heated tool temperature Supplement 4 satisfied satisfied
– incorrect heating tool
Note:
Pay attention to the required flow rate cross-
section!
33
34
no. according to
I II
2.9 Foreign substance inclusions Axial separations or detachments locally or over Testing and inspection Impermissible if the Impermissible if the
large areas, e.g. due to: necessary according to the requirements according to requirements according to
DVS 2203-6 technical code, the DVS 2203-1 technical the DVS 2203-1 technical
– foreign substances
Supplement 1 and assess- code, Supplement 4 are not code, Supplement 4 are not
– contaminated surfaces
ment according to the satisfied satisfied
(e.g. dirt, grease, dust ...)
Supplement 4
File: C:\DVS\Merkblätter und Richtlinien\2202-1-E\2202-1_EN-2007.fm
Created on: 11.02.2005
Last changed on: 06.11.2007
January 2008
DVS – DEUTSCHER VERBAND Imperfections in thermoplastic welded

FÜR SCHWEISSEN UND joints Technical Code
VERWANDTE VERFAHREN E.V. Features, description, evaluation DVS 2202-1
Translation of the German version from July 2006
Contents joints with the objective of enabling a generally valid evaluation

that takes due consideration of a system of multiple quality re-
1 Scope quirement levels. The description of the imperfections is based
1.1 Welding processes on the terminology defined in DIN 32502. However, the order of
1.2 Materials the descriptions has been altered in the present document.
2 Acceptance levels This guideline is intended primarily for weld evaluation by visual
2.1 Classification inspection but does not exclude further tests.
2.2 Criteria for establishing acceptance levels
3 Requirements on welded joints New plastics or plastics developed in future may have different
3.1 Quality features of welded joint execution characteristics (e. g. bead and flash shapes). If different materi-
Reprinting and copying, even in the form of excerpts, is only allowed subject to the publishers’ permission
3.2 Additional requirements on weld quality als are to be welded together (e. g. PE 80 / PE 100 or fittings with
3.3 Requirements on finishing processes an MFR considerably higher than the tubing to which they are
4 Symbolic representation and dimensions of welds welded) then this difference must also be taken into considera-
5 Inspection, testing and evaluation tion in the evaluation.
5.1 General If specific imperfections are to be excluded or kept within certain
5.2 Comparison with requirements limits when welded joints are made, this can be emphasized by
5.2.1 Requirements classification into one of the acceptance levels.
5.2.2 Combinations and frequent occurrence of imperfections
5.3 Evaluation Application of the guideline and the measures necessary for con-
5.3.1 Non-permissible imperfections forming with it may be governed by statutory regulations, by
5.3.2 Localized imperfections generally recognized rules of technology, or may be based on
5.3.3 Imperfections which are permissible subject to certain delivery agreements.
conditions Weld evaluation in accordance with this guideline may only be
5.3.4 Adaptation of tolerance limits carried out by a qualified expert who has the required
6 Reworking of welds found to have imperfections experience1).
7 Annex
7.1 Explanatory notes 1.1 Welding processes
7.2 Other applicable standards and guidelines
This guideline deals with imperfections which may occur in the
7.3 Table 1:
following welding processes:
Description of the acceptance levels for welds made by
heated tool butt welding (HS)
Welding process Abbreviation Table Page
7.4 Table 2:
Description of the acceptance levels for welds made by Heated tool butt HS 1 5
heated tool socket welding (HD)
7.5 Table 3: Heated tool socket HD 2 8
Electrofusion HM 3 11
electrofusion welding (HM)
7.6 Table 4: Hot gas round nozzle WF
Description of the acceptance levels for welds made by hot
hot gas high-speed 4 16
gas high-speed nozzle welding and hot gas round nozzle WZ
welding (WZ, WF) nozzle
7.7 Table 5:
Hot gas extrusion WE 5 20
Description of the acceptance levels for welds made by hot
gas extrusion welding (WE) Non-contact
7.8 Table 6: (IR) 6 25
heated tool
contactless heating tool butt welding (IR)
1) For example, specialist for plastics welding in accordance with DVS
2213 or having equivalent qualifications.
1 Scope
1.2 Materials
This guideline categorizes and describes, for the methods cov-
ered by the document, imperfections in thermoplastic welded This guideline applies to welded joints of components and as-
This publication has been compiled by a group of experienced professionals working as a team in an honorary capacity and is recommended as an important source
of knowledge which is to be taken into consideration. All users must consider whether and to what extent the information contained is applicable to their particular
purposes and check whether the edition at hand is still valid. DVS and all parties involved in the compiling of the document accept no liability of any kind whatsoever.

(DVS, Technical Committee, Working Group "Joining of Plastics")
Obtainable from: Verlag für Schweißen und verwandte Verfahren DVS-Verlag GmbH, Postfach 10 19 65, 40010 Düsseldorf, Telephone +49 (0)2 11 1591- 0,
Telefax +49 (0)2 11 1591-150
35
Page 2 of DVS 2202-1
semblies, for example fabrications and pipelines made from the tions. These shading variations are not actually visible in the
plastic materials listed below: material.
The welded joint can then be evaluated according to standard-
Abbreviation Material designation ized criteria (e. g. during acceptance inspections) on the basis of
the respective features, i. e. on the type and extent of permissible
PE 63
deviations.
PE 80 Polyethylene
3.2 Additional requirements on weld quality
PE 100
Materials-engineering requirements such as those listed below
PE-X Cross-linked polyethylene are not the subject of this guideline:
PP-H Polypropylene homopolymer (type 1) – resistance to shape changes (e. g. weld strength reduction
factor) in accordance with DVS 2203-2 and -4,
PP-B Polypropylene block copolymer (type 2) – tolerance to shape changes (e. g. bend angle or displacement
PP-R Polypropylene random copolymer (type 3) when crack appears) in accordance with DVS 2203-5,
– resistance to attack by chemicals (e. g. resistance factor) in
PVC-C Chlorinated polyvinyl chloride accordance with DVS 2205-1.
PVC-U Polyvinyl chloride
3.3 Requirements on finishing processes
PVDF Polvinylidene fluoride In certain cases, it may be necessary to dress the completed
welds.
The application of this guideline for welding other thermoplastics
shall be agreed individually between the contracting parties. This may be necessary, for instance:
– to resist dynamic loads (e. g. by ensuring notch-free junctions)
– to smooth weld surfaces (e. g. of linings)
2 Acceptance levels – to improve fluid dynamic characteristics (e. g. removing
internal beads in pipelines)
2.1 Classification – for technical inspection reasons.
The contracting company shall specify the quality by selecting an It is advisable to test and/or evaluate the weld both before and af-
acceptance level. The requirements thereby defined shall be met ter mechanical dressing.
when the welding work is executed.
Acceptance level Requirement level 4 Weld designation
I Strict requirements concerning safety The requirements on the respective welded joints shall be de-
and load-bearing capability fined in the fabrication instruction documents (e. g. assembly
II Medium requirements concerning safety drawing, welding diagram), with reference to the DVS guideline.
and load-bearing capability Normally, it is sufficient to identify a weld by means of a three-
part designation code (DIN EN 22553) as follows:
III Low requirements concerning safety and
load-bearing capability The first part is the (German) abbreviation for the welding proc-
ess (DIN 1910-3), followed by a hyphen, the second code is the
abbreviation of the weld shape followed by another hyphen and
2.2 Criteria for establishing acceptance levels the third code designates the acceptance level.
When establishing the acceptance levels, the following factors, Example: WZ-V-II
among others, shall be taken into account. If all the welded joints of a particular assembly are to be made to
– production (e. g. workshop, construction site, welding in the same acceptance level, then this can be specified in a field
confined spaces) provided for this purpose on the drawing.
– potential hazards (e. g. gas, liquids potentially dangerous to E. g.: all welds to be evaluated in accordance with
ground water) acceptance level
– statutory requirements (e. g. water-protection laws, Pressure II-DVS 2202-1
Equipment Directive) Additional requirements on the welding operation or for weld
– material behaviour (e. g. tough, brittle) characteristics, as well as for mechanical dressing of the joints
– operating conditions (e. g. static, changing) should also be noted in the fabrication documents.
– types of loads and stresses applied (e. g. static, dynamic)
5 Inspection, testing and evaluation
3 Requirements for welded joints
5.1 General
3.1 Quality features of the welded joints Visual inspection, measurements and, where necessary, suitable
The quality requirements of a welded joint are classified accord- non-destructive or destructive testing procedures are to be used
ing to the acceptance levels. It may be necessary for the welding to verify conformity with the requirements for the individual ac-
contractor to make sample welds before beginning production ceptance levels.
welding. This would serve to determine whether the requirements Tests shall be carried out on the welded joints of the assembly.
can be achieved by the respective welders and equipment. Specific characteristics can also be verified on test specimens
The specific features to be achieved and the descriptions used that are manufactured under comparable conditions.
for the findings of an inspection of external and/or internal fea- The nature and extent of the tests as well as the times at which
tures of the weld shall be checked in accordance with the they are to be conducted shall be agreed between the
definitions in tables 1 to 6. The shade variations in the schematic contracting parties. The test results should be documented in a
drawings in these tables indicate the location of the imperfec- suitable manner.
36
5.2 Comparison with requirements be made because the inspection was primarily carried out visual-
ly and by measurements, further inspections and tests shall be
5.2.1 Requirements conducted.
The test and inspection records can be compared with the con- If suitable tests subsequently prove that a tolerance limit given in
tents of tables 1 to 6 in order to determine where the results do columns I to III does not have any significant effect on the operat-
not conform with the requirements. When the part, assembly or ing characteristics of the welded joint or on other requirements in
an individual weld does not achieve the required acceptance lev- the intended application, then the inspecting expert may accept a
el – see subclause 2.1 – re-working is permitted. wider tolerance, provided that the user/operator or other entity re-
sponsible for the item in question is in agreement. The reasons
5.2.2 Combinations and multiple occurrence of for deviating from the specified tolerance limits as well as for the
imperfections acceptability of the changes shall be documented.
If an assembly or a weld contains two or more types of imperfec-

tions (even if they are of different acceptance levels), this may 6 Repair of welds found to have imperfections
amplify their effect. It must then be checked whether the assem-
bly or the welded joint still meets the specified requirements or In as far as possible, and if approved by the inspecting expert,
whether restrictions have to be imposed regarding safety and welds found to have non-permissible imperfections may be re-
load-bearing capability due to the accumulation of faults. paired by suitably qualified staff working according to generally
accepted procedures. The objective of such reworking is to
5.3 Evaluation achieve a weld quality conforming with the requirements. Where
necessary, the results shall be verified by extended inspections
Weld evaluation in accordance with this guideline may only be and tests.
carried out by a qualified expert who has the necessary experi-
ence 1). The welds shall be evaluated on the basis of the If reworking is not possible, the respective part or assembly does
imperfections shown in tables 1 to 6 (process defects, irregulari- not conform with the requirements of the present guideline.
ties, imperfections etc.) in which the respective evaluation
instructions and acceptance tolerance limits, where applicable,
are listed in columns I to III. The individual imperfection evalua- 7 Annex
tions are explained below in order to assist the inspecting expert.
7.1 Explanatory notes
5.3.1 Non-permissible imperfections With reference to the edition of 12/98, the following
important changes have been made:
If the imperfections detected are evaluated according to columns
I to III as being imperfections that are not permitted, the – Adaptation of the information in the acceptance levels to
inspecting expert is obliged to request mandatory repairs or pro- current experience, particularly with respect to the extremely
duction of a new weld. Furthermore, the inspecting expert shall different bead and flash shapes and their significance, as well
check whether a systematic fault that will impair the suitability of as to the angle errors as imperfect shapes of joints made by
the entire assembly (e. g. container, pipeline) has occurred. The electrofusion welding (HM).
results of this investigation shall be documented and submitted to – Extension by the additional table 6: “Description of the
the user/operator. Where necessary, recommendations for re- acceptance levels for welds made by non-contact heated tool
pairs shall be attached. butt welding (IR)”.
If any imperfection is detected which is not classified as being not – All figures have been completely revised. The same applies to
permitted in all acceptance levels in columns I to III, the inspect- the tables, which have been extended, to which new
ing expert may adjust the acceptance level accordingly, taking imperfections have been included and/or from which
into account the expected load on the welded joint and the poten- imperfections found to be no longer relevant have been
tial hazard in case of failure, and with the permission of the user/ removed, and to which new materials and material
operator or other entity responsible for the item in question. The modifications have been added (e. g. PE 100, PE-X).
decision of the inspecting expert shall be justified by calculations – Evaluations of welded joints in accordance with the present
or tests where necessary. guideline may only be made by qualified experts who can
provide proof of suitable experience.
5.3.2 Localized imperfections – The large number of available materials and material variants
is making it increasingly necessary to make test welds in order
Imperfections that have only occurred in a localized section of a to be able to evaluate the respective features.
welded joint may be permitted if they have no or very little effect
on the useability of the item when compared to the magnitude
and intensity of the expected loads and stresses. General experi-
ence has shown that this is ensured if the findings are within the
tolerance limits given in columns I to III. In all other cases, the
measures described in subclause 5.3.4 shall be taken.
5.3.3 Imperfections which are permissible subject to certain

conditions
The expression ‘permissible subject to certain conditions’ is
essentially understood to mean deviations from generally accept-
ed rules which do not affect the actual welded joint. Imperfections
permissible under certain conditions include cases where short
piping sections have to be welded together due to faulty prepara-
tion (measurement errors).
5.3.4 Adaptation of tolerance limits

When applying the tolerance limits given in this guideline to eval-
uate welds, the inspecting expert shall decide whether the
respective findings will affect the operating characteristics of the
inspected weld or any other requirements. If this decision cannot
37
7.2 Other applicable standards and technical codes

DIN 1910-3 Welding; welding of plastics, processes DVS 2207-4 Schweißen von thermoplastischen Kunststoffen;
DIN 32502 Imperfections in plastic welded joints, classifica- Extrusionsschweißen von Rohren, Rohrleitungs-
tion, terms, explanations teilen und Tafeln; Verfahren, Anforderungen
(Welding of thermoplastics - extrusion welding of
DIN EN 22553 Welded, brazed and soldered joints – symbolic pipes, pipeline components and sheets – meth-
representation on drawings (ISO 2553:1992) ods, requirements)
DVS 2201-1 Testing of semifinished products of thermoplas-
tics; Bases – indications DVS 2207-5 Welding of thermoplastics - welding of PE casing
pipes - tubes and tubular components
DVS 2203-1 Testing of welded joints of thermoplastics plates
and tubes; test methods – requirements DVS 2207-6 Welding of thermoplastics - Non-contact heated
tool butt welding of pipes, pipeline components
DVS 2203-2 Testing of welded joints of thermoplastic materials
and sheets – methods, equipment, parameters
– tensile test
DVS 2207-11 Welding of thermoplastics - Heated tool welding
of pipes, pipeline, components and sheets out of
and tubes – tensile creep test
PP
DVS 2207-15 Schweißen von thermoplastischen Kunststoffen;
and tubes; technological bend test
Heizelementschweißen von Rohren, Rohrlei-
DVS 2206 Prüfung von Bauteilen und Konstruktionen aus tungsteilen und Tafeln aus PVDF (Welding of
thermoplastischen Kunststoffen (Testing of build- thermoplastics - Heated tool welding of pipes,
ing components and structures made of pipeline components and sheets made of PVDF)
thermoplastics)
DVS 2207-1 Schweißen von thermoplastischen Kunststoffen; Maschinen und Geräte für das Heizelement-
Heizelementschweißen von Rohren, Rohrlei- stumpfschweißen von Rohren, Rohrleitungsteilen
tungsteilen und Tafeln aus PE-HD (Welding of und Tafeln (Welding of thermoplastics - machin-
thermoplastics - Electrofusion welding of pipes ery and equipment for heated tool butt welding of
and pipeline components made of PE-HD) pipes, pipeline components and sheets)
Warmgaszieh- und Warmgasfächelschweißen
von Rohren, Rohrleitungsteilen und Tafeln; Ver-
fahren, Anforderungen (Welding of thermoplastics
– hot gas high-speed nozzle welding and hot gas
round nozzle welding of pipes, pipeline compo-
nents and sheets – methods, requirements)
38
7.3 Table 1. Description of the acceptance levels for welds made by heated tool butt welding (HS)
Acceptance level
No. Feature Description
I II III
External condition of joint
1 Cracks Cracks oriented lengthwise to or across the weld not permitted not permitted not permitted
These may be located:
– in the weld
– in the parent material
– in the zone exposed to heating
2 Welding flash notches Welding flash notches with k < 0, e. g. due to not permitted, k < 0 not permitted, k < 0 not permitted, k < 0
– insufficient joint pressure
– heating-up time too short
– cooling time too short
– surfaces not parallel
– change of clamped workpiece position during welding
– mismatch
3 Notches and score marks Notches in the edge of the parent material, lengthwise or cross- locally permissible if locally permissible if locally permissible if
wise to weld, e. g. due to: the ends get gradu- ending flat and the ending flat and the
– clamping tools ally shallower and bottom of the notch bottom of the notch
the bottom of the or groove is not or groove is not
– incorrect transportation
notch or groove is acute acute
– edge preparation faults not acute ∆s ≤ 0.1 s ∆s ≤ 0.15 s
∆s ≤ 0.1 s but not greater than but not greater than
but not greater than 1 mm 2 mm
0.5 mm
4 Mismatch of joint faces The joint faces are not aligned or the thicknesses have not been permissible if permissible if permissible if
matched correctly, e ≤ 0.1 s e ≤ 0.15 s e ≤ 0.2 s
– depending on the material and the material thickness, this may
impair the joint quality.
39
40
Table 1. continued.
Acceptance level
I II III
5 Angular mismatch of joint faces E. g. due to: permissible for pipes permissible for pipes permissible for pipes
– machine tool fault (straight lengths) (straight lengths) (straight lengths)
and sheets if and sheets if and sheets if
– tool set-up fault
– non-permissible pressure applied during cooling e ≤ 1 mm e ≤ 2 mm e ≤ 4 mm
– deformation
– pipes removed from clamp too soon
6 Weld flash shape Due to the large variety of materials, material types and the result- The fabrication and The fabrication and The fabrication and
ing different flash formations which may evolve, it is not possible testing of sample testing of sample testing of sample
to define a standardized evaluation scheme here. welds as a reference welds as a reference welds as a reference
It is not possible to predict the long-term behaviour of the welded is recommended. is recommended. is recommended.
joint by inspecting the shape of the flash.
7a Upset volume is noticeably too small or too Due to wrong welding parameter values not permitted not permitted not permitted
large – make a comparison weld to verify welding parameter settings
7b Irregular weld bead width Weld beads of different width, either along a part or the entire joint permissible if permissible if permissible if
length or circumference: b1 ≥ 0.7 b2 b1 ≥ 0.6 b2 b1 ≥ 0.5 b2
– heated tool at an angle
– joint face not orthogonal to axis
– MFRs of the materials joined differ (flashes are of a different
size all along the joint)
8 Flash containing bubbles or lumps Thermal damage: not permitted not permitted not permitted
– heated tool too hot
– mating and/or heating-up time too long
– damp or wet surfaces
When PVC-U and/or PVC-C is welded, the small bubbles forming
on the flash surfaces owing to the material properties have no ef-
fect on the quality of the welded joint.
Table 1. continued
Acceptance level
I II III
Internal condition of joint
9 Lack of fusion No fusion at all or incomplete fusion of the joint faces, either of not permitted not permitted not permitted
sections or distributed throughout the cross-section of the weld,
with or without bubbles or lumps, e. g. due to:
– contaminated joint faces
– oxidized joint faces
– changeover time too long
– wrong heated tool temperature
– joint compression force too low
10 Pores and foreign matter inclusions Numerous isolated pores and/or inclusions distributed throughout small isolated pores pores and rows of pores and rows of
weld or occurring in local concentrations, e. g. due to: are permitted if pores are permitted pores are permitted
– evaporation during welding (water, solvents, ∆s ≤ 0.05 s if if
cleansing agents …) ∆s ≤ 0.10 s ∆s ≤ 0.15 s
– dirty heated tool
11 Shrinkage cavities / pores Cavities in the joint plane, e. g. due to: small isolated pores pores and rows of pores and rows of
– joint compression force too low are permitted if pores are permitted pores are permitted
∆s ≤ 0.05 s if if
Note: In high-crystallinity materials such as PP or PVDF, shrink- ∆s ≤ 0.10 s ∆s ≤ 0.15 s
age cavities may occur for physical reasons, depending on the
material type and thickness.
41
42
7.4 Table 2. Description of the acceptance levels for welds made by heated tool socket welding (HD)
Acceptance level
I II III
1.1 Faulty weld flash formation 1) Varying flash shapes (b) or flash missing on one or both sides (a)
(either in parts or around the entire circumference) due to
a b
– tool temperature too high (b)
– heat applied for too long (b)
– unacceptable tolerances (a and b)
– heated tool not hot enough (a)
– heating-up time too short (a)
– clamping force of prismatic clamping devices was too high
1)normally occurs in conjunction with inter-
Under normal conditions, heated tool socket welding leads to a
nal imperfections – fixation time too short. circumferential flash formation at the edge of the sleeve or socket.
This flash is an initial indicator for a correctly made weld.
not permitted not permitted not permitted
1.2 One-sided flash formation due to:
– heated tool not hot enough
– unacceptable tolerances
– only one of the items being joined was heated
1.3 Large upset volumes e. g. due to:

– incorrect movement parts being joined, e. g. due to inadequate
fixation
– unacceptable tolerances
2 Angular misalignment (imperfect shape) Pipe welded into one or both sides of the socket at an angle´, with permissible if permissible if permissible if
or without slight stress applied, e. g. due to e ≤ 1 mm e ≤ 2 mm e ≤ 4 mm
– machine tool fault
3.1 Lack of fusion due to deformation Deformation or oval shape of pipe end or socket due to localized permitted difference permitted difference permitted difference
pipe
welding pressure or inadequate welding pressure, e. g. due to: from the average ex- from the average ex- from the average ex-
Rohr
– radii of collar curvature are too low ternal diameter of ternal diameter of ternal diameter of
the pipe the pipe the pipe
Muffe – incorrect storage of the pipe/tube and/or fitting

socket 1.5% 2% 3%
but not greater than but not greater than but not greater than
1.5 mm 2 mm 2 mm
Table 2. continued
Acceptance level
I II III
3.2 Lack of fusion due to incomplete insertion E. g. due to: permitted if the weld permitted up to permitted up to
of pipe – heating-up time too short is only slightly short- x ≤ 0.1 d x ≤ 0.1 d
er than the specified
– pipe ends not cut off square and and
weld length and has
– heated tool not hot enough an uninterrupted, x ≤ 0.15 ∙ socket x ≤ 0.2 ∙ socket
– axial movement while joint was cooling notch-free flash of depth depth
– resetting time too long up to
– irregular insertion speed x ≤ 0.05 d
and
x ≤ 0.1 ∙ socket
depth
3.3 Lack of fusion due to poor fit Localized, extensive axial or circular channel formation, e. g. due not permitted not permitted not permitted
to:
– notches in the pipe surfaces
– pipe or socket dimensions out of tolerance
– wrong mechanical preparation
– pipe not correctly aligned with socket
3.4 Lack of fusion due to poor material bonding Localized or extensive incomplete welding with separation in the not permitted not permitted not permitted
joint plane, e. g. due to:
– pipe inserted too far
– thermal damage
– incorrect matching of materials
– residues on the heated tool
4 Constricted pipe cross-section Pipe inserted too far during heating or joining, due to not permitted not permitted not permitted
– welding of pipes with too-thin walls into sockets*
– heating-up time too long
– axial movement while joint was cooling

*Note: such imperfections can be permitted under certain

conditions in thin-walled pipes made of PVDF.
43
44
Table 2. continued
Acceptance level
I II III
5 Pores caused by foreign matter inclusions Numerous isolated pores and/or inclusions distributed throughout small isolated pores pores and rows of pores and rows of
weld or occurring in local concentrations, e.g. due to: are permitted if pores are permitted pores are permitted
– evaporation during welding (water, solvents) ∆x ≤ 0.05 x if if
– dirty heated tool ∆x ≤ 0.10 x ∆x ≤ 0.15 x
– foreign matter
7.5 Table 3. Description of the acceptance levels for welds made by electrofusion welding (HM)
Acceptance level
I II III
External condition of welds of straight pipe sections, branches or tapping tees and fittings
1.1 Molten material exuding between sleeve Localized exuding of melted material, frequently observed at the not permitted not permitted not permitted
and pipe fitting sockets or the circumference of one or both ends of the fit-
ting sleeve, usually with a shiny or porous surface, e. g. caused
by:
– too high welding energy applied
– excessive welding time
– welding process repeated immediately without interim cooling
– equipment fault
– warping
1.2 Angular misalignment (imperfect shape)* Pipe which has been welded into a fitting at an angle on one or permitted, for pipes permitted, for pipes permitted, for pipes
both sides, e. g. due to: (straight lengths): (straight lengths): (straight lengths):
– tool set-up fault e ≤ 2 mm / 0.4° e ≤ 3 mm / 0.6° e ≤ 6 mm / 1.2°
– movement of parts during welding for PE-X: for PE-X: for PE-X:
permitted if permitted if permitted if
e ≤ 1 mm e ≤ 2 mm e ≤ 4 mm
* An angular misalignment is an externally

visible imperfection which may cause an
internal imperfection.
Internal condition of welds of straight pipe sections, branches or tapping tees and fittings
2.1 Warping Angular misalignment with displacement of filament and molten not permitted not permitted not permitted
masses due to uneven welding pressures, with or without separa-
tion in the joint plane, e. g. due to:
– pipe ends not aligned correctly
– radii of coiled bundles too small
– bending moments applied to socket/sleeve.
2.2 Deformation Deformation or oval shape of pipe end or fitting with inadequate permitted deviation permitted deviation permitted deviation
pipe welding pressure in places, e. g. due to: from the average ex- from the average ex- from the average ex-
Rohr
– pipes not pressed to correct circular shape, particularly with ternal pipe diameter ternal pipe diameter ternal pipe diameter
coiled bundles = 1.5 %, but not = 1.5 %, but not = 1.5 %, but not
Muffe
socket more than 3 mm more than 3 mm more than 3 mm
– pipes and sleeves or fittings that were stored incorrectly
Manufacturer’s Manufacturer’s Manufacturer’s

specifications are to specifications are to specifications are to
be observed be observed be observed
45
46
Table 3. continued
Acceptance level
I II III
2.3 Lack of fusion due to weld preparation Pipe joint surface: not permitted not permitted not permitted
faults – not prepared mechanically

pipe
Rohr – too much material removed by preparation process, leading to
insufficient form-fit between socket and pipe
Muffe – too much material removed in parts by preparation process,
socket
with flattened areas
– unsuitable clamping device (e. g. prismatic clamping
equipment)
2.4 Lack of fusion due to incomplete insertion Pipe ends displaced from centre of sleeve or not pushed against permitted if the inserted length is slightly, permitted if the in-
of pipe one another or against stop on one or both sides, e. g. due to i. e. up to 10 %, less than the specified inserted length is
a) – pipes not inserted far enough at both ends (a) sertion distance slightly, i. e. up to
15 %, less than the
– unequal lengths of pipe inserted (b)
specified insertion
– pipe ends not cut off square distance
b)
c)
Table 3. continued
Acceptance level
I II III
2.5 Lack of fusion due to poor form fit Localized, extensive axial or circular channel formation, e. g. due not permitted not permitted not permitted
to:
– notches in the pipe surfaces
– pipe or socket dimensions out of tolerance
– wrong mechanical preparation
– pipe ends have shrunk too much
2.6 Lack of fusion due to poor material bonding Localized or extensive incomplete welding, depending on materi- not permitted not permitted not permitted
al, with or without separation in the joint plane, e. g. due to:
– welding energy too low
– heating conductors damaged
– contaminated surface
– material pairs which do not conform with processing
instructions
3.1 Radial heating filament winding Heating filament windings in a wavy, bunched or displaced ar- not permitted slightly wavy fila- slightly wavy fila-
displacement rangement relative to welding surface, e. g. due to: ment winding ment winding
– overheating of weld region arrangement is arrangement is
permitted permitted
– contaminated joint surfaces
– warping
3.2 Axial heating filament winding Windings more closely grouped in an axial direction at certain not permitted not permitted not permitted
displacement points, e. g. due to:
– parts to be joined are out of tolerance
– pipe pushed in at an angle
– pipe end not cut off square
– pipe ends shrunk
4 Inclusions of foreign matter Localized, extensive axial or circular channel formation, joint sep- not permitted not permitted not permitted
aration or heating filament separation e. g. due to: (isolated individual (isolated individual (isolated individual
– contaminated surfaces pores can be pores can be pores can be
permitted) permitted) permitted)
– steam or gas formation during welding
47
48
Table 3. continued
Acceptance level
I II III
5.1 Lack of fusion due to poor form fit of the – due to poor axial fit of the saddle clamped onto pipe not permitted not permitted not permitted
welding surface
– due to poor radial fit
5.2 Lack of fusion at the tapping point due to – due to localized or extensive channel or cavity formation not permitted not permitted not permitted
poor form fit of the weld surface
Table 3. continued
Acceptance level
I II III
6 Lack of fusion due to bent pipe Localized or extensive incomplete welding, with or without sepa- not permitted not permitted not permitted
ration in the joint surface, e. g. due to:
– uneven pressure application
– clamping device used on one side only
– poor external geometry of fitting
49
50
7.6 Table 4. Description of the acceptance levels for welds made by hot gas high-speed nozzle welding and hot gas round nozzle welding (WZ, WF)
Acceptance level
I II III
External condition of the surfaces of single-V welds and double-V welds
1 Cracks Cracks aligned with weld or oriented across to weld, e. g.: not permitted not permitted not permitted
– in the weld
2 Welding bead notches Clearly visible and palpable depressions along or between the in- permissible if permissible if permissible if
dividual weld runs, e. g. due to: 0 < k ≤ 0.3 ∙ d 0 < k ≤ 0.4 ∙ d 0 < k ≤ 0.5 ∙ d
– fault in the hot gas nozzle
– poor welding rod guidance
– incorrect bead layer structure
d = welding rod diameter

3 Edge notches / continuous undercut Notches (undercuts) in the parent material along the weld, e. g. not permitted permitted for local- permitted for continu-
due to: ized occurrences ous lengths providing
– edges of nozzle tip penetrating parent material providing the notch the notch sides are
sides are not steep not steep
– incorrect joint preparation
∆s ≤ 0.1 s ∆s ≤ 0.1 s
– insufficient welding of the edge zones but not greater than but not greater than
1 mm 1 mm
4 Incomplete root penetration Notch in the root because filler material has not penetrated to the not permitted not permitted not permitted
root, e. g. because:
– bevel angle of prepared edge is too small
– root gap is too small
– filler material rod or wire used for root run was too thick
– welding pressure was too low
– joint was not preheated enough
5 Incompletely welded cross-section e. g. due to: not permitted not permitted not permitted
– poor edge preparation
– insufficient welding pressure
– joint not preheated enough
Table 4. continued
Acceptance level
I II III
6 Excessive penetration / root protrusion e. g. due to: permitted localized permissible if permissible if
– root gap too wide occurrence if ∆s ≤ 0.2 s ∆s ≤ 0.25 s
∆s ≤ 0.15 s but not greater than but not greater than
– root run made with too high pressure
but not greater than 3 mm 4 mm
2 mm
7 Bead too high / excess filler e. g. due to: permitted over con- permitted over con- permitted over con-
– too many runs applied tinuous lengths if tinuous lengths if tinuous lengths if
– incorrect edge preparation 0.1 s ≤ ∆s ≤ 0.4 s 0.05 s ≤ ∆s ≤ 0.5 s 0.05 s ≤ ∆s ≤ 0.6 s
8 Incompletely filled groove – missing final run not permitted not permitted not permitted
– insufficient filler material fed into weld
9 Mismatch of joint faces e. g. due to: permissible if permissible if permissible if

– differences in wall thickness were not compensated e1 ≤ 0.1 s e1 ≤ 0.15 s e1 ≤ 0.2 s
e2 ≤ 0.1 s e2 ≤ 0.15 s e2 ≤ 0.2 s
– materials of equal wall thickness not aligned
– depending on material and thickness:
such imperfections can impair the weld quality, e. g. in PP and
PVDF
10 Angular misalignment If it is not possible to conform with the required, i. e. permissible permissible if permissible if permissible if
angular misalignment limits due to factors relating to the materi- e ≤ 3 mm e ≤ 5 mm e ≤ 8 mm
als, crystallinity, joining of different materials and sheet
thicknesses, then experimental proof shall be provided that the
angular misalignment is due only to the properties named above.
51
52
Table 4. continued
Acceptance level
I II III
11a Weld intersections not permitted not permitted not permitted
11b Staggered weld junctions permitted if a ≥ 3 x final run width and at least 30 mm
12 Rough weld surface, thermal damage Discoloration, small open bubbles, streaks or lumps and similar not permitted only isolated occur- permissible in limited
flaws e. g. due to: rences permissible areas
– contaminated hot gas nozzle
– gas too hot
13 Start fault Incompletely filled weld cross-section at one or both ends of the not permitted small cross-section reductions permissible if
weld. there are no sharp transitions
External condition of the surface of fillet welds
14 Excessive weld thickness The fillet weld thickness exceeds the standard permissible if permissible if permissible if
nominal dimension a = 0.7 s1, s2 > s1 b ≤ 0.4 a b ≤ 0.5 a b ≤ 0.6 a
1
Table 4. continued
Acceptance level
I II III
15 Insufficient weld thickness The fillet weld thickness is less than the standard not permitted permissible if throat – permitted if
nominal dimension a = 0.7 s1, s2 > s1 is only slightly thin- nominal
– missing final run ner than nominal dimension a is not
dimension a at indi- achieved at
vidual positions individual
b ≤ 0.15 a positions
b ≤ 0.3 a
– permitted for
welds which are
not subjected to
loads
1
16 Excessive fillet asymmetry a = 0.7 s1, s2 > s1 not permitted permissible if permissible if
z ≤ 0.15 a z ≤ 0.3 a
Internal condition of V welds and fillet welds

17 Lack of fusion Lack of fusion along the weld or at angle to weld between runs or not permitted not permitted not permitted
between filler and parent material edges; isolated pores and/or in-
clusions or local concentrations of pores and/or inclusions, e. g.
due to:
– welding temperatures too low
– inclusions of foreign matter
– individual runs not reworked
– steam or gas formation during welding
53
54
7.7 Table 5. Description of the acceptance levels for welds made by hot gas extrusion welding (WE)
Acceptance level
I II III
1 Cracks Isolated cracks or groups of cracks with and without branching, not permitted not permitted not permitted
oriented parallel to or across weld.
– in the weld
2 Dents in final run bead Continuous or localized flat deformation aligned with weld direc- permitted if occur- permitted if occur- permitted if occur-
tion, e. g. due to: rence is localized rence is localized rence is localized
– welding shoe fault and and and
k>0 k>0 k>0
– incorrect welding tool guidance
– faulty weld starts
3 Edge notches / continuous undercut Notches (undercuts) in the parent material along the weld, e. g. permitted if occur- permitted providing permitted providing
due to: rence is localized the notch sides are the notch sides are
– incorrect welding tool guidance and providing the not steep and not steep and
notch sides are not ∆s ≤ 0.1 s ∆s ≤ 0.2 s
– incorrect preparation of edges
steep and but not greater than but not greater than
– welding shoe fault ∆s ≤ 0.1 s 2 mm 3 mm
but not greater than
1 mm
4 Insufficient welding of the edge zones Insufficient overlapping of the edges of the weld, either on one or permissible if transi- permissible if transi- permissible if transi-
on both sides, e. g. due to tion is smooth, tion is smooth, tion is smooth,
– welding shoe fault notch-free and notch-free and notch-free and
∆b ≥ 0.2 s ∆b ≥ 0.1 s ∆b ≥ 0.05 s
– wrong welding shoe size
but at least = 3 mm but at least = 2 mm but at least = 1 mm
– welding tool speed too high
5 Root notch / incomplete root penetration Notch in the root because filler material has not penetrated to the not permitted not permitted permissible if
root, e. g. due to: ∆s ≤ 0.1 s
– joint faces bent and not welded but not greater than
1 mm
– root retraction due to shrinkage

Table 5. continued
Acceptance level
I II III
6 Incompletely welded cross-section E. g. due to: not permitted not permitted permitted if occur-
– wrong joint edge preparation rence is localized
and
∆s ≤ 0.1 s
– insufficient preheating
7 Excess penetration / root protrusion E. g. due to: permissible for PE permissible for PE permissible for PE
– root gap too wide and PP if and PP if and PP if
0.1 s ≤ ∆s ≤ 0.25 s 0.05 s ≤ ∆s ≤ 0.3 s 0 ≤ ∆s ≤ 0.4 s
– wrong welding parameter settings (speed, temperature,
and weld has been and weld has been and weld has been
pressure)
made without root made without root made without root
notches or grooves. notches or grooves. notches or grooves.
Other materials shall be investigated individually.
8 Bead too high / excess filler Unacceptable deviation from the nominal bead height, e. g. due permissible if permissible if permissible if
to: 0.1 s ≤ ∆s ≤ 0.3 s 0.05 s ≤ ∆s ≤ 0.4 s 0 ≤ ∆s ≤ 0.5 s
– welding shoe fault but not greater than but not greater than but not greater than
6 mm 8 mm 10 mm
– joining force too low (normally in conjunction with imperfection
number 6)
9 Filler material overflow (unfused overlap) Filler material overlaps parent material on one or both sides of not permitted permitted if occur- permissible if
weld, usually without adequate fusion with parent material, e. g. rence is localized ∆b ≤ 10 mm
due to: and
– welding shoe fault ∆b ≤ 5 mm
– incorrect welding tool guidance
– not executed in accordance with DVS 2207-4
10 Sagging Weld has not been given the specified cross-section, e. g. due to: not permitted not permitted not permitted
– filler material shrinkage
– welding tool speed too high
– faulty welding shoe or wrong welding shoe size
55
56
Table 5. continued
Acceptance level
I II III
11 Mismatch of joint faces E. g. due to: permissible if permissible if permissible if
– differences in wall thicknesses were not compensated e1 ≤ 0.1 s e1 ≤ 0.2 s e1 ≤ 0.3 s

e2 ≤ 0.1 s e2 ≤ 0.2 s e2 ≤ 0.3 s
– linear misalignment
12a Weld intersections not permitted not permitted not permitted
12b Staggered weld junctions permitted if a ≥ 3 x final run width and at least 50 mm
13 Asymmetrical overlap Welding shoe was not centred on joint not permitted permissible if only lo- permissible if there
calized and there are are no other
no other imperfections
imperfections
14 Wavy bead surface E. g. due to: permitted if only permitted permitted

– uneven application of welding pressure occurs in isolated
sections
– welding tool speed was not constant
Table 5. continued
Acceptance level
I II III
15 Rough weld surface Small open bubbles, streaks or lumps and similar flaws e. g. due not permitted not permitted not permitted
to:
– damp filler material
– wrong filler compound temperature
– wrong welding shoe temperature
– unsuitable filler compounds
– unsuitable preparation and execution
16 Thermal damage Discoloration, small lumps, shiny weld bead surfaces and similar not permitted not permitted not permitted
flaws
17 Bead too high / excess filler Unacceptable deviations from the specified weld geometry permissible if permissible if permissible if
nominal dimension a = 0.7 s1, s2 > s1 b ≤ 0.2 a b ≤ 0.4 a b ≤ 0.6 a
e. g. due to: but not greater than but not greater than but not greater than
4 mm 6 mm 8 mm
– welding shoe fault
18 Throat thickness deviations Deviation from specified, nominal dimension a due to insufficient permissible if permissible if permissible if
or excessive throat thickness b≥a b ≥ 0.9 a b ≥ 0.8 a
nominal dimension a = 0.7 s1, s2 > s1 b1 ≤ 1.2 a b1 ≤ 1.4 a b1 ≤ 1.6 a
e. g. due to:
– wrong design specifications
– filler material shrinkage
– wrong welding shoe
– welding shoe fault
57
58
Table 5. continued
Acceptance level
I II III
Internal condition of V welds, double-V welds and fillet welds
19 Pores and cavities Numerous isolated pores and/or inclusions distributed throughout small isolated pores pores and rows of pores and rows of
– evaporation during welding (water, solvents) ∆s ≤ 0.1 s if if
∆s ≤ 0.15 s ∆s ≤ 0.2 s
– too rapid and/or uneven cooling (shrinkage cavity formation)
20 Lack of fusion No fusion with, or incomplete fusion with, other runs, tacking not permitted not permitted not permitted
points and weld edge surfaces, e g. due to:
– welding pressure too low
– insufficient heating
7.8 Table 6. Description of the acceptance levels for welds made by contactless heating tool butt welding (IR)
Acceptance level
I II III
1 Cracks Cracks oriented parallel to or across the weld not permitted not permitted not permitted
– in the weld
2 Welding flash notches Welding flash notches with k < 0 e. g. due to not permitted k < 0 not permitted k < 0 not permitted k < 0
– lack of parallelism of surfaces
– change of clamped workpiece position during welding
3 Notches and flutes Notches in the edge of the parent material, parallel to or across permissible if only lo- permissible if only lo- permissible if only lo-
the weld, e. g. due to: calized and the calized and the calized and the
– clamping tools groove ends get groove ends get groove ends get
gradually shallower gradually shallower gradually shallower
– incorrect transportation
and the bottom of and and
– edge preparation faults the notch or groove ∆s ≤ 0.1 s ∆s ≤ 0.15 s
is not acute but not greater than but not greater than
∆s ≤ 0.1 s 1 mm 2 mm
but not greater than
0.5 mm
4 Mismatch of joint faces The joint faces are not aligned or the thicknesses have not been permissible if permissible if permissible if
matched correctly. e ≤ 0.1 s e ≤ 0.15 s e ≤ 0.2 s
– depending on the materials and thicknesses, such but not greater than but not greater than but not greater than
misalignment can impair the weld quality, e. g. of PVDF. 2 mm 4 mm 5 mm
59
60
Table 6. continued
Acceptance level
I II III
5 Angular mismatch of joint faces E. g. due to: permissible for pipes permissible for pipes permissible for pipes
– machine tool fault (straight lengths) if (straight lengths) if (straight lengths) if

e ≤ 1 mm e ≤ 2 mm e ≤ 4 mm
– impermissible force applied during cooling permissible for permissible for permissible for
sheets if sheets if sheets if
e ≤ 2 mm e ≤ 3 mm e ≤ 6 mm
6 Weld flash shape Due to the wide variety of materials, material types and the result- The fabrication and The fabrication and The fabrication and
ing different bead and flash formations which may evolve, it is not testing of sample testing of sample testing of sample
possible to define a standardized evaluation scheme here. welds as a reference welds as a reference welds as a reference
is recommended. is recommended. is recommended.
7a Upset or bead volume is noticeably too Due to wrong welding parameter values not permitted not permitted not permitted
small or too large – make a comparison weld to verify welding parameter settings
7b Irregular weld bead/flash shape Weld beads of different width, either along a part or the entire joint permissible if permissible if permitted if
length or circumference: b1 ≥ 0.7 b2 b1 ≥ 0.6 b2 b1 ≥ 0.5 b2
– heated tool at an angle
– joint face not orthogonal to axis
Note: Where different materials are joined by welding, these shall

be considered as special welding cases.
8 Upset with bubbles or lumps Thermal damage: not permitted not permitted not permitted
– mating and/or heating-up time too long
9 Lack of fusion No fusion at all or incomplete fusion of the joint faces, either of not permitted not permitted not permitted
sections or distributed throughout the cross section of the weld,
with or without bubbles or lumps, e. g. due to:

– oxidized joint faces
– resetting time too long
– wrong heated tool temperature
Table 6. continued
Acceptance level
I II III
10 Pores or foreign matter inclusions Numerous isolated pores and/or inclusions distributed throughout small isolated pores pores and rows of pores and rows of
– evaporation during welding (water, solvents, ∆s ≤ 0.05 s if if
cleansing agents …) ∆s ≤ 0.10 s ∆s ≤ 0.15 s
– dirty heated tool
11 Shrinkage cavities Cavities in the joint plane, e.g. due to: small isolated pores pores and rows of pores and rows of
– joint compression force too low are permitted if pores are permitted pores are permitted
∆s ≤ 0.05 s if if
∆s ≤ 0.10 s ∆s ≤ 0.15 s
Note: In high-crystallinity materials such as PP or PVDF, shrink-
age cavities may occur due to physical reasons, depending on the
material type and thickness.
61
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January 2003
DVS – DEUTSCHER VERBAND Testing of welded joints

FÜR SCHWEISSEN UND of thermoplastic sheets and pipes Directive
VERWANDTE VERFAHREN E.V. Test methods – Requirements DVS 2203-1
Contents: Table 1. Materials and letter symbols.
1 Scope Letter symbol Description of material1)

2 Materials and characteristics PE-HD High density polyethylene
3 Tests
3.1 Non-destructive tests PE 63 (Subdivision of PE into strength classes)
3.2 Destructive tests
PE 80 (Subdivision of PE into strength classes)
4 Requirements
4.1 Non-destructive tests PE 100 (Subdivision of PE into strength classes)
4.2 Destructive tests
5 Relevant Standards and Directives PE Xa Peroxide-crosslinked polyethylene
PP Polypropylene
1 Scope PP-H Polypropylene homopolymer (type 1)
PP-B Polypropylene block copolymer (type 2)

This directive provides the processor of semifinished products of
thermoplastics and the user of the products with instructions for PP-R Polypropylene random copolymer (type 3)
testing welded joints. The requirements of the tests which are
treated in detail in part 2 – 5 of this directive are mentioned in the PVC-U Polyvinyl chloride unplasticized
corresponding supplements of part 1. PVC-NI Polyvinyl chloride normal impact
The useful test procedure has to be chosen according to the
PVC-RI Polyvinyl chloride raised impact
corresponding execution and application. Here it has to be
considered that the test results depend on the manufacturing PVC-HI Polyvinyl chloride high impact
conditions for the test specimens and on the test conditions. For
this reason they are only transferable to the behaviour of a PVC-C Polyvinyl chloride chlorinated
product or to the design calculation if the arising practical PVDF Polyvinylidene fluoride
requirements correspond to manufacturing and test conditions or
if the influence of form and stress is considered. Footnote 1):
– PE-HD is subdivided into strength classes with the names PE 63
2 Materials and characteristics (MRS ≥ 6,3 N/mm2), PE 80 (MRS ≥ 8,3 N/mm2), PE 100 (MRS ≥ 10,0
N/mm2).
This directive covers the plastics listed in table 1 which are – PVC-U: Name for PVC unplasticized, until now also used for normal
mainly used in the apparatus and piping engineering: impact PVC. New name: PVC-NI (normal impact).
These plastics have specific characteristics regarding processing – PVC-HI: Name for all impact-resistant modified PVC types. New name:
and application technology due to their molecular structure. PVC-RI (raised impact); PVC-HI (high impact).
These material properties have to be considered for applications
of thermoplastic semifinished products, mainly for load-bearing
components, especially when they are at the same time 3 Tests
subjected to mechanical, thermal and chemical stress.
The characteristics of the semifinished products – pipes, sheets, Different kinds of tests can be used for testing welded joints with
profiles, fittings – with the relevant tests are described in DVS regard to the set requirements or the desired results and the
2201-1. The characteristic values of the semifinished products given possibilities.
can be taken from the pertinent DIN standards or the
specifications according to EN. The welding fillers are treated in Besides the measures described in DVS 2201-2 welding trials
DVS 2211 or DIN EN 12943. The characteristic values of the subjected to testings conforming to the practice are necessary for
most common thermoplastics for design calculation can be testing the weldability of a given combination of basic material
found in DVS 2205-1 or DIN EN 1778. and filler material.
liability can be accepted by the Deutscher Verband für Schweißtechnik e.V., and those participating in the drawing up of the document.
DVS, Technical Committee, Working Group “Joining of Plastics”
62
3.1 Non-destructive tests 5 Relevant Standards and Directives

The non-destructive tests such as dimensional inspection, visual
inspection, leak test, ultrasonic test, high-voltage test as well as Paperback: DVS instruction sheets and directives “Joining of
radiographic test are described in the directive DVS 2206 and plastics”, 10th edition 2003, series of reference books: welding
can be applied by analogy for the welded joints. technique, volume 68/IV
CD-ROM: DVS-Guidelines and -Worksheets, Plastics, Welding
3.2 Destructive tests and Adhesive Bonding, German and English, Edition 2002. DVS-
Scope, set-up as well as carrying-out of the test and Verlag GmbH, Düsseldorf.
interpretation of the indivual test results are described in the parts DIN EN ISO 15013 Extruded sheets of polypropylene (PP) –
of this directive mentioned in table 2. (1999-05) Requirements and test methods
DIN EN ISO 14632 Extruded sheets of polyethylene (PE) –
Table 2. Tests and requirements for welded joints.
(1999-05) Requirements and test methods
Test method Directive Requirements ISO 11833-1 Plastics – Unplasticized poly(vinyl
(1998) chloride) sheets –Types, dimensions and
Tensile test DVS 2203-2 2203-1 supplement 1 characteristics – Part 1: Sheets of
Impact tensile test DVS 2203-3 None thickness not less than 1 mm
DIN 16927 Unplasticized polyvinylchloride sheets –
Tensile creep test DVS 2203-4 2203-1 supplement 2
(1988) Technical delivery conditions
Technological bend test DVS 2203-5 2203-1 supplement 3 (E) DIN EN ISO 15014 Extruded sheets of polyvinylidene fluoride
(1999-05) (PVDF) – Requirements and test methods
DIN 16972 Compression moulded plates made of
4 Requirements (1995) polyethylene high-density (PE-UHMW),
(PE-HMW), (PE-HD) – Technical
The plastics/semifinished products used for the welded joints specifications
have to comply with the standards and directives mentioned in
section 5. The directive DVS 2201-1 has furthermore to be (E) DIN EN ISO 15527 Compression moulded plates made of
considered. (1999-05) polyethylene high-density (PE-UHMW),
(PE-HMW), (PE-HD) – Requirements and
4.1 Non-destructive tests test methods
The requirements are to be taken from DIN 32502 Detection of DIN 16985 Semi-finished thermoplastics products –
defects, Directive DVS 2202 and Directive DVS 2206. (1989) Technical delivery conditions
DIN EN 12943 Filler materials for thermoplastics, scope,
4.2 Destructive tests (1999-12) designation, requirements, testing
The requirements on the welded joints are to be taken from the prEN 12814-8 Testing of welded joints of thermoplastics
supplements of this directive. The values of requirement semi-finished products – Part 8:
represent minimum values. Requirements
63
August 2010

Testing of welded joints between panels
FÜR SCHWEISSEN UND
and pipes made of thermoplastics – Technical Code
Requirements in the tensile test – DVS 2203-1
Short-time tensile welding factor fz Supplement 1
Replaces April 2006 edition
Contents: 2 Requirements
1 Scope of application The demanded mean value for the short-time tensile welding fac-
2 Requirements tor fz according to Table 1 must be complied with for the specified
welding processes.
This supplement is applicable in connection with the DVS 2203-1

technical code. The requirements for the tensile test according to
DVS 2203-2 are indicated in this supplement.
Table 1. Minimum short-time tensile welding factor fz.
Process Short-time tensile welding factor fz

PE 63 PP-H PVC-U PVC-C PVDF

PE 80 PP-R
PE 100 PP-B
HS Heated tool butt welding 0.9 0.9 0.9 0.8 0.9
IR Non-contact heated tool butt welding – 0.9 * – – 0.9
WF and WZ Hot gas fan and string-bead welding 0.8 0.8 0.8 0.7 0.8
WEcont Hot gas extrusion welding, continuous 0.8 0.8 0.8 – –
WEdis Hot gas extrusion welding, discontinuous 0.8 – – – –
* Displacement-controlled for PP-H and pressure-controlled for all PPs
The prerequisites for the specified values were the command of

the corresponding welding processes and the execution by quali-
fied and certified personnel. The short-time tensile welding fac-
tors apply to the total loading time up to one hour. Corresponding
proof is the prerequisite for the computation with higher welding
factors than stipulated in the above table.
64
May 2014
Testing of welded joints

DVS – DEUTSCHER VERBAND between panels and pipes
FÜR SCHWEISSEN UND made of thermoplastics – Technical Code
VERWANDTE VERFAHREN E.V. Requirements in the tensile creep test – DVS 2203-1
Tensile creep welding factor fs Supplement 2
1 Scope of application The established tensile creep welding factor fs must satisfy the
2 Requirements requirements according to Table 1.

technical code. The requirements for the tensile creep test
according to the DVS 2203-4 technical code are indicated in this
supplement.
Table 1. Minimum tensile creep welding factor fs.
Process Tensile creep welding factor fs

PE 63 PP-H PVC-U PVC-C PVDF
PE 80 PP-R
PE 100 PP-B
HS Heated tool butt welding 0.8 0.8 0.6 0.6 0.6
IR Non-contact heated tool butt welding 0.7 0.8 – – 0.8
WF, WZ Hot gas fan and string-bead welding 0.4 0.4 0.4 0.4 0.4
WEcont Hot gas extrusion welding, continuous 0.6 0.6 0.6 – –
WEdis Hot gas extrusion welding, discontinuous 0.4 – – – –
The prerequisites for the specified values are the command of

the corresponding welding processes and the execution by quali-
fied and certified personnel. The prerequisite for computation
with higher welding factors than stipulated in the above table is
corresponding proof.
65
June 2012

FÜR SCHWEISSEN UND
and pipes made of thermoplastics – Technical Code
Requirements in the technological bending test – DVS 2203-1
Bending angle / bending path Supplement 3
Replaces January 2003 edition
Contents:
2 Requirements

technical code. The values required for the bending test according
to DVS 2203-5 are portrayed in this supplement. The evaluation
can be made optionally using the bending angle or the bending
path.
2 Requirements
For welded joints between the PE-HD, PP, PVC and PVDF mate-
rials, the minimum bending angles are specified on Figs. 1 to 5
and the minimum bending paths on Figs. 6 to 10, depending on
the material thickness.1)
1) For the material designation, see Table 1 in DVS 2203-1

HS: Heated tool butt welding
WF: Hot gas fan welding
WZ: Hot gas string-bead welding
WE: Hot gas extrusion welding
66
Page 2 to DVS 2203-1 Supplement 3
Bending angle in °
Specimen thickness in mm
Figure 1. Minimum bending angle for PE-HD (PE 63, PE 80 and PE 100).
67
Bending angle in °
Figure 2. Minimum bending angle for PP-B / PP-H / electrically conductive PE.
68
Bending angle in °
Figure 3. Minimum bending angle for PP-R.
69
Bending angle in °
Figure 4. Minimum bending angle for PVDF.
70
Bending angle in °
Figure 5. Minimum bending angle for PVC-U.
71
Bending path in mm
Figure 6. Minimum bending path for PE-HD (PE 63, PE 80 and PE 100).
72
Bending path in mm
Figure 7. Minimum bending path for PP-B / PP-H / electrically conductive PE.
73
Bending path in mm
Figure 8. Minimum bending path for PP-R.
74
Bending path in mm
Figure 9. Minimum bending path for PVDF.
75
Bending path in mm
Figure 10. Minimum bending path for PVC-U.
76
File: D:\Eigene Dateien\Kunden\DVS\Ri+Me\2203neu\englisch Teil 1\e2203-1bb4.fm
Erstellt am:
10.10.2008
20.10.2008
December 2008
Testing of welded joints between panels and

DVS – DEUTSCHER VERBAND pipes made of thermoplastics
FÜR SCHWEISSEN UND Requirements on shear and peeling tests for sleeve welding with Technical Code
VERWANDTE VERFAHREN E.V. an incorporated electric heating element (HM) and heated tool DVS 2203-1
sleeve welding (HD) on pipes and fittings Supplement 4
Translation of the German edition from November 2008
Contents: – The joining zone length (L) crucial for the assessment of the
welded joint is the distance between the first and last heater
1 Scope of application spirals.
2 Requirements – In saddle components only test specimens taken entirely from
2.1 Joints executed by means of sleeve welding with an the welding zone may be assessed.
incorporated electric heating element (HM)
2.2 Joints executed by means of heated tool sleeve welding (HD) – Defects in the joining plane (e. g. shrinkage cavities, foreign
inclusions or displaced heater spirals) must be recorded and
3 Remarks
assessed according to DVS 2202-1. In the case of welded
4 Standards and technical codes
joints with diameters ≥ 250 mm, a higher number of imperfec-
tions (shrinkage cavities or air inclusions) may occur for physi-
1 Scope of application cal reasons.
The requirements on the flawless proportions of the joining faces Requirement for joints executed by means of sleeve welding with
in the case of shear and peeling tests on joints executed between an incorporated electric heating element:
pipes by means of sleeve welding with an incorporated electric The flawless proportion of the joining zone length L (L minus the
heating element and heated tool sleeve welding according to total of the defect lengths a1, a2 ...) must not be less than 75 % in
DVS 2203-6 are stipulated in this supplement. In conjunction with any test specimen.
further tests, the requirements may be referred to as an evalua-
tion criterion for the welded joint. The assessment of welded
joints according to this technical code may only be made by an
expert with the experience necessary for this purpose (e. g. spe-
cialist for plastics welding according to DVS 2213). This technical
code applies to the PE 80, PE 100, PE-Xa, PE-XcPP-H, PP-B,
PP-R, PVDF and PB materials.
2 Requirements
2.1 Joints executed by means of sleeve welding with an

incorporated electric heating element (HM)
The following stipulations apply to the assessment:
Figure 1. Joining zone length (L) and imperfection examples (a , a …)
– The assessment is made for the fracture faces not only on the in the case of test specimens executed by means of sleeve
pipe but also on the fitting. welding with an incorporated electric heating element (HM).
Table 1. Examples of fracture patterns in joints executed by means of sleeve welding with an incorporated electric heating element (HM).
Material Ductile fracture (plastic fracture)* Smooth fracture (brittle fracture)**

PE
(PE 80 and PE 100)
PE-Xa
* Ductile fracture patterns are caused by
a plastic fracture and indicate good wel-
ding in principle. The plastic deformation
in the joining plane is characteristic, i. e.
material stretched in a "pasty" form or
filament formation.
** Smooth fracture patterns are caused by
a brittle fracture and indicate inadequate
welding. A smooth, non-stretched sur-
face in the joining plane is characteristic.
77
2.2 Joints executed by means of heated tool sleeve welding

(HD) Bead formation
The following stipulations apply to the assessment:
– In principle, it is only possible to assess those joints which
have been executed by means of heated tool sleeve welding
with the required insert depth according to DVS 2207.
– The assessment is made for the fracture faces not only on the
pipe but also on the fitting.
– The insert depth is regarded as the assessment length (B).
– Defects (e. g. shrinkage cavities or foreign inclusions) must be
recorded and assessed according to DVS 2202-1.
Requirement for joints executed by means of heated tool sleeve Figure 2. Assessment length (B) and imperfection examples (a and a )
welding: in the case of test specimens executed by means of heated
tool sleeve welding (HD).
The flawless proportion of the assessment length (B minus the
total of the defect lengths a1, a2 ...) must not be less than 90 % in
any test specimen (see Figure 2).
Tabelle 2. Examples of fracture patterns in joints executed by means of heated tool sleeve welding (HD).
Material Ductile fracture (plastic fracture)* Smooth fracture (brittle fracture)**

PE
(PE 80 and PE 100)
PP
PVDF
PB
* Ductile fracture patterns are caused by a plastic fracture and indicate good welding in principle. The
plastic deformation in the joining plane is characteristic, i. e. material stretched in a "pasty" form or
filament formation.
** Smooth fracture patterns are caused by a brittle fracture and indicate inadequate welding. A smooth,
non-stretched surface in the joining plane is characteristic.
78
lizensiert für: SLV Nord gGmbH Page 3 to DVS 2203-1 Supplement 4
3 Remarks
The requirements of this technical code should be preferred to

those listed in DVS 2207-1, as the requirements will be omitted
from this technical code in the next revision.
Product standards and manufacturer’s specifications should be
considered where applicable.
4 Standards and technical codes
DVS 2202-1 Defects in welded joints between thermoplastics

- Characteristics, description and assessment
DVS 2203-4 Testing of welded joints between panels and
Supplement 1 pipes made of thermoplastics - Tensile creep
test - Testing of sleeve-welded joints between
pipes
DVS 2203-6 Testing of joints between polymeric materials -
Shear and peeling tests
of pipes, piping parts and panels made of
PE-HD
DVS 2207-1 Welding of thermoplastics - Sleeve welding with
Supplement 1 an incorporated electric heating element of
pipes made of PE-X with piping parts made of
PE-HD
of pipes, piping parts and panels made of PP
of pipes, piping parts and panels made of PVDF
79
August 2010
DVS – DEUTSCHER VERBAND Testing of welded joints between panels

FÜR SCHWEISSEN UND and pipes made of thermoplastics – Technical Code
VERWANDTE VERFAHREN E.V. Tensile test DVS 2203-2
Replaces July 1985 edition
Contents: 3 Shape and manufacture of the test specimens
1 Scope of application Joining weld

2 Removal and number of the test specimens, type and
structure
3 Shape and manufacture of the test specimens
4 Execution
5 Evaluation
6 Test report
7 Literature
Figure 1. Test specimen, Shape 1.
Joining weld
In order to assess the welding execution, reference can be made
to the tensile test in conjunction with other tests.

The short-time welding factor and the fracture pattern give an
indication of the ductility of the joint and thus of the quality of the
execution. The results are not transferable to the creep behaviour
of the welded structure subjected to tensile stresses.
Figure 2. Test specimen, Shape 2.

structure
Joining weld
The tensile test is performed with reference to DIN EN ISO 527.
Welded joints are tested according to the actual execution, i.e.
with or without a welding bead.
The test specimens may only be removed eight hours after the
welding. Each test specimen must be marked in such a way that
its original position in the test piece is comprehensible.
The specimens must be neither heat-treated nor subjected to
mechanical stresses.
The test is carried out on at least six welded test specimens and
six unwelded reference test specimens which were removed as
uniformly distributed as possible around the circumference or
over the length. In the case of pipes with a diameter  63 mm, the Figure 3. Test specimen, Shape 3.
number of the test specimens can be reduced to four.
If the test specimens according to Fig. 1 crack or stretch within Table 1. Dimensions of the test specimens with Shape 1 and Shape
the clamping region, it is necessary to use test specimens with 2 from panels.
Shape 2 according to Fig. 2 or with Shape 3 according to Fig. 3.
The dimensions for the test specimens are included in Table 1 or Thickness s Test specimens Test specimens
Table 2 respectively. (nominal with Shapes 1 and 2 with Shape 2
dimension) b L0 L be
mm mm mm mm mm
 10 15 120  170 20
10 s  20 30 120  300 40
 20 1.5 . s 200  400 80
80
Table 2. Dimensions of the test specimens with Shape 1 and Shape 2 from pipes.
Test specimens Test specimens

Diameter d Thickness s with Shapes 1 and 2 with Shape 2
(nominal dimension) (nominal dimension)
mm mm b L0 L be
mm mm mm mm
20  d < 50 80  120 b + 10
s + d/10
50  d < 100 120  170 (but min. b + 5)
 10 15 120  170 20
 100 10 < s  20 30 120  300 40
 20 1.5 . s 200  400 80
Table 3. Dimensions of the test specimens with Shape 3 from panels. Table 5. Testing speeds for a few plastics.
Thickness s L be b = be /2 Material Testing speed

(nominal dimension) mm mm mm mm/min
mm
PE
 10 160 14 7 PP-R 50  10 %
10 < s  20 180 18 9
PA 12
 20 180 28 14
PP-H
PP-B
Table 4. Dimensions of the test specimens with Shape 3 from pipes.
PVDF 20  10 %
Diameter d L be b = be /2
PE, electrically conductive
(nominal dimension) mm mm mm
mm E-CTFE
20 160 10 5 PVC-U
10  20 %
25 – 63 160 12 6 PVC-C
75 – 110 160 14 7
The force at the moment of the cracking must be recorded. If the
125 – 160 180 16 8 specimen is stretched, the force at the yield stress must be
200 180 18 9 recorded.
225 – 250 180 20 10

280 – 315 180 22 11 5 Evaluation
355 180 24 12 The short-time tensile welding factor fz = w/r is determined
400 180 26 13 from the arithmetic mean values of the fracture stress of the
welded test specimens (w) and of the reference test specimens
450 180 28 14 (r). If the test specimens are stretched before the cracking, the
yield stress may be utilised as the reference variable. The values
All the surfaces of the test specimens must be free from visible required for the short-time tensile welding factors are included in
imperfections, scratches or other defects. Any heating caused by DVS 2203-1, Supplement 1.
the machining must be kept at a low level. Before the test, it is
necessary to visually detect and to document the appearance of Clamping fractures are ignored in the test evaluation. Substitute
the test specimens and, in particular, the welding execution. test specimens must be tested instead.
Note: In order to obtain a fracture failure in the weld and thus The fracture type and the fracture pattern must be detected visu-
better differentiation for assessing the weld quality, the joining ally and documented.
weld in the specimen can be weakened by a central hole notch
with a diameter of (for example) 3 mm but max. 1/3 of the speci-
men width. This special test is recommendable particularly when- 6 Test report
ever no fracture in the region of the joining weld is obtained
during the normal test. For assessment purposes, the tests with a The following items must be specified in the test report with an
hole notch must also be conducted with corresponding reference indication of this technical code:
specimens. – type, supply form and designation of the product
– manufacturing date and process of the test specimens
4 Execution – appearance of the test specimens before the test
– visual assessment of the welding execution
Unless anything else has been agreed upon or specified in the – hole notch (if present)
technical terms of delivery for the product to be tested, the test is – position of the test specimens in the product
carried out in a standard atmosphere according to ISO 554-23/50
(normal tolerances). – shape of the test specimens
– thickness of the test specimens in mm
The testing speeds are listed in Table 5 for selected materials.
– width of the test specimens in mm
For other materials, the speed is established, if necessary in a
preliminary test, in such a way that the yield strength of the un- – number of the test specimens
welded specimen is reached in about one minute and the next – testing atmosphere (in so far as it deviates from this technical
standard speed according to DIN EN ISO 527-1 is then selected. code)
81
– testing speed
– short-time tensile welding factor fz (from the arithmetic mean
values)
– visual assessment of the fracture pattern and the fracture type
– testing date, testing agency and name of the tester
7 Literature
ISO 554 Standard atmospheres for conditioning and/

or testing; requirements
DIN EN ISO 527-1 Plastics – Determination of the tensile prop-
erties – Part 1: General principles
erties – Part 2: Testing conditions for
moulding and extrusion materials
DVS 2203-1, Testing of welded joints between panels
Supplement 1 and pipes made of thermoplastics – Re-
quirements in the tensile test – Short-time
tensile welding factor fz
82
August 2010

VERWANDTE VERFAHREN E.V. Low-temperature tensile test DVS 2203-2
Supplement 1
Contents: 3 Shape and manufacture of the test specimens
2 Removal and number of the test specimens, type and structure Joining weld
3 Shape and manufacture of the test specimens
4 Execution
5 Evaluation
6 Test report
7 Literature
In order to assess the welding execution, reference can be made

to the low-temperature tensile test in conjunction with other tests.
In particular, this applies to materials with which the tensile test at
the room temperature does not allow any differentiation.
The low-temperature short-time tensile welding factor fzT and the Figure 1. Test specimen shape.
fracture pattern give an indication of the ductility of the joint and
thus of the quality of the execution. The results are not transfera-
Table 1. Dimensions of the test specimens from panels.
ble to the creep behaviour of the welded structure subjected to
tensile stresses. Thickness s L be b = be /2
(nominal dimension) mm mm mm
mm
structure ≤ 10 160 14 7
10 < s ≤ 20 180 18 9
The tensile test is performed with reference to DIN EN ISO 527.
Welded joints are tested according to the actual execution, i.e. > 20 180 28 14
with or without a welding bead.
The test specimens may only be removed eight hours after the Table 2. Dimensions of the test specimens from pipes.
welding. Each test specimen must be marked in such a way that
its original position in the test piece is comprehensible. Diameter d L be b = be /2
The specimens must be neither heat-treated nor subjected to (nominal dimension) mm mm mm
mechanical stresses. mm
The test is carried out on at least six welded test specimens and 25 – 63 160 12 6
six unwelded reference test specimens which were removed as 75 – 110 160 14 7
uniformly distributed as possible around the circumference or
over the length. In the case of pipes with a diameter of ≤ 63 mm, 125 – 160 180 16 8
the number of the test specimens can be reduced to four. 200 180 18 9
The dimensions of the test specimen are included in Table 1.
225 – 250 180 20 10
280 – 315 180 22 11
355 180 24 12
400 180 26 13
450 180 28 14
All the surfaces of the test specimens must be free from visible
imperfections, scratches or other defects. Any heating caused by
the machining must be kept at a low level. Before the test, it is
necessary to visually detect the appearance of the test speci-
mens and, in particular, the welding execution.
83
4 Execution 6 Test report
The testing speeds and the testing temperatures are listed in The following items must be specified in the test report with an
Table 3 for selected materials. For other materials, the tempera- indication of this technical code:
tures must be chosen in such a way that a brittle fracture arises.
– type, supply form and designation of the product
For this purpose, the testing temperature concerned must be well
below the glass transition temperature of the material in question. – manufacturing date and process of the test specimens
– appearance of the test specimens before the test
It must be ensured that the entire test specimen has taken on the
testing temperature before the test. – visual assessment of the welding execution
– position of the test specimens in the product
Table 3. Testing speeds and testing temperatures for a few plastics. – shape of the test specimens
Material Testing speed Testing temperature range * – width of the test specimens in mm
mm/min °C
– number of the test specimens
– testing temperature
PVDF 50 ± 10 % - 40 to - 50
– testing speed
PP-H 50 ± 10 % - 40 to - 50 – low-temperature short-time tensile welding factor fzT
PP-R 100 ± 10 % - 40 to - 50 (arithmetic mean values)
– visual assessment of the fracture pattern and the fracture type
PE 80 and PE 100 200 ± 10 % - 80 to - 90
– testing date, testing agency and name of the tester
PA12 200 ± 10 % - 80 to - 90
* In each case, ± 2°C 7 Literature
The force at the moment of the fracture must be recorded. DIN EN ISO 527-1 Plastics – Determination of the tensile prop-
erties – Part 1: General principles
5 Evaluation erties – Part 2: Testing conditions for mould-
ing and extrusion materials
The low-temperature short-time tensile welding factor is deter-
mined from the arithmetic mean values of the fracture stress of
the welded test specimens (σwT) and of the reference test speci-
mens (σrT):
fzT = σwT/σrT
If the test specimen is stretched, the result must not be assessed
and the testing parameters must be adjusted with regard to a
brittle fracture to be obtained.
The fracture type and the fracture pattern must be detected visu-
ally and documented.
84
April 2011

VERWANDTE VERFAHREN E.V. Tensile impact test DVS 2203-3
Contents: 4 Execution
1 Scope of application Unless anything else has been agreed upon or specified in the
2 Type and structure technical terms of delivery for the product to be tested, the test is
3 Brief description carried out in a standard atmosphere according to ISO 554-23/50
4 Execution (normal tolerances).
5 Evaluation The test specimens are tested on a pendulum impact testing ma-
6 Test report chine in Class 1 according to DIN 51222 which is additionally
7 Literature equipped with a facility for the execution of tensile impact tests.
The tensile impact test is carried out according to DIN EN ISO 8256.
The decision about which of the pendulum impact testing ma-
1 Scope of application chines and which pendulum hammer should be used is geared to
the type of the product to be tested and to the thickness of the
In order to assess the welding execution, reference can be made to test specimen. The test conditions should always be chosen in
the tensile impact test in conjunction with other tests. The short- such a way that the corrected impact energy is min. 20 % and
max. 80 % of the greatest impact energy of the pendulum ham-
time welding factor and the fracture pattern give an indication of

the ductility of the joint and thus of the quality of the execution. mer. If more than one pendulum satisifies these requirements,
The results cannot be readily transferred to just any welded the pendulum with the higher energy capacity must be utilised.
structures since the values are dependent on the shape of the
mouldings and on their manufacturing conditions. 5 Evaluation
The corrected impact energies WZV and WZB are established

2 Type and structure from the mean values of the consumed impact energies of the
joined specimens WSV and of the reference specimens WSB using
The tensile impact test is performed with reference to DIN EN the centrifugal energy correction curves according to DIN EN ISO
ISO 8256. It should be utilised predominantly for specimens with 8256 for the pendulum hammer in question. The short-time welding
a thickness < 4 mm. Welded joints are tested according to the factor is then calculated as follows:
actual execution, i.e. with or without a welding bead. The test is
f = W /W
conducted on at least ten welded specimens and ten reference
specimens. The shapes and dimensions of the test specimens In the case of test specimens with different thicknesses and
are described in DIN EN ISO 8256. widths, the impact energy should be related to the product b x h
(b = specimen width and h = specimen thickness) in the centre of
Before the test, it is necessary to visually detect and to document
the specimen or immediately next to the joint. The short-time
the appearance of the test specimens and, in particular, the welding
welding factor is then calculated according to the formula:
execution.
W b ⋅h W b h
In order to obtain a fracture failure in the weld and thus better f = ----------------- ⋅ ----------------- = ------------ ⋅ ------ ⋅ ------
differentiation for assessing the weld quality, the joining weld in b ⋅h W W b h
the specimen can be weakened by a central hole notch with a
In addition to the impact energy, it is recommended to establish
diameter of (for example) 3 mm. For assessment purposes, the
the permanent elongation at fracture too. The level of the perma-
tests with a hole notch must be carried out with the corresponding
nent elongation at fracture also provides a good assessment cri-
reference specimens as well. This special test is recommendable
terion for the quality of the joint. The permanent elongation at
particularly whenever no fracture in the region of the joining weld
fracture εbl is established from:
is obtained during the normal test.
l –l
ε = --------------- ⋅ 100
l
3 Brief description
l0 original measuring length
The test is performed by subjecting the test specimen to impact- lbl measuring length of the test specimen brought together after
like loads once at the low point of the pendulum movement of the the test
tensile impact machine. The test specimen is located in a hori-
zontal position at the time when the fracture occurs. and specified in percent.
The appearance of the test specimens after the test must be de-
tected and, in particular, the fracture type and the fracture pattern
must be assessed.
85
6 Test report 7 Literature
The following items must be specified in the test report with an in- DIN EN ISO 8256 Plastics – Determination of the tensile im-
dication of this technical code: pact strength
– type, supply form and designation of the product DIN EN ISO 13802 Plastics – Verification of pendulum impact
testing machines – Charpy, Izod and tensile
– manufacturing date and process of the test specimens impact tests
– appearance of the test specimens before the test
ISO 554 Standard atmospheres for conditioning and/
– visual assessment of the welding execution or testing; requirements
– hole notch diameter (if present) DIN 51222 Testing of metallic materials – Notched-bar
– position of the test specimens in the product bend impact test – Particular requirements
on pendulum impact testing machines with
a nominal energy capacity ≤ 50 J and their
– width of the test specimens in mm verification
– pretreatment of the test specimens
– utilised pendulum hammer as well as mass of the utilised cross-
beam in g
– testing atmosphere (in so far as it deviates from this technical
code)
– corrected impact energies of the joined specimens WZV and of
the reference specimens WZB in mJ/mm² or kJ/m², rounded to
three value-displaying figures
– short-time welding factor fSZ
– permanent elongation at fracture of the joined specimens εbl V
and of the reference specimens εbl B in % to ± 5 %
– appearance of the test specimens after the test
– visual assessment of the fracture pattern
– testing date
86
File-Name: e2203t4.fm
DVS – DEUTSCHER VERBAND Testing of welded joints Direction D

of thermoplastics plates and tubes DVS 2203-4
VERWANDTE VERFAHREN E.V. – Tensible creep test – (July 1997) S 
Content: bath. A schematic drawing of a test equipment is shown in fig. 1.

The test equipment must be able to apply a constant load and a
1 Scope constant temperature. According to the test medium a circulation
2 Test method and test design of the test fluid may be necessary. Appropriate equipment has to
3 Type and number of test specimens be applied to record the failure time of the individual specimen
4 Test conditions and – if required – the elongation.
5 Performance
6 Evaluation
7 Test report
8 Standards and guidelines
1 Scope
To assess the performance of welded assemblies, made from

thermoplastics materials – especially their long term strength –
the tensile creep test has proved its worth in conjunction with
other tests.
There is a lot of experience with this test for the polyolefine
materials PE and PP (polyethylene and polypropylene). First
experiences with this test are also available for PVC-U (polyvinyl
chloride without plasticizer and PVDF (polyvinylidene fluoride).
Tensile creep tests are applicable to sheets, pipes and profiles.
The relevant guideline for the application field ”Membranes in
geotechnical and hydraulic application” is DVS 2226-4.
The long term tensile welding factors and the fracture surfaces
give evidence about the quality of the welded joint. The test
results can be used when designing welded semi-finished
products under static load.
Figure 2. Dimensions of specimens according to DVS 2203-2.
a = Type 1
b = Type 2
c = Type 1 or type 2 with butt welded joint (e. g. V-seam)
L = Total length of specemen
Lf = Distance between clamps
Lp = Parallel length ≥ 60 mm + bN, but 3 × B + bN at least
B = idth of specimen in the parallel length
Bs = Width of shoulder ≥ B + 10 mm
S = Thickness of specimen
bN = Width of seam
Ez = Area of influence of the clamps
Figure 1. Test equipment for long term tensile creep tests.

3 Type and number of test specimens
2 Test method and test design The types and dimensions of the test specimens shall be in
accordance with guideline 2203-2, table 11).
The tensile creep test is performed following DIN 53 444. A test
equipment is needed which guaranties a constant load, a
constant temperature and constant ambient conditions in the test 1) The total length L can be shortened according to the test equipment
87
The welded joints are tested according to their actual design, that results.
means where the beads are left intact in service, they shall be left
To determine the slope of the creep rupture curve in a bi-
intact for the test. Where the beads are removed in service, they
logarithmic scale, tests shall be carried out at a minimum of two
shall be removed prior to testing. The joint shall be located in the
stress levels. A minimum of 6 welded and unwelded test
middle of the test specimen (Fig. 2). The appearance of the test
specimens shall be tested per stress level. The mean value shall
specimens, especially of the welding, shall be inspected prior
be calculated as the geometric mean value from the single
testing. The test specimens shall be machined without producing
values.
notches. If necessary the machined surfaces shall be smoothed
in length direction of the test specimen. Suitable methods for the
production of the test specimens (for example) are:
Sawing (circular saw with a hardened metal sawing blade),
milling, and water jet cutting with optimised parameters. Die-
cutting is not allowed. During cutting, heating of the test
specimen shall be minimised (if necessary: water cooling). For
comparative tests with a welded joint and parent material with
statistical evaluation a minimum number of six welded test
specimens and six unwelded test specimens shall be tested.
Welded and unwelded test specimens shall be taken from the
same test piece in the same direction related to the direction of
Figure 3. Crack surface of a PE-HD extrusion weld seam.
production of the semi-finished product.
a = Area of crack surface which has undergone brittle
fracture (minimum 30 %)
4 Test conditions b = Area of crack surface which has undergone ductile
fracture
Generally the test conditions shall be adjusted to the service
conditions. The tensile creep tests are performed in a watertank
(like the internal pressure tests of pipes below 100 °C). To 6 Evaluation
shorten the test times (acceleration of failure) the tests are
carried out at elevated temperatures in a suitable test medium. In order to determine the long term tensile welding factor (fs), the
Only such media shall be used which cause no swelling or creep rupture curves of the welded and unwelded test specimens
degradation of the polymer. In case of the tensile creep test an shall be established. The regression curves shall be calculated
aquous solution of demineralized water with 2 % ARKOPAL N- from the geometric mean of the single values, i.e.
1002) has proved to be good. The test conditions shall be chosen
in such a way that at least 30 % of the fracture area has log mean = [log t1 + log t2 + ... log tn] / n.
undergone brittle failure, as described in figure 3. The test force Based on these curves, as shown in figure 4, the long term
is calculated from the given test stress related to the minimum tensile welding factor (fs) shall be calculated as the ratio of the
cross section of the test specimen. Brittle failure is obtained with stress value of the weld (σs) and of the parent material (σt) at
the above mentioned test fluid using the maximum test identical failure times.
parameters (stress/ temperature) given in table 1. These test
conditions lead to the shortest failure times. With reference to the regression curves for the parent material
and for the welded joint the tensile welding factor can be
calculated for all stress levels.
5 Performance Fig. 5 shows an alternative method to determine the long term
tensile welding factor (fs) with reference to the test stress of the
Relating to the materials tested the tensile creep test is carried parent material.
out at different temperatures and loads. The test temperatures
and test stresses for the single materials shall be selected Providing a long term welding factor and reference stress, a
according to the test evaluation (see clause 6). simplified method, but without information about the slopes of the
creep curves, can be used by testing the parent material at σb
The stress is applied to the test specimen at constant and the welded material at σs multiplied by required long term
temperature (± 1 °C), static tensile load (±1 %) and constant welding factor (see fig. 6).
ambient conditions. The test specimen shall be loaded free from
external torsion and bending effects (symmetrical and flexible For example
clamping). The test specimens shall be progressively subjected – Test stress for the parent material (reference specimens): σb =
to the test load which shall be kept constant during the whole test 4 N/mm²
period. The duration of the test shall be taken from the moment of
reaching test load until the test specimen fractures and shall be – Test stress for the welded specimens e.g. fs= 0.8
recorded by an instrument. – σs= fs x σb = 0.8 x 4 N/mm² = 3.2 N/mm².
To shorten the duration of the test (time-lapse-effect) an aqueous
The creep rupture time of the welded test specimen shall at least
surfactant solution (2 % w/w) of deionized water and Arkopal
be equal to that of the parent material.
N-100® is used.
The applicability of the long term welding factor for design
A local and temporary constant concentration (2 ± 0,5 %) shall
purposes requires a minimum creep rupture time for the parent
be guaranteed. The test stresses shall be chosen in such a way
material (Table 2).
that at least 30 % of the fracture area has undergone brittle
failure, as described in figure 3. In other cases lower test stresses Independent of this, individual minimum requirements to the
shall be applied. Failures within a distance of 1 times thickness quality of semi-finished products can be established in
from the clamps shall not be used in the evaluation of the test application standards and guidelines (e.g. EN 263, DVS 2207-5).
2) (Registered trade mark: Hoechst AG; Clariant GmbH) Extensive test experiences are available for this test fluid which allow the comparison of test
results and the definition of requirements. If other products are used the number of molecules of ethyleneoxide in the chain of polyglycolether shall be
compared. Lit.: Hessel, J. and Mauer, E.: Tensile creep tests of polyethylene in aquous solution of detergent. Materials Testing 36 (1994) 6, S. 94/101
88
Table 1. Recommended test stresses and test temperatures. At this 8 Standards and guidelines
test conditions brittle failure is achieved in aqueous
surfactant solution (2 % w/w) of deionized water and DIN 8061 Unplasticized polyvinyl chloride pipes; general
Arkopal N-100® as experience shows. quality requirements and testing
Material Test Test DIN 8062 Unplasticized polyvinyl chloride pipes; dimensions
stress temperature DIN 8063 Pipe joints and their elements for unplasticized
(N/mm²) (°C) polyvinyl chloride pipes under pressure
PE-HD 4 95 DIN 8074 Pipes of high-density polethylene; dimensions
PP type 1 (homopolymer) 4 95 DIN 8075 Pipes of high-density polethylene; general quality
requirements and testing
PP type 2 (block-copolymer) 3,5 95
DIN 8077 Pipes of polypropylene; dimensions
PP type 3 (random-copolymer) 3,5 95
DIN 8078 Pipes of polypropylene; general quality require-
PVDF (homopolymer) 12,5 95 ments and testing
PVC-NI (normal impact) *) 12,5 60 DIN 16925 Sheets of polyethylene; requirements, testing
*) pressed plate; tested at ®Trovidur-NL, Registered trade mark of Hüls- DIN 16927 Sheets of polyvinyl chloride normal impact; tech-
Troisdorf AG nical delivery specifications
DIN 16962 Pipe joints and their elements for pipes of poly-
Table 2. Minimum creep rupture times for parent materials as a propylene under pressure
condition for the applicability to determine the long term
welding factor (Test fluid: Aqueous surfactant solution (2 % DIN 16963 Pipe joints and their elements for pipes of poly-
w/w) of deionized water and Arkopal N-100® 2 %) ethyene under pressure
DIN 16971 Sheets of polypropylene; technical delivery specifi-
Material Test stress Test temperature Minimum creep
cations
rupture time
(N/mm²) (°C) (h) DIN 53444 Testing of plastics; tensile creep test
EN 253 Preinsulated bonded pipe systems for underground
PP type 1 4 95 800
hot water networks - Pipe assembly of steel service
PP type 1 3,5 95 1300 pipes, polyurethane thermal insulation and outer
PE 4 95 30 casing of high density polyethylene.
DVS 2203-2 Testing of welded joints of thermoplastics – Tensile
PE 4 80 500
test –
DVS 2207-5 Welding of thermoplastics – Welding of PE-casing
7 Test report pipes, - tubes and components -
DVS 2226-4 Testing of joints on polymer lining membranes,
Referring to this guideline the test report shall cover: tensile creep test
– nature, form of delivery and marking of the product
– date of production and procedure of production of the
specimens
– appearance of the test pieces before the test; visual
examination of welding work
– position of the specimens in the sample
– shape of the specimens
– thickness of the specimens in mm (mean value)
– width of the specimens in mm (mean value)
– number of specimens
– pretreatment of the specimens (beads removed or not)
– test temperature
– test medium
– test force or stress
– time to fracture
– calculated value of the long term welding factor fs with
information about the reference stress of the parent material
– if measured: elongation of the test specimens after fracture
– appearance of the test specimens after fracture; visual
examination of the crack surface
– date of test
89
Figure 4. Schematic drawing for the

definition of the welding factor in
the long term tensile creep test.
Figure 5. Schematic drawing for the

definition of the welding factor in
the long term tensile creep test
with only one test stress of the
reference specimen.
Figure 6. Simplified method to proof the

required tensile welding factor.
90

C:\DVS Merkblätter\2203\2203-4\2203-4bei1\e2203-4b1.fm

Testing of welded joints Directive D
of thermoplastic sheets and pipes DVS 2203-4
FÜR SCHWEISSEN UND
– Tensile creep test – Supplement 1 V
Testing of socket joints (December 2001) S 
Content: The test specimens shall be prepared by initially cutting rough

specimens1) with larger dimensions than the desired final
1 Scope dimensions, from the joint by e.g. a jig-saw or a hole-driller.
2 Number and cutting of test specimens These rough specimens will later be machined to the final
3 Shape and preparation of test specimens dimensions. The specimens shall be taken from the middle of the
4 Testing fusion length according to fig. 1. For electrofusion fittings, the
4.1 Heated element fittings specimens shall be cut such that there are 2 wires from within the
4.2 Electrofusion fittings fusion length either side of the cross section of the specimen.
5 Evaluation
6 Test report
3 Shape and preparation of test specimens
1 Scope
The test specimens are shown in fig. 2.
This supplement applies to the testing of socket joints and is valid

for heated tool socket and electrofusion fittings welded to pipes
with a minimum wall thickness of 5 mm. The procedures are
given in directive DVS 2203-4 except for the sampling,
preparation of test specimens, recommended test stress and the
evaluation of the test results. The test results can be used for
comparative purposes and can be used to optimize e.g. the
welding process or the construction of the fitting. The comparison
between electrofusion and heated tool socket fitting systems is
not possible without additional analysis. Length of specimen l
Width of specimen b Diameter of specimen
2 Number and cutting of test specimens
At least 6 specimens shall be cut from each side of the welded Shape 1 Shape 2
joint and shall be equally spaced around the circumference. An
Figure 2. Shapes and geometries of specimens.
exception to this are electrofusion fittings where both sides are
welded simultaneously. In this case 3 specimens from each side
are sufficient. If there are significant differences between the two 1) The final specimen is produced by welding clamping bars to the rough
sides the number of specimens shall be increased to 6. specimen and then machining to the final dimensions.
fitting
pipe
pipe
rough specimen
welded sample position of the rough-specimen in the welded sample
Figure 1. a) Cutting the rough specimen from the socket joint,
b) longitudinal cross-section of electrofusion weld assembly showing the location of the rough specimen,
c) longitudinal cross-section of heated tool socket weld assembly showing the location of the rough specimen.
91
Shape 1: 4.2 Electrofusion fittings (HM)
The width of the specimen b, shall be equal to the pipe wall Specimens cut from electrofusion joints shall be tested at lower
thickness s, but with a minimum value of 10 mm and a maximum test stress than specified in DVS 2203-4. This is due to the notch
value of 20 mm. effect and the decrease in the effective cross-section area etc.
caused by the wires.
The length of the specimen is different for heated tool socket and
electrofusion fittings. The specimen cross section is given by the width of the test
specimen multiplied by the length for shape 1 or by the area of
Heated tool socket fittings: l = 1.5 x b the circle of the test specimen for shape 2. The reduction of the
Electrofusion fittings: l=2xb cross-section due to the wires is not taken onto account.
The recommended test parameters for PE-joints are:
Shape 2:
Test temperature (°C) Test stress (N/mm²)
The diameter of the specimens shall be between 10 and 25 mm. 80 3
Specimens cut from electrofusion fittings shall contain at least 3 95 2
wires. There are insufficient data available for other materials.
In order to test the specimens clamping bars can be welded to
the specimen, as shown in fig 3. Heated tool butt welds have 5 Evaluation
been proved to be suitable for this.
During welding of clamping bars heating of the test specimens As defined in DVS 2203-4 a at least 30 % of the fracture surface
fusion line between the pipe and the socket shall be minimized. If shall be brittle. If not lower test stresses shall be used.
necessary the test specimens can be quenched directly after In order to evaluate the test results the geometric mean value is
welding of the clamping bars. calculated from the single rupture times and is used as a
The final specimen dimensions and preparation shall be as comparative value.
given in section 3 of DVS 2203-4. Only test specimens that do not fail in the clamping bars or in the
butt welds between specimens and clamping bars shall be used
in the evaluation.
4 Testing
The determination of the long term welding factor is not required
in this supplement.
4.1 Heated tool socket fittings (HD)
The heated tool socket joints shall be considered as butt welded
joints. The specimen cross section is given by the width of the 6 Test report
test specimen multiplied by the length for shape 1 or by the area
of the circle of the test specimen for shape 2. The test loads shall DVS 2203-4 chapter 7 shall be applied except “long term welding
be calculated from these respective cross-sections. factor”.
clamping bar
fitting
rough-specimen
e.g. electrofusion joint
welded sample
heated tool butt weld
pipe
Figure 3. Assembly of specimen.
92
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Testing of welded joints of thermoplastic Directive D
sheets and pipes – Tensile creep test; DVS 2203-4
FÜR SCHWEISSEN UND
Testing of the resistance to slow crack growth Supplement 2 V
using the Full Notch Creep Test (FNCT) (December 2001) S 
Content: 2 Number and Cutting of test specimens
1 Scope While cutting the test specimens from the semi-finished product it
2 Number and cutting of test specimens should be taken into account that the properties may depend on
2 Type and preparation of test specimens the direction of production. A statistical evaluation requires at
4 Testing least 6 specimens. However, trends can be found by testing a
5 Evaluation smaller number of specimens due to the low scattering of the test
6 Test Report results.
1 Scope 3 Shape and preparation of test specimens
This supplement applies to the test of the resistance to slow The test specimens for the FNCT shall be cut with parallel sides
crack growth of semi-finished products. The procedure is as as shown in fig. 1.
given in directive DVS 2203-4 except for the sampling,
preparation of test specimens, recommended test stress and the A typical test specimen has a nominal thickness of 10 mm and a
evaluation of the test results. The test results can be used for total length of 100 mm. Other sizes of test specimens are
comparative values. possible.
Einspannung
Clamp
Test specimen
Probekörper
an = thickness of test specimen

b = width of test specimen
Einspannung c = depth of the notch = 17 % ± 2 % of an
Clamp I: Test specimen with square cross section
II: Test specimen with curved surface (e.g.
from a pipe wall)
an = b is to be preferred
Figure 1. Type of FNCT test specimens.
This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration is recommended. The user should
always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. The Deutscher Verband für Schweißtech-
nik e.V. and those involved in preparing this publication are exempt from any liability.
93
The test specimen shall be notched on all four sides in the same Calculation of the test load (Ft)
plane. The depth of the notch should be equal at all 4 sides. It
shall be between 15 % and 19 % of the nominal thickness. A Ft = A x σ
notch is produced by pressing a razor blade or a similar tool into
where Ft = test load (N)
the test specimen. The test specimens shall be notched at room
temperature of 23 ± 1 °C after a conditioning time of at least A = ligament area of the test specimen after notching
24 hours. = (mm²)
To ensure consistency of the results the condition of the notching σ = tensile stress (N/mm2)
tool shall be checked after notching 20 specimens (e.g. with a It is recommended to apply the test stresses given in directive
microscope, magnifying class). DVS 2203-4.
4 Testing 5 Evaluation
The test specimen with a length between the clamps of approx. As shown in DVS 2203-4, a minimum brittle fracture surface area
50 % of the total length and the notch in the middle shall be of 30 % of the total ligament area is required, if not lower test
installed in the test equipment. The whole test specimen shall be stresses shall be applied.
immersed in the test medium.
In order to evaluate the test results the geometric mean value
The test specimen with a thickness of 10 mm shall be shall be calculated from the single rupture times. This value shall
conditioned 2 hours ± 30 minutes prior loading. Thicker test be used for comparative purposes.
specimens require longer conditioning times.
6 Test report
The test report shall be as defined in section 7 of DVS 2203-4

except that the “long term welding factor” shall be omitted.
94
Draft January 2008

DVS – DEUTSCHER VERBAND and pipes made of thermoplastics –
FÜR SCHWEISSEN UND Tensile creep-rupture test – Technical Code
Checking of the demanded tensile creep-rupture welding factor
VERWANDTE VERFAHREN E.V. and of the minimum service life of welded joints between DVS 2203-4
polyethylenes (PE 80 and PE 100) Supplement 3
Objections by April 30, 2008
This draft is being submitted to the public for examination and comments. Supplement or amendment suggestions are requested to
DVS, P.O. Box 101965, 40010 Düsseldorf.
Contents: 2 Terms and definitions
1 Scope of application EA Activation energy

2 Terms and definitions The activation energy is the energy which is required in
3 Testing concept order to drive a crack through a thermoplastic body at a
4 Number and sampling of the test specimens speed depending on the temperature. It is a characteristic
5 Specimen shape and specimen manufacture variable for describing the temperature-dependent and
6 Testing stress-dependent strength behaviour of thermoplastic
7 Evaluation materials.
7.1 Calculation of the acceleration factor
fB Acceleration factor
7.2 Statistical evaluations about the tests on welded test
specimens at the highest chosen testing temperature Ratio of the geometrical means of the creep-rupture
7.3 Calculations about the service life of the welded joint in times of (for example) welded, FNCT or 2NCT specimens
operating conditions in water and in an aqueous wetting agent solution.
7.4 Calculation of the required activation energy MAC Modified Arrhenius Concept
7.5 Calculation of the required mean creep-rupture time of MAC generates testing conditions for the creep-rupture
welded test specimens in the control condition test. The concept is based on the simultaneous change
7.6 Calculation of the geometrical mean from the creep-rupture in the testing temperature and testing stress parameters.
and testing times of the welded test specimens in the The prerequisites in this respect are that the activation
control condition energy does not drop at low stresses and that the same
7.7 Assessment fracture mechanism is retained.
8 Test report
n Number of the tested specimens
9 Explanations
9.1 Calculation of the acceleration factor tB Minimum service life of the welded joint in operating
9.2 Statistical evaluations about the tests on welded test conditions
specimens at the highest testing temperature TB (Absolute) temperature in operating conditions
9.3 Calculations about the service life of the welded joint at the
tBN Mean service life of the welded joint in the testing medium
operating temperature
in operating conditions
9.4 Calculation of the required activation energy with variable
stress from the testing conditions at 80°C and the operating tBN, min Minimum service life of the welded joint in the testing
conditions at 20°C medium in operating conditions
9.5 Calculation of the required mean creep-rupture time of tH Geometrical mean of the creep-rupture times of welded
welded test specimens at the control temperature of 60°C test specimens at the highest testing temperature
9.6 Calculation of the geometrical mean from creep-rupture
TH (Absolute) temperature in testing conditions
and testing times of welded test specimens in the control
condition tH, min Minimum creep-rupture time of welded test specimens
9.7 Assessment at the highest testing temperature
10 Literature tK Geometrical mean of the creep-rupture times of welded
test specimens in the control condition
TK (Absolute) temperature in control conditions
tK, erf Required mean creep-rupture time (geometrical mean)
In connection with the DVS 2203-4, DVS 2203-1 and DVS 2205-1 which must be achieved by welded test specimens in
technical codes, this supplement applies to the tensile creep-rupture the control condition (required time)
testing of welded joints between polyethylenes1) (PE 80 and tN Geometrical mean of the creep-rupture times of test
PE 100). It serves to prove the demanded tensile creep-rupture specimens in an aqueous wetting agent solution
welding factor for the applied welding process and to establish the
tW Geometrical mean of the creep-rupture times of test
minimum service life of welded joints, e.g. in operating conditions
specimens in water
for media with A2B = 1 according to the DVS 2205-1 technical code.
1) It should be assumed that the technical code can be applied to welded joints between polypropylene since the creep-rupture curves for PP in DIN 8078
and EN 1778 follow the same systematics as the creep-rupture curves for PE 80 and PE 100 in DIN 8075 (the creep-rupture curves run in parallel and
the distance between the curves is proportional to the reciprocal absolute temperature).
95
H Testing stress of welded test specimens at the highest At least six test specimens per medium are required for the as-
testing temperature sured statistical evaluation. Tendencies can also be recognised
K Testing stress of welded test specimens at the control with a lower number of specimens.
temperature
B Stress of the welded joint from the operating conditions 5 Specimen shape and specimen manufacture
The information in the DVS 2203-2 technical code applies to the

3 Testing concept
shape and dimensions of the welded test specimens. Shape 1
with the information from Table 1 is to be recommended.
The checking of the demanded tensile creep-rupture welding factor
and of the minimum service life of welded joints between polyethyl- The welded joints are tested according to the actual execution,
enes can be divided into six partial steps. i.e. with or without a welding bead. The joint is located in the centre
of the test specimen. Before the test, it is necessary to record the
1) Determination of the acceleration factor fB which relates the appearance of the specimens (particularly the welding execution
times from the tensile creep-rupture testing of the same type and the notch misalignment) using measuring technology and to
of specimens in water and in an aqueous wetting agent solution document this in the test report.
to each other. The acceleration factor makes the connection
between the testing medium in the creep-rupture test and the The information in the DVS 2203-4 technical code, Supplement 2
operating medium in the application. applies to the shape and dimensions of the FNCT test specimens.
2) Testing of test specimens from the welded joint in the tensile The information in DIN EN 12814-3, Appendix A.2 applies to the
creep-rupture test at the highest chosen testing temperature shape and dimensions of the 2NCT test specimens.
(e.g. 80°C) and recommended testing stress which may gene- The cut edges of the test specimens must be manufactured with-
rally be expected to lead to a brittle fracture failure. Evaluation out any notches3) and, if necessary, the cut face must be rema-
of the results and indication of the geometrical mean, the mini- chined by means of grinding in the longitudinal direction. Suitable
mum value and the variance of the creep-rupture times. manufacturing methods are, for example, sawing (circular saw
3) Formulation of the operating conditions in which the welded with a double saw blade equipped with hard metal), milling and
joint is utilised. Transfer of the requirements for the utilisation water jet cutting with optimised parameters. Punching is not per-
of the welded joint in the testing medium at the operating missible. The cutting conditions must be chosen in such a way
temperature (e.g. 20°C) using the acceleration factor and the that no thermally induced changes arise (if necessary, water
variance. cooling).
4) Calculation of the required activation energy of the welded

joint with variable stress from the operating and testing condi- 6 Testing
tions.
5) Formulation of the requirement on the welded joint with the Tensile creep-rupture tests must be performed on welded and, if
aid of the activation energy at a minimum of one other testing necessary, FNCT or 2NCT test specimens. Recommended initial
temperature (control temperature) which is located between stresses and testing temperatures for test specimens made of
the selected highest testing temperature and the operating PE 80 and PE 100 are specified in Table 1.
temperature.
Table 1. Initial stresses and testing temperatures for PE 80 and PE 100.
6) Checking of the requirement in the control condition using ten-
sile creep-rupture tests on additional test specimens from the Testing PE 80 PE 100 Remarks
welded joint. temperature
The publication [1] is recommended for a more detailed description
20°C 8.00 N/mm² 10.00 N/mm² Minimum creep-
of the subject matter.
rupture strength*)
according to
DIN EN ISO 12162
4 Number and sampling of the test specimens
40°C 6.16 N/mm² 7.71 N/mm² Stresses from the
When sampling the test specimens from the semi-finished prod- Arrhenius approach
uct, it must be borne in mind that the properties may be different 60°C 4.90 N/mm² 6.13 N/mm²
depending on the direction (e.g. for manufacturing reasons) 80°C 4.00 N/mm² 5.00 N/mm² Brittle fractures**)
It is necessary to utilise at least two testing temperatures and at *) 50 years at 20°C subject to the effect of water
least six welded test specimens per testing temperature 2). **) Stresses with which brittle fractures are to be expected according to
The following test specimens can be used in order to determine DIN 8075
the acceleration factor fB and to assess the brittle fracture proportion
of the fracture faces at different testing temperatures: The testing stresses of the welded test specimens must be
– welded test specimens according to the DVS 2203-2 technical established by multiplying the stresses from Table 1 by the demand-
code or ed minimum tensile creep-rupture welding factor fS according to
the DVS 2203-1 technical code, Supplement 2 or by the long-time
– FNCT test specimens according to the DVS 2203-4 technical welding factor fS according to the DVS 2205-1 technical code,
code, Supplement 2 or Supplement 17.
– 2NCT test specimens according to DIN EN 12814-3, Appendix Table 2 includes the testing stresses for the demanded long-time
A.2 welding factor fS of welded test specimens made of PE 80.
2) It is not necessary to sample unwelded comparative specimens (base material specimens)

3) The test result must not be influenced by any notches or grooves produced during the preparation of the test specimens, i.e. fractures originating from
the cut faces of the test specimens must not be assessed. Additional test specimens must be tested instead.
96
Table 2. Testing temperatures and testing stresses for welded test 7.1.1 Calculation of the geometrical mean from the creep-
specimens made of PE 80. rupture times of the test specimens in water
Testing fS = 0.4 fS = 0.6 fS = 0.8 tW = n t W1  t W2    t Wn (1)
temperature
20°C 3.20 N/mm² 4.80 N/mm² 6.40 N/mm² tW = Geometrical mean of the creep-rupture times
of test specimens in water in hours
40°C 2.47 N/mm² 3.70 N/mm² 4.93 N/mm² tW1, tW2, ... tWn = Individual creep-rupture times of the test speci-
60°C 1.96 N/mm² 2.94 N/mm² 3.92 N/mm² mens W1, W2, ... Wn in water in hours
n = Number of the tested specimens
80°C 1.60 N/mm² 2.40 N/mm² 3.20 N/mm²
7.1.2 Calculation of the geometrical mean from the creep-
Table 3 includes the testing stresses for the demanded long-time rupture times of the test specimens in an aqueous
welding factor fS of welded test specimens made of PE 100. wetting agent solution
tN = n t N1  t N2    t Nn (2)
Table 3. Testing temperatures and testing stresses for welded test
specimens made of PE 100.
tN = Geometrical mean of the creep-rupture times
Testing fS = 0. fS = 0.6 fS = 0.8 of test specimens in an aqueous wetting agent
temperature solution in hours
tN1, tN2, ... tNn = Individual creep-rupture times of the test speci-
20°C 4.00 N/mm² 6.00 N/mm² 8.00 N/mm² mens N1, N2, ... Nn in an aqueous wetting
40°C 3.08 N/mm² 4.62 N/mm² 6.16 N/mm² agent solution in hours
60°C 2.45 N/mm² 3.68 N/mm² 4.90 N/mm²
80°C 2.00 N/mm² 3.00 N/mm² 4.00 N/mm² 7.1.3 Calculation of the acceleration factor from the geo-
metrical means of the creep-rupture times of test
specimens in water tw and in an aqueous wetting
6.1 Acceleration factor
agent solution tN
In order to determine the acceleration factor fB, it is necessary to tW
establish the creep-rupture times of identical test specimens in f B = -----
-
water and in an aqueous wetting agent solution in one of the test- ! tN (3)
ing conditions specified in Section 4. The testing stresses from fB > 1
Table 1 apply to FNCT and 2NCT test specimens. The testing
stresses from Table 2 (PE 80) or Table 3 (PE 100) must be used fB = Acceleration factor (dimensionless)
for welded test specimens. Testing at a higher temperature is to tW = Geometrical mean of the creep-rupture times of test speci-
be recommended for a conservative consideration since the ac- mens in water in hours
celeration factor rises as the testing temperature falls [2].
tN = Geometrical mean of the creep-rupture times of test speci-
For the tensile creep-rupture test in an aqueous wetting agent so- mens in an aqueous wetting agent solution in hours
lution, it must be ensured (e.g. by testing reference specimens)
that the effectiveness of the testing medium is constant over the 7.2 Statistical evaluations about the tests on welded test
testing period within the framework of the customary variance specimens at the highest chosen testing temperature
( 20 %).
7.2.1 Calculation of the geometrical mean
6.2 Tests on welded specimens
tH = n t H1  t H2    t Hn (4)
Welded test specimens must be tested at a minimum of two tem-
peratures with the stresses from Table 2 (PE 80) or Table 3 tH = Geometrical mean of the creep-rupture times
(PE 100) reduced by the demanded welding factor. In order to of welded test specimens in an aqueous wet-
exclude any change in the fracture mechanism from brittle failure ting agent solution at the highest testing tem-
at high temperatures to ductile failure at low temperatures, it perature in hours
must be ensured that the brittle fracture proportion at the fracture tH1, tH2, ... tHn = Individual creep-rupture times of the welded
faces is no smaller at low testing temperatures than at the highest test specimens H1, H2, ... Hn in an aqueous
chosen testing temperature. wetting agent solution in hours
In order to assess the brittle fracture proportion of the fracture n = Number of the welded test specimens
faces, it is also possible to refer to FNCT or 2NCT test specimens
which have been tested at the temperatures of the welded test 7.2.2 Calculation of the standard deviation of the logarithms
specimens and with the corresponding stresses from Table 1.
1 n 1 n 2
 log tH1  log tH1
2
sL = ------------ – --- (5)
n–1 n
7 Evaluation i=1 i=1
7.1 Calculation of the acceleration factor sL = Standard deviation of the logarithms from the creep-rupture
times of the welded test specimens in an aqueous wetting
The acceleration factor is established from the geometrical agent solution at the highest testing temperature in hours
means of the creep-rupture times of welded, FNCT or 2NCT test tHi = Individual creep-rupture times of the welded test speci-
specimens which have been tested in water and in an aqueous mens H1, H2, ... Hn in an aqueous wetting agent solution
wetting agent solution in the tensile creep-rupture test in the at the highest testing temperature in hours
same testing conditions (same type of test specimens at the
n = Number of the welded test specimens
same temperature and with the same testing stress).
97
7.2.3 Calculation of the variance factor tBN, min = Minimum service life of the welded joint in an aqueous
wetting agent solution in operating conditions in hours
SL
S F = 10 (6) sL = Standard deviation of the logarithms4) from the creep-
rupture times of the welded test specimens in hours
SF = Variance factor (dimensionless) SF = Variance factor4) (dimensionless)
sL = Standard deviation of the logarithms from the creep-rupture
times of the welded test specimens in an aqueous wetting 7.4 Calculation of the required activation energy
agent solution at the highest testing temperature in hours The activation energy [4] with variable stress is determined from
the established minimum times in testing and operating condi-
7.2.4 Calculation of the minimum creep-rupture time tions.
The minimum creep-rupture time in an aqueous wetting agent – 2 log t BN, min – log t H, min
solution at the highest testing temperature is calculated from the E A = 1.91152  10 ----------------------------------------------------------- (10)
1 2
geometrical mean of the creep-rupture times minus the variance. ------ – -------
TB TH
The variance is represented by twice the standard deviation
(2 x s) of the logarithms from the individual creep-rupture times or
by the squared variance factor. 95.4 % of the characteristic values EA = Activation energy in kJ/mol
to be expected are located within the interval described by the tBN, min = Minimum service life of the welded joint in an aqueous
mean X and twice the standard deviation 2 x s (X  2 x s) [3]. wetting agent solution in operating conditions in hours
2.3 % of the characteristic values are located underneath the tH, min = Minimum creep-rupture time of the welded test speci-
threshold (X - 2 x s), i.e. statistically, 2.3 % of all the tested specimens at the highest testing temperature in hours
mens fail before achieving the minimum creep-rupture time.
TB = Absolute temperature in kelvin from the operating
log t H – 2  s L conditions
t H,min = 10 (7a)
TH = Absolute temperature in kelvin which was selected as
tH the highest testing temperature
t H,min = -------------
- (7b)
2
 SF  7.5 Calculation of the required mean creep-rupture time of
welded test specimens in the control condition
tH, min = Minimum creep-rupture time of the welded test speci-
mens at the highest testing temperature in hours With known activation energy, the requirement on the welded
tH = Geometrical mean of the creep-rupture times of welded joint in the control condition can be formulated by means of inter-
test specimens at the highest testing temperature in polation.
hours exp
t K, erf. = 10
sL = Standard deviation of the logarithms from the creep-
EA
-   ------ – ------
1 1
rupture times of the welded test specimens in hours exp = log t BN – ----------------------------------- (11)
–2  T 
SF = Variance factor (dimensionless) 1.9152 – 10 B TK
tK, erf. = Required mean creep-rupture time in hours (geometrical

7.3 Calculations about the service life of the welded joint in mean) which must be achieved by welded test speci-
operating conditions mens in the control condition (Table 2 or 3) – required
time
7.3.1 Calculation of the minimum service life of the welded
joint in an aqueous wetting agent solution in operating tBN = Mean service life of the welded joint in an aqueous wetting
conditions agent solution in operating conditions in hours
EA = Activation energy in kJ/mol
t
t BN, min = ----B (8) TB = Absolute temperature in kelvin from the operating con-
fB ditions
tBN, min = Minimum service life of the welded joint in an aqueous TK = Absolute temperature in kelvin which was selected as
wetting agent solution in operating conditions the control temperature
tB = Minimum service life of the welded joint in the medium
with A2B = 1 in operating conditions 7.6 Calculation of the geometrical mean from the creep-
rupture and testing times of the welded test specimens
fB = Acceleration factor (dimensionless)
in the control condition
7.3.2 Calculation of the mean service life of the welded joint tK = n t K1  t K2    t Kn (12)
in an aqueous wetting agent solution in operating
conditions tK = Geometrical mean from the creep-rupture and
testing times of welded test specimens in the
log t BN, min + 2  s L
t BN = 10 (9a) control condition in hours
tK1, tK2, ... tKn = Individual times of the welded test specimens
2
t BN = t BN, min   S F  (9b) K1, K2, ... Kn in an aqueous wetting agent solu-
tion in the control condition
tBN = Mean service life of the welded joint in an aqueous n = Number of the welded test specimens in the
wetting agent solution in operating conditions in hours control condition
4) The standard deviation of the logarithms and the variance factor are assumed to be invariant with regard to the testing temperature. It is possible to
transfer the results of the welded test specimens at the highest testing temperature from Sections 6.2.2 and 6.2.3.
98
7.7 Assessment – Testing temperatures

The demanded tensile creep-rupture welding factor and the mini- – Testing media
mum service life of the welded joint in operating conditions are – Testing forces and testing stresses
considered to be fulfilled if the geometrical mean from the creep- – Length of time until the fracture
rupture and testing times of the welded test specimens in the
– Appearance of the test specimen after the test and visual
control condition achieve the required mean creep-rupture time
evaluation of the fracture pattern
which is demanded of the welded test specimens.
– Testing date
!
REQUIREMENT: t K  t K, erf (13)
9 Explanations
tK = Geometrical mean from the creep-rupture and testing
times of welded test specimens in the control condition Example calculation for a joint between PE 80, executed by means
in hours of heated tool butt welding (fS = 0.8)
In the following example for heated tool butt welds between
mean) which must be achieved by welded test speci-
PE 80 pipes, the long-time welding factor of fS = 0.8 is checked
mens in the control condition (Table 2 or 3) – required
and it is proven that, at an operating temperature of 20°C and
time
with a circumferential stress of 8 N/mm², the welded joints
achieve a minimum service life of 50 years in water as the oper-
ating medium.
8 Test report
For this purpose, six test specimens of the butt-welded joint from
the pipe are tested in an aqueous wetting agent solution at 80°C
With an indication of this technical code, the following items must
with the testing stress of 3.2 N/mm² lowered by the welding factor
be specified in the test report:
(Table 2) and the creep-rupture times are evaluated statistically.
– Type, supply form and designation of the products
For the determination of the acceleration factor, six FNCT test
– Manufacturing date and process for the test specimens specimens in each case are tested in water and in an aqueous
– Position of the test specimens in the product wetting agent solution at 80°C with a testing stress of 4.0 N/mm²
– Type, shape and number of the test specimens (Table 1) and the geometrical means of the creep-rupture times
are related to each other.
– Dimensions of the test specimens
– Pretreatment of the test specimens In order to check the service life approach and to prove the long-
(e.g. with or without a welding bead) time welding factor, six more welded test specimens are tested in
an aqueous wetting agent solution at 60°C with 3.92 N/mm² (control
– Misalignment of the welded test specimens (quantitative)
condition from Table 2) and their geometrical mean from the creep-
– Demanded welding factor rupture and testing times must exceed the calculated required
– Proof of the service life of the welded joint time tk, erf at 60°C.
.
.
. .
. Minimum curve
. Mean curve
. .
.
.
.
.
, , , , , ,
Figure 1. Representation of the testing concept on the Arrhenius diagram.
99
Results of the example calculation are represented on the Arrhe- tN = Geometrical mean of the creep-rupture times
nius diagram (Fig. 1). The utilised abbreviations are explained in of test specimens in an aqueous wetting agent
Section 2: "Terms and definitions". solution in hours
Computing operation tN1, tN2, ... tNn = Individual creep-rupture times of the test speci-
mens N1, N2, ... Nn in an aqueous wetting agent
9.1 Calculation of the acceleration factor solution in hours
The acceleration factor is calculated from the geometrical means n = Number of the tested specimens
of the creep-rupture times of six FNCT test specimens in each The geometrical mean from the creep-rupture times of the speci-
case which have been tested in the same testing conditions in mens in an aqueous wetting agent solution is 126.1 hours.
the tensile creep-rupture test in water and in an aqueous wetting
agent solution. 9.1.3 Calculation of the acceleration factor from the
As the testing conditions, a testing temperature of 80°C and a geometrical means of the creep-rupture times of
testing stress of 4 N/mm² are selected from Table 1 for PE 80. specimens in water and in an aqueous wetting agent
solution:
9.1.1 Calculation of the geometrical mean from the creep-
rupture times of six FNCT test specimens, tested with tW
f B = ------  1 (3)
4 N/mm² at 80°C in water: tN
3,601.0h
Table 4. Creep-rupture times of FNCT test specimens in water. f B = -----------------------
126.1h
Specimen Creep-rupture time tWi
designation [h] f B = 28.6
W1 3,164.1 fB = Acceleration factor (dimensionless)

W2 3,384.5 tW = Geometrical mean of the creep-rupture times of test speci-
mens in water in hours
W3 3,506.6 tN = Geometrical mean of the creep-rupture times of test speci-
W4 3,698.6 mens in an aqueous wetting agent solution in hours
W5 3,794.0 The acceleration factor is 28.6.

W6 4,137.5 9.2 Statistical evaluations about the tests on welded test
specimens at the highest testing temperature
tW = n t W1  t W2    t Wn (1) The testing conditions of the welded test specimens made of
PE 80 are indicated in Table 2. 80°C is selected as the highest
t W = 6 3,164.1h  3,384.5h  3,506.6h  3,698.6h  3,794.0h  4,137.5h
testing temperature. Taking account of the long-time welding factor
t W = 3,601.0h of fS = 0.8, the testing stress is 3.2 N/mm². The tensile creep-
rupture testing of the six welded test specimens is carried out in
tW = Geometrical mean of the creep-rupture times an aqueous wetting agent solution.
of test specimens in water in hours
The geometrical mean, the standard deviation of the logarithms,
tW1, tW2, ... tWn = Individual creep-rupture times of the test the variance factor and the minimum creep-rupture time are calcu-
specimens W1, W2, ... Wn in water in hours lated from the creep-rupture times of the six welded test specimens.
Table 6. Results of welded test specimens at 80°C in an aqueous
The geometrical mean from the creep-rupture times of the FNCT wetting agent solution.
test specimens in water is 3,601.0 hours.
Specimen Creep-rupture Logarithm Squared logarithm
9.1.2 Calculation of the geometrical mean from the creep- designation time tHi of the creep- of the creep-
rupture times of six FNCT test specimens, tested with [h] rupture time rupture time
4 N/mm² at 80°C in an aqueous wetting agent solution:
H1 228.5 2.35889 5.56434
Table 5. Creep-rupture times of FNCT test specimens in an aqueous
H2 256.5 2.40909 5.80370
wetting agent solution.
H3 297.9 2.47407 6.12102
Specimen Creep-rupture time tNi
designation [h] H4 458.3 2.66115 7.08172
N1 113.8 H5 619.8 2.79225 7.79667
N2 117.7 H6 657.2 2.81770 7.93942
N3 124.1 Total: 15.51314 40.30688
N4 129.7
tH = n t H1  t H2    t Hn (4)
N5 135.9
N6 137.0 tH = 6 228.5h  256.5h  297.9h  458.3h  619.8h  657.2h
tN = n t N1  t N2    t Nn (2) t H = 385.1h
tH = Geometrical mean of the creep-rupture times

tN = 6 113.8h  117.7h  124.1h  129.7h  135.9h  137.0h
of welded test specimens at the highest testing
t N = 126.1h temperature in hours
100
tH1, tH2, ... tHn = Individual creep-rupture times of the welded 9.3 Calculations about the service life of the welded joint at
test specimens H1, H2, ... Hn in hours the operating temperature
n = Number of the welded test specimens With the aid of the acceleration factor, the equivalent minimum
The geometrical mean from the creep-rupture times of the welded service life at the same temperature in an aqueous wetting agent
test specimens at 80°C in an aqueous wetting agent solution is solution is derived from the demanded minimum service life of the
385.1 hours. welded joint of 50 years (438,000 hours) at 20°C in water as the
operating medium. Taking account of the long-time welding fac-
The totalised logarithms from Table 6 are used in order to calculate tor of fS = 0.8, the calculation is based on a stress of 6.4 N/mm²
the standard deviation of the logarithms from the creep-rupture (Table 2).
times of the welded test specimens.
t
n t BN, min = ----B
(
n 2 (8)
sL =
1
------------
n–1   log tH1 
i=1
2 1
– ---
n  log tH1
i=1 ) (5) fB
438,000h
t BN, min = -------------------------
1 28.6
sL = ------------ 40.307 – 1
---  15.513
2
6–1 6 t BN, min = 15,314.7h
s L = 0.199 tBN, min = Minimum service life of the welded joint in an aqueous
wetting agent solution in operating conditions
sL = Standard deviation of the logarithms from the creep-rupture
times of the welded test specimens in hours tB = Minimum service life of the welded joint in the medium
with A2B = 1 in operating conditions
tHi = Individual creep-rupture times of the welded test speci-
mens at the highest testing temperature in hours fB = Acceleration factor (dimensionless)
n = Number of the welded test specimens
The minimum service life of the welded joint in an aqueous
The standard deviation of the logarithms from the creep-rupture wetting agent solution at the operating temperature of 20°C is
times of the welded test specimens at 80°C in an aqueous wet- 15,314.7 hours.
ting agent solution is 0.199. The mean service life of the welded joint in an aqueous wetting
The variance factor is established from the standard deviation of agent solution at the operating temperature of 20°C results from
the logarithms. the minimum service life in the testing medium plus the variance.
log t BN, min – 2  S L 2
SL t BN = 10 (9a) t BN = t BN, min   S F  (9b)
S F = 10 (6)
log 15,314.7h + 2  0.199 2
0.199 t BN = 10 t BN = 15,314.7   1.58 
S F = 10
4.5831 t BN = 38,231.6h
S F = 1.58  58 % =t BN =
10 38,292.0h
(Deviation due to rounding up or down)
SF = Variance factor (dimensionless)
sL = Standard deviation of the logarithms from the creep-rupture tBN = Mean service life of the welded joint in an aqueous
times of the welded test specimens in hours wetting agent solution in operating conditions in hours
The variance factor from the creep-rupture times of the welded tBN, min = Minimum service life of the welded joint in an aqueous
test specimens at 80°C is 1.58 (58 %). wetting agent solution in operating conditions in hours
The minimum creep-rupture time of the welded test specimens at sL = Standard deviation of the logarithms5) from the creep-
80°C can be determined with the aid of the standard deviation of rupture times of the welded test specimens in hours
the logarithms (7a) or of the variance factor (7b). SF = Variance factor5) (dimensionless)
log t H – 2  S L tH The mean service life of the welded joint in an aqueous wetting
t H,min = 10 (7a) t H, min = -------------
- (7b) agent solution at the operating temperature of 20°C is 38,292.0
2
 SF  hours.
log 385.1 – 2  0.199
t H, min = 10 h 385.1h
t H, min = -------------------
2 9.4 Calculation of the required activation energy with
2.188
 1.58  variable stress from the testing conditions at 80°C
t H, min = 10 h
t H, min = 154.3h and the operating conditions at 20°C
t H, min = 154.3h log t BN, min – log t H, min
–2
E A = 1.9152  10 ----------------------------------------------------------- (10)
1 1
tH, min = Minimum creep-rupture time of the welded test speci- ------ – -------
mens at the highest testing temperature in hours TB TH
tH = Geometrical mean of the creep-rupture times of welded –2 log 15,314.7h – log 154.3h kJ
test specimens at the highest testing temperature in E A = 1.9152  10 ---------------------------------------------------------------------- ---------
1 1 mol
hours ------------------ – ------------------
293.16 353.16
sL = Standard deviation of the logarithms from the creep-
rupture times of the welded test specimens in hours kJ
E A = 66.0 ---------
SF = Variance factor (dimensionless) mol
The minimum creep-rupture time which is statistically exceeded EA = Activation energy in kJ/mol
by 97.7 % of the welded test specimens in the tensile creep-rup- tBN, min = Minimum service life of the welded joint in an aqueous
ture test at 80°C in an aqueous wetting agent solution is 154.3 wettting agent solution in operating conditions (20°C)
hours. in hours
5) The standard deviation of the logarithms and the variance factor are viewed as invariant with regard to the testing temperature.
101
tH, min = Minimum creep-rupture time of the welded test speci- tK = n t K1  t K2    t Kn (12)
mens at the highest testing temperature (80°C) in
hours tK = 6 1,366.5h  1,587.6h  1,802.3h  1,956.3h  2,235.9h  2,564.3h
TB = Absolute temperature in kelvin from the operating
conditions t K = 1,877.9h
TH = Absolute temperature in kelvin which was selected as
tK = Geometrical mean from the creep-rupture and
the highest testing temperature
testing times of welded test specimens in the
The required activation energy with variable stress from the mini- control condition in hours
mum times at 20°C and 80°C in an aqueous wetting agent solu- tK1, tK2, ... tKn = Individual times of the welded test specimens
tion is 66.0 kJ/mol. K1, K2, ... Kn in the control condition
n = Number of the welded test specimens in the
9.5 Calculation of the required mean creep-rupture time of control condition
welded test specimens at the control temperature of
60°C The geometrical mean from the creep-rupture times of the weld-
ed test specimens at 60°C in an aqueous wetting agent solution
In order to check the service life approach, the testing temperature
is 1,877.9 hours.
selected from Table 2 is 60°C.
exp 9.7 Assessment
t K, erf. = 10
The geometrical mean of the creep-rupture times of welded test
EA
-   ------ – ------ 
1 1
exp = log t BN – --------------------------------- (10) specimens which have been tested in the control condition ex-
–2  T 
1.9152  10 B TK ceeds the required time.
=
t K, erf. =
10
3.1718
1,485h REQUIREMENT: t K  t K, erf (13)
1,877.9 h  1,485 h Requirement satisfied

mean) which must be achieved by welded test speci- tK = Geometrical mean from the creep-rupture and testing
mens in the control condition (Table 2 or 3) – required times of welded test specimens in the control condition
time in hours
tBN = Mean service life of the welded joint in operating condi- tK, erf. = Required mean creep-rupture time in hours (geomet-
tions in the testing medium (aqueous wetting agent rical mean) which must be achieved by welded test
solution) in hours specimens in the control condition (Table 2 or 3) –
EA = Activation energy in 1 kJ/mol required time
TB = Absolute temperature in kelvin from the operating con-
ditions The demanded tensile creep-rupture welding factor of fS = 0.8
and the minimum service life of the welded joint of 50 years in
TK = Absolute temperature in kelvin which was selected as
operating conditions are considered to be fulfilled.
the control temperature
The requirement on the welded test specimens at the control

10 Literature
temperature of 60°C is a geometrical mean of 1,485 hours.
[1] DVS Working Group AG W 4.04, Chairman: J. Grieser, HES-
9.6 Calculation of the geometrical mean from creep-rupture SEL Ingenieurtechnik GmbH:
and testing times of welded test specimens in the control Checking of the demanded tensile creep-rupture welding factor
condition and of the minimum service life of welded joints between poly-
Six more welded test specimens are tested in the control condition. ethylenes, Joining Plastics – Fügen von Kunststoffen, 1/2007
60°C is selected as the testing temperature. The assigned testing [2] Ulrich Schulte and Joachim Hessel:
stress from Table 2 is 3.92 N/mm². The tensile creep-rupture Remaining service life of Hostalen GM5010 after an operating
testing of the welded test specimens is carried out in an aqueous time of 41 years, 3R INTERNATIONAL, Year 45, No. 9, 2006
wetting agent solution. The results of the test are portrayed in
Table 7. [3] Lothar Sachs:
Applied statistics, 9th edition, Springer Verlag, Berlin, Heidel-
berg 1999
Table 7. Creep-rupture times of welded test specimens at 60°C in an
aqueous wetting agent solution. [4] W. H. Westphal:
Physical dictionary, Springer Verlag, Berlin, Göttingen, Heidel-
Specimen Creep-rupture Logarithm Squared logarithm berg, 1952
designation time tS of the creep- of the creep-
[h] rupture time rupture time DVS 2203-1 Testing of welded joints between panels
and pipes made of thermoplastics – Test
K1 1,366.5 3.13561 9.83203 procedures – Requirements
K2 1,587.6 3.20074 10.24472 DVS 2203-1 Testing of welded joints between panels
Supplement 2 and pipes made of thermoplastics – Re-
K3 1,802.3 3.25582 10.60035 quirements in the tensile creep-rupture test
(tensile creep-rupture welding factor fs)
K4 1,956.3 3.29142 10.83348
DVS 2203-2 Testing of welded joints between thermo-
K5 2,235.9 3.34945 11.21881 plastics; Tensile test
K6 2,564.3 3.40896 11.62103 DVS 2203-4 Testing of welded joints between panels
and pipes made of thermoplastics – Tensile
Total: 19.64200 64.35043 creep-rupture test
102
DVS 2203-4 Testing of welded joints between panels

Supplement 2 and pipes made of thermoplastics – Tensile
creep-rupture test – Testing of the resist-
ance to slow crack growth in the full notch
creep-rupture test (FNCT)
DVS 2205-1 Calculation of tanks and apparatus made of
thermoplastics – Characteristic values
DVS 2205-1 Calculation of tanks and apparatus made of
Supplement 17 thermoplastics – Welding factors
DIN 8075 Pipes made of polyethylene (PE) – PE 63,
PE 80, PE 100 and PE-HD – General quality
requirements and tests
DIN 8078 Pipes made of polypropylene (PO) – PP-H,
PP-B, PP-R and PP-RCT – General quality
requirements and testing
DIN EN 12814-3 Testing of welded joints between thermo-
plastics – Tensile creep-rupture test
DIN EN ISO 12162 Thermoplastic materials for pipes and fittings
in the case of applications under pressure –
Classification and material identification –
Total operating (calculation) coefficient
103
File-Name: e2203-5.fm August 1999
DVS – DEUTSCHER VERBAND Testing of welded joints

FÜR SCHWEISSEN UND of thermoplastics plates and tubes: Technical Code
VERWANDTE VERFAHREN E.V. Technological bend test DVS 2203-5
Replaces July 1985 edition
Contents: 2 Method and design
1 Scope The technological bend test is performed with reference to DIN

2 Method and design 50 121.
2.1 Requirements on test equipment The tests shall be carried out at least eight hours after welding.
2.1.1 Measurement of bend angle No heat treatment operations are allowed to be carried out on the
2.1.2 Measurement of ram displacement test specimen.
3 Performance Fig. 1 shows the test arrangement.
3.1 Evaluation
3.1.1 Determination of the bend angle
3.1.2 Determination of the ram displacement
3.1.3 Good/bad evaluation
3.1.4 Study of parameters/Comparison of methods
3.2 Criteria of failure

4 Test report
5 Normative references
1 Scope
The bend test may be used in conjunction with other tests to

assess the performance of butt welded assemblies made from
thermoplastics materials.
Welded parts with comparable seam geometries, e.g. on profiles,
can also be tested with reference to this guideline.
The bend angle, the ram displacement while bending and the
fracture appearance when the test is terminated provide a guide s thickness of test specimen f ram displacement
to the ductility of a welded joint and hence the weld quality. b width of test specimen  bend angle
L1 total length of specimen a diameter of ram
The ductility properties of the material, the applied weld methods LS distance between axes of rollers D Diameter of the rollers in mm
and the geometry of the test specimens influence the achievable
bend angle resp. ram displacement and they have to be taken in Figure 1. Sketch of the test arrangement.
consideration while evaluating.
Table 1 gives the dimensions of the test arrangement and the
The results derived from the bend tests can only partly be used test specimens. The dimensions of the specimens mentioned are
to assess the long term behaviour of welded joints. related to the nominal dimensions of the semi-finished products.
The bend tests can also be used to optimize welding parameters. For a thickness > 30 mm it is recommended to reduce the
In this case it is helpful to use none standard test conditions (e.g. thicknesses of the test specimens to no less than 30 mm by
to decrease the test temperature or to increase the speed of machining from the sides in contact with the ram end (pipes: from
bending). the outside). In case of pipes the maximum thicknesses at the
Table 1. Dimensions of the test arrangement and the test specimens.
test specimen distance between diameter of ram a

axes of rollers Ls [mm]
thickness s width b minimum length L1 [mm]
[mm] [mm] [mm]
nominal value
pipe plate
3<s 5 0.1 × d1) 20 150 80 4
5 < s  10 min.: 6 20 200 90 8
10 < s  15 max.: 30 20 200 100 12.5
15 < s  20 30 250 120 16
20 < s  30 30 300 160 25
1) Nominal diameter
This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration is recommended. The user should
always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid. The Deutscher Verband für Schweißtech-
nik e.V. and those involved in preparing this publication are exempt from any liability.
104
edges of the specimens have to be taken into account before At least 6 test specimens shall be tested for each welded test
applying the chamfers. The distance between the rollers for test piece. In the case of welded plates, 3 test specimens shall be
specimens with thickness > 30 mm which will be tested without tested for each face of the weld. In case of welded pipes the
reduction of thickness is calculated with the formula: inside shall be subjected to extension.
LS = D + a + 3 s. The ram speed is given in table 2.
(D = 50 mm; a = 25 mm; s = thickness of test specimen).
The width of ram and the width of supports have to be larger than Table 2. Ram speed for some thermoplastics.
the width of specimen. The ram has to be positioned in the
middle of the weld. The tendency of the specimens to slip during material test speed
testing can be reduced by using a corrugated ram or grinding mm/min
paper at the tip of the ram.
PE-HD 50
In case of welded pipes the test specimens have to be cut PP-R 50
uniformly distributed around the circumference of the pipe. The PP-H, -B 20
test specimens shall be cut either radially or with parallel sides. PVDF 20
The width of the specimens cut radially is given by the mean PVC-U 10
value of the largest and the smallest width.
3.1 Evaluation
The technological bending test does not provide values for the
design of thermoplastic constructions. Nevertheless a specialist
is able to assess generally the welded joints by the results of the
deformation behaviour.
The results of technological bending tests can be evaluated in
two ways, as bend angle or as ram displacement. Bend angle
and ram displacement cannot be transferred into each other
mathematically.
3.1.1 Determination of the bend angle
Figure 2. Cross sections of specimens cut from pipes.

The bend angle is determined as the difference between the final
angle when either fracture occurs or a crack is visible and the
The beads have to be removed where the ram is in contact with initial angle. The angles at both ends of the specimen outside of
the specimen during testing. A maximum of 1 mm of the the rollers are measured. The bend angle is calculated by
longitudinal edges of the test specimen to be subjected to addition of both values. Possibly existing angle-deviations from
extension shall be removed at an angle of approximately 45°. the horizontal are to be determined and considered (Fig. 4).
These chamfers shall be continuous through the bead. The full bending of the specimen in the described test equipment
is considered as “no failure” and the bend angle is defined with a
value of 160° for the calculation of the mean value.
3.1.2 Determination of the ram displacement
The ram displacement is determined as the difference between

the final ram displacement when either fracture occurs or a crack
Figure 3. Geometry of the chamfers. is visible and the initial position of the ram. The full bending of the
specimen in the described test equipment is considered as “no
2.1 Requirements on test equipment failure” and the ram displacement taken from table 3 for the
The moment when the tip of the ram is in contact with the calculation of the mean value.
specimen has to be recorded reproducibly. The test procedure
has to be stopped automatically or manually when the specimen Table 3. Ram displacements corresponding to the bend angle of
breaks or a crack occurs. The result has to be recorded. 160° in case of no failure for the calculation of the mean
value.
2.1.1 Measurement of bend angle
The accuracy of the measuring device and the display shall be at thickness of test specimen bend angle ram displacement
least 1°. For this reason the equipment shall have an s [mm] [o ] f [mm]
electronical or mechanical measuring device with sufficient 3<s 5 60
precision. 5 < s  15 70
Due to the fact that the point of contact between the specimen 16 < s  20 160 85
and the rollers is moving continuously during the test the result 21 < s  25 170
shall to be corrected by an non-linear scale, a correction factor or 26 < s  30 150
an appropriate measuring equipment which is able to guide the
centre. 3.1.3 Good/ bad evaluation
2.1.2 Measurement of ram displacement For a good/bad evaluation the single values shall be taken into
consideration. Each value shall be equal or larger to the
The accuracy of the measuring device and the display shall be minimum bend angles or the minimum ram displacements given
0.1 mm at least. in guideline DVS 2203-1. If up to two test specimens do not
achieve the minimum bend angle or ram displacement as
specified in the requirements, two further test specimens from the
3 Performance same welded test piece cut in the same direction can be tested.
Unless otherwise specified or fixed by technical specifications the No more than two additional test specimens shall be tested. The
test shall be carried out according to DIN 50014-23/50-2. additional test specimens shall meet the requirements.
105
3.1.4 Study of parameters/Comparison of methods

The calculation of arithmetic mean values without additional
specimens is recommended in the case of comparative
investigations like optimizing welding parameters or optimizing
welding procedures.
3.2 Criteria of failure

The test specimen can fail by a spontaneous break or by starting
a crack and continuous crack growth.
When either a crack occurs or a starting crack becomes visible
with the naked eye, the measured value is determined. A starting
crack has a depth of ca. 0.5 mm. Condition for the sure
recognition is a sufficient illumination of the critical areas of the
test specimen and a sufficient observation e.g. by a mirror.
4 Test report
The test report shall refer to this guideline and it shall include at
least the following information:
– material, kind of delivery and designation of the product
– date and method of the welded joint
– position of the test specimen in the product
– shape of the test specimen (either radial or parallel sides)
– thickness of the test specimens in mm (nominal value)
– width of the test specimens in mm
– conditioning while testing
– test speed in mm/min
– bend angle or ram displacement
– kind of failure, crack progress if necessary
Figure 4. Schematic graph of the determination of bend angle and ram – test date
displacement.
5 Normative references
DIN 50014 Atmospheres and their technical application, standard

atmosphere
106
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December 2008
DVS – DEUTSCHER VERBAND Testing of joints between

FÜR SCHWEISSEN UND polymeric materials Technical Code
VERWANDTE VERFAHREN E.V. Shear and peeling tests DVS 2203-6
Translation of the German edition from January 2008
Contents: 1 Scope of application
1 Scope of application This technical code gives an overview of the shear and peeling
2 Overview list of the peeling and shear tests tests on joints between polymeric materials.
3 Standards, technical codes and guidelines which are also
applicable
2 Overview list of the peeling and shear tests
Test Joining process* Materials* Applic Standards,

ation technical codes
and guidelines
Peeling Peel decohesion test HM PE Pipes ISO 13954
tests
HD PE, PP, PB and PVDF Pipes DIN EN 12814-4
Peeling test HH, WE and WU PE, PP, PVC-P, ECB, E-VA, EPDM, Sheets DVS 2225-2
Diffusion and CR, NBR, CSM, IIR and PVC-P DIN EN 12316-2
adhesive bonding DVS 2226-3
DIN EN 12316-2
Radial peeling test, HM and HD PB, PE, PE-X, PP and PVDF Pipes DVS 2203-6, Supp. 1
manual DVS 2212-1
Manual peeling test HM PE (shell pipes) Pipes DVS 2207-5
PE, PP, PB; PVDF and PE-X Pipes DIN EN 12814-4
Roller peeling test Adhesive-bonded – Panels DIN EN 1464
joints Sheets DVS 2203-6, Supp. 2
Shear Torsion shear test, HM and HD PB, PE, PE-X, PP and PVDF Pipes DVS 2203-6, Supp. 1
tests manual DVS 2212-1
Torsion shear test, HM and HD PB, PE, PE-X, PP and PVDF Pipes DVS 2203-6. Supp. 1
mechanised
Ring shear test Adhesive-bonded PVC-U, PVC-C, ABS, PS and fibre Pipes DVS 2204-1, -3 and -5
joints composite EN ISO 9311-2
DVS 2203-6, Supp. 2
Overlaminated joints Fibre composite Pipes DIN 53769-1
Segment shear test Overlaminated joints Fibre composite Pipes DIN 53769-1
Adhesive-bonded
joints
Tensile shear test Adhesive-bonded PVC-U, PVC-C, ABS, PS and fibre Pipes DVS 2204-1, -3 and -5
joints composite Panels DVS 2203-6, Supp. 2
DIN EN 1465
Overlaminated joints Fibre composite Pipes DIN EN ISO 527-4
Panels
Compression shear test Adhesive-bonded PVC-U, PVC-C, ABS and PS Pipes DIN 16970
joints DIN EN ISO 9311-2
DVS 2203-6, Supp. 2
Tensile shear test HH, WE and WU PE, PP, PVC-P, ECB, E-VA, EPDM, Sheets DVS 2226-2
CR, NBR, CSM, IIR and PVC-P DIN EN 12317-2
* For abbreviations: See the following table
107
3 Standards, technical codes and guidelines which are

Joining process
also applicable
HD Heated tool sleeve welding
DIN 16970 Adhesives for the joining of pipes and
HH Heated wedge welding piping parts made of hard PVC – General
HM Sleeve welding with an incorporated electric heating quality requirements and tests
element DIN 53769-1 Testing of piping made of glass-fibre-rein-
forced plastics – Determination of the bond
WE Hot gas extrusion welding shear strength of piping parts correspond-
WU Hot gas lap welding ing to Pipe Type B
DIN EN 1464 Adhesives – Determination of the peeling
Materials
resistance of high-strength adhesive-bond-
ABS Acrylonitrile butadiene styrene ed joints – Roller peeling test
CR Chloroprene rubber DIN EN 1465 Adhesives – Determination of the tensile

shear strength of high-strength adhesive-
CSM Chlorosulphonated polyethylene bonded lap joints
ECB Ethylene copolymer bitumen DIN EN 12316-2 Sealing sheets – Determination of the
peeling resistance of the joining welds –
EPDM Ethylene propylene terpolymer Part 2: Plastic and elastomer sheets for
roof sealing
EVA Ethylene vinyl acetate
DIN EN 12317-2 Sealing sheets – Determination of the
IIR Butyl rubber shear resistance of the joining welds – Part
2: Plastic and elastomer sheets for roof
NBR Nitrile rubber
sealing
PB Polybutene DIN EN 12814-4 Testing of welded joints between thermo-
PE Polyethylene plastics – Part 4: Peeling test
DIN EN ISO 527-4 Plastics – Determination of the tensile
PE-X Cross-linked polyethylene properties – Part 4: Testing conditions for
PP Polypropylene plastic composite materials with isotropic
and anisotropic fibre reinforcement
PS Polystyrene
DIN EN ISO 9311-2 Adhesives for thermoplastic piping sys-
PVC-U Unplasticised polyvinyl chloride tems – Part 2: Determination of the shear
strength
PVC-P Plasticised polyvinyl chloride
ISO 13954 Plastic pipes and fittings – Peeling
PVC-C Chlorinated polyvinyl chloride strength testing of polyethylene (PE) elec-
trofusion joints with a nominal diameter
PVDF Polyvinylidene fluoride greater than or equal to 90 mm
DVS 2204-3 Adhesive bonding of thermoplastics; poly-
styrene and generically related plastics
DVS 2204-5 Adhesive bonding of pipes and fittings
made of thermoplastics – Chlorinated poly-
vinyl chloride (PVC-C)
DVS 2207-5 Welding of thermoplastics – Welding of PE
shell pipes – Pipes and piping parts
DVS 2212-1 Qualification testing of plastics welders –
Qualification Test Groups I and II
DVS 2225-2 Joining of sealing sheets made of polymer-
ic materials in earthwork construction and
water engineering – Site tests
DVS 2226-2 Testing of joints between sealing sheets
made of polymeric materials – Tensile
shear test
DVS 2226-3 Testing of joints between sealing sheets
made of polymeric materials – Peeling test
108
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December 2008
Testing of joints between

DVS – DEUTSCHER VERBAND polymeric materials
FÜR SCHWEISSEN UND Torsion shear and radial peeling tests for joints executed Technical Code
VERWANDTE VERFAHREN E.V. by means of sleeve welding with an incorporated electric DVS 2203-6
heating element and heated tool sleeve welding Supplement 1
Translation of the German edition from January 2008
Contents: uniformly distributed around the circumference. The dimensions

and the number of test specimens are included in Table 1. In the
1 Scope of application case of tapping valves, the test specimens must be taken
2 Sampling according to Figure 3.
3 Testing method
3.1 Torsion shear test b
b
3.1.1 Torsion shear test, manual (TSTmanual)
3.1.2 Torsion shear test, mechanised (TSTmechanised) Joining plane
Fügeebene
3.2 Radial peeling test (RPT) sRohr
sRohr
Fitting
Formteil
4 Assessment
5 Test report Rohr
Pipe
6 Appendix
6.1 Explanations
6.2 Standards, technical codes and guidelines which are also ddRohr
Rohr
applicable
6.3 Example of a test report b b == Probenbreite
Specimen width
= Probenbreite
sRohr = Wall thickness of the pipe
sRohr
dRohr = Wanddicke
==Wanddicke
Pipe diameter des Rohres
1 Scope of application d
DRohr = Rohrdurchmesser
= Durchmesser
In conjunction with other tests, the shear tests characterise the Specimen executed
quality of a welded joint in the case of sleeve welding with an by means of sleeve
incorporated electric heating element (HM) and heated tool welding with an
sleeve welding (HD). The evaluation of the fracture behaviour s incorporated electric
and of the fracture pattern results in a statement about the heating element
execution and quality of a welded joint. Subject to certain
prerequisites, the manual torsion shear test and the radial b
peeling test are also suitable for checking the quality of the
welded joint in situ.
The specific materials and material properties influence the
quality of the welded joint or the fracture pattern and must be Specimen executed
taken into consideration during the evaluation. The PE (PE 63, by means of heated
PE 80 and PE 100), PP, PB and PVDF materials are normally tool sleeve welding
s
used for sleeve welding with an incorporated electric heating
element (HM) and heated tool sleeve welding (HD).
Combinations with other materials are also possible, e. g. in the
case of the sleeve welding with an incorporated electric heating b
element of pipes made of PE-X and fittings made of PE 100.
The results obtained in the shear tests are not transferable to the
creep behaviour of a welded joint. Figure 1. Specimen section with parallel faces (cross-section or longitu-
dinal sections).
2 Sampling a
The specimen preparation has a considerable influence on the
test results. Therefore, it must be ensured that lines, notches or
miscellaneous damage are removed from the cut faces of the
test specimens before the test. The cut faces must be parallel
(see Figure 1). d
The test specimens may be manufactured, at the earliest, twelve b
hours after the welding.
For an orientational site test, the test specimens may also be
manufactured and the test performed at an earlier point in time.
In this respect, it must be guaranteed that the test specimens
have reached the ambient temperature. c
Figs. 2 and 3 show how the test specimens are taken from the Figure 2. Positions (a to d) at which the test specimens are taken from
joints executed by means of sleeve welding with an incorporated joints executed by means of sleeve welding with an incorporat-
electric heating element and heated tool sleeve welding. The test ed electric heating element and heated tool sleeve welding
specimens must be taken by means of slitting and must be (does not apply to tapping valves).
109
Table 1. Dimensions and minimum number of test specimens in the case of sleeve welding with an incorporated electric heating element and
heated tool sleeve welding.
Pipe diameter Test specimen width b Test specimen length Minimum number of test specimens
in mm in mm* in mm distributed around the circumference**
Up to 63 2.5 ± 0.5 (≤ 5*) ≥ joining zone length 2
> 63 - 225 4.0 ± 1.0 (≤ 10*) ≥ joining zone length 4
> 225 4.0 ± 1.0 (≤ 10*) ≥ joining zone length 6
* Maximum values for the torsion shear test, permissible within the framework of orientational site tests.
** With tapping valves, four test specimens must be taken in each case according to Figure 3.
3.1.2 Mechanised torsion shear test (TSTmechanised)

The test can also be performed using an apparatus (see Figure
5). This must be designed in such a way that the rotating speed
c during the rotation by (min.) 90° is constant and is approx. 1° per
second. The holder must be designed in such a way that the test
b specimens are held securely and are not damaged. The point of
d
rotation must be in the centre of the heater spiral plane. If the
heater spiral plane is larger than the clamping length of the
a holder, the test specimen can also be tested in the split condition.
The distance between the holders must be infinitely adjustable to
the various diameters. In the case of different joining and heater
Figure 3. Taking test specimens (a to d) in the case of tapping valves for spiral planes in the sleeve, this must be taken into consideration
the manual (TST ) and mechanised (TST )
during the test.
torsion shear tests and the radial peeling test (RPT).
3 Testing method
In principle, the test specimens for the test must have reached
the room temperature. The test must be performed at the room Specimen
temperature. Orientational site tests may be carried out at the
ambient temperature. This must be taken into consideration and
Torque sensor
documented during the evaluation.
3.1 Torsion shear test (TST) Drive

The torsion shear test can be performed not only manually (see
3.1.1) but also in a mechanised process (see 3.1.2). Specimen holder
3.1.1 Manual torsion shear test (TSTmanual)

For testing purposes, the test specimen is clamped in a vice in
such a way that the joining plane is located just outside and
parallel to the clamping area. The individual segments are
gripped over the entire joining length using a suitable tool without Figure 5. Principle of the test set-up for the mechanised torsion shear
any sharp edges and are then rotated by min. 90° in the joining test (TST ).
plane. In this respect, the rotating speed must be uniform and
very low (approx. 5 - 10 seconds for 90°) in order to eliminate its 3.2 Radial peeling test (RPT)
influence on the fracture behaviour to a great extent. The
For testing purposes, the test specimen must be clamped in a
clamping faces should be slightly undercut (max. 2°) in order to
vice in such a way that the joining plane is located just outside
be able to introduce the torsion moment into the joining plane in a
the clamping area (see Figure 6). The individual segments must
targeted way.
be gripped using a suitable tool without any sharp edges (e. g.
pipe pliers) and must then be radially peeled at a speed as
uniform as possible (approx. 2 seconds for 90°). It may be
necessary to apply the tool several times. The clamping faces
should be slightly undercut (max. 2°) in order to be able to
introduce the peeling force into the joining plane in a targeted
way.
Figure 4.
Manual torsion shear test Figure 6. Radial peeling test (RPT) for joints executed by means of
(TST ). sleeve welding with an incorporated electric heating element
and heated tool sleeve welding.
110
4 Assessment 6 Appendix
The appearance of the fracture faces must be evaluated during 6.1 Explanations
the assessment. In principle, a distinction must be made between This supplement is intended to summarise the peeling and shear
brittle (smooth) and ductile (stretched) fracture faces (see Figs. 7 tests which have been included in other technical codes until now
and 8). It is necessary to determine the percentage of these (e. g. DVS 2212-1 and DVS 2207-1).
fracture face types (without taking account of the heater spiral
areas). The requirements are stipulated in DVS 2203-1, 6.2 Standards, technical codes and guidelines which are
Supplement 4. also applicable
Any defects (e. g. bubbles, shrinkage cavities, foreign inclusions DVS 2202-1 Defects in welded joints between thermoplastics;
or displaced heater spirals) are assessed according to characteristics, description and assessment
DVS 2202-1.
pipes made of thermoplastics; test procedures -
requirements
pipes made of thermoplastics; tensile creep test
DVS 2207-1 Welding of thermoplastics; heated tool welding of
pipes, piping parts and panels made of PE-HD
DVS 2207-5 Welding of thermoplastics; welding of PE shell
pipes; pipes and piping parts
pipes, piping parts and panels made of PP
Figure 7. Example of a ductile fracture face for PE*. pipes, piping parts and panels made of PVDF
DVS 2212-1 Qualification testing of plastics welders, Qualifi-
cation Test Groups I and II
Figure 8. Example of a smooth fracture face for PE*.
* Typical fracture patterns for the individual materials are included in

DVS 2203-1, Supplement 4.
5 Test report
With reference to this technical code, the following minimum

items must be indicated in the test report:
– type, delivery form and identification of the components
– information about the welding date, the sampling location, the
executing company, the welder, the welding process and the
welding parameters (welding record sheet)
– number and position of the test specimens
– test specimen dimensions (wall thickness, length of the joining
plane and width)
– temperature / air humidity during the test
– evaluation of the fracture pattern (determination of the
percentage fracture face types without the proportion of the
heater spiral areas) and assessment according to DVS
2203-1, Supplement 4
– test date, name and signature of the tester
111
6.3 Example of a test report
Test report: Torsion shear test (TST) and radial peeling test (RPT)
Company:
Name of the welder:
Sampling:
Sampling location / building site:
Pipes: identification
Pipes: material
Fitting: identification
Fitting: material
Welding process:
Manufacture of the test specimens:
Wall thickness of the pipes in mm:
(nominal dimension)
Diameter of the pipes in mm:
(nominal dimension)
Draw in the position of the test specimens a
("time"):
c
d
b d b
Number of test specimens:
Test specimen width: Side 1 a. b. c. d. e. f.

in mm (actual dimensions) Side 2 a. b. c. d. e. f.
Length of the joining zones: Side 1 a. b. c. d. e. f.
in mm (actual dimensions) Side 2 a. b. c. d. e. f.
Testing:
Testing temperature:
Testing device: TSTmanual TSTmechanised RPT
Identification:
Test results:
Proportion of the ductile areas in %: 1. 2. 3. 4. 5. 6.
(without heater spiral areas) 1. 2. 3. 4. 5. 6.
Remarks:
Date: Name:
Signature:
112
January 2008
Testing of joints
between polymeric materials
FÜR SCHWEISSEN UND Technical Code
Testing of adhesive-bonded joints DVS 2203-6
in the shear and peeling tests Supplement 2
Contents: 3 Tests
1 Scope of application In most cases, tests on adhesive-bonded joints have various

2 Stress types objectives.
3 Tests
A few are specified below:
3.1 Type and set-up
3.2 Tensile shear test – determination of the adhesive bonding execution and adhesive
3.3 Compression shear test suitable for a certain adhesive bonding task
3.4 Peeling test
4 Assessment – determination of the strength values required for an adhesive
bonding task (maximum and long-time strength behaviour)
5 Standards and guidelines which are also applicable
– determination of the deformation behaviour of an adhesive-
bonded joint with regard to external forces
– determination of the behaviour of the adhesive-bonded joint in
This supplement deals with the testing of adhesive-bonded joints operating conditions close to practice (strength, temperature,
media etc.)
between polymeric materials with each other and with other

materials by means of shear and peeling tests. – determination of the adhesive/material-specific optimum pre-
treatment process (cleaning, roughening, pickling etc.)
2 Stress types – determination of suitable application processes for the adhe-

sive bonding operation
As a rule, the forces effective on an adhesive-bonded joint arise – refinement of an adhesive formulation for special applications
in the form of tensile, shear or peeling stresses (Fig. 1). Peeling in agreement between the user and the adhesive manufacturer
stresses must be reduced to a minimum by taking design-related
measures. – checking of the adhesive bonding execution according to DVS
2221
3.1 Type and set-up

The test specimens can either be manufactured in the form of
single specimens or be cut out of two-dimensional trial adhesive-
bonded joints. Fixing jigs are used for the adhesive bonding of
single specimens in order to obtain reproducible adhesive-bond-
1. Peeling stresses 2. Shear stresses ed joints. At least five test specimens per test are required for a
sufficient statistical collection.
The testing methods described below serve to establish the proper-
ties and behaviour to be expected from an adhesive-bonded
joint. The overlapping length lü to be tested is dependent on the
material, the adhesive and the thickness. It is usually 10 mm.
3.2 Tensile shear test

3. Tensile shear stresses 4. Tensile stresses The specimens described in greater detail below are used in the
tensile shear test:
Tensile shear test specimen adhesive-bonded with a single overlap
In the case of the tensile shear test specimen adhesive-bonded
with a single overlap, it is necessary to take account of the arising
bending moment which influences the measured value due to
peripheral peeling forces.
5. Compressive stresses 6. Torsional stresses
Figure 1. Stress types.
113
Where:
luü "F" is the maximum force in Newton

"d" is the inside diameter of the fitting in millimetres
Figure 2. Tensile shear test specimen, adhesive-bonded with an overlap. "l" is the length of the parts joined with each other in millimetres
The shear strength is the arithmetic mean of the results from five
Strip-shaped tensile shear test specimen from a two-dimensional tests.
adhesive-bonded joint
Two-dimensional trial adhesive-bonded joints are more efficient
and more reliable to manufacture but require the careful cutting-
out of the tensile shear test specimens. Fig. 3 shows the side Pressure piston
Druckstempel
view of a strip-shaped tensile shear test specimen which was cut
out of a two-dimensional adhesive-bonded joint. The two saw
cuts which delimit the testing length lü are characteristic. Rohr
Pipe
Adhesive-bonded
Klebenaht Sleeve
Muffe
Sägeschnitt
Saw Cut 1 1 seam
s
s
l Saw Cut 2 2
Sägeschnitt
Figure 3. Tensile shear test speceimen from a two-dimensional adhe-

sive-bonded joint, overlapping length limited by saw cuts.
Figure 6. Shear test according to DIN 16970. The shearing of an adhe-
Tensile shear test specimen with a double cover strap sive-bonded pipe-sleeve joint or of similarly adhesive-bonded
components is tested with the pressure beam of a testing
In the case of the tensile shear test specimen with a double cover machine or on a press.
strap, two identical bending moments are effective against each
other so that no additional peeling forces arise.
3.4 Peeling test
In the case of thin, flexible materials, the testing and the assess-
ment are frequently carried out using peeling test specimens in
the "floating-roller test" according to DIN EN 1464 (Fig. 7).
lü / 2
Figure 4. Tensile shear test specimen, with a double cover strap.
3.3 Compression shear test

In the case of the compression shear test, pressure is used in
order to apply the shear forces in the adhesive-bonded face to
one of the adhesive-bonded joining members. A few common
test arrangements are portrayed below. Figure 7. Test specimen for floating-roller test.
Compression shear test according to ASTM D 2564-02

This test according to ASTM D 2564-2 is suitable for PVC adhe- 4 Assessment
sive-bonded joints.
A basic distinction is made between qualitative and quantitative
evaluation.
Qualitative evaluation:
Depending on the type of adhesive, the fracture patterns must be
evaluated according to DIN EN ISO 10365 or DVS 2221.
Quantitative evaluation:
A shear or peel resistance or strength is determined from the
measured shear or peeling forces via the specimen geometry.
For this purpose, the measured maximum force is divided by the
Adhesive-bonded
Klebenaht specimen width (resistance) or by the adhesive-bonded area
Figure 5. (strength), different depending on the applied standard.
seam Compression shear test accord-
ing to ASTM D 2564-02.
Pipe-sleeve adhesive bonding test 5 Standards and guidelines which are also applicable
The shear test specimen according to DIN 16970 (Fig. 6) or ac- ASTM D 2564 Standard specification for solvent ce-
cording to DIN EN ISO 9311-2 is suitable for adhesive-bonded ments for poly(vinyl chloride) (PVC) plas-
pipe-sleeve joints with a cylindrical adhesive bonding face. tic piping systems
The testing speed is (5 ± 0.5) mm/min. It is necessary to record DIN 16970 Adhesives for the joining of pipes and pip-
the greatest force at which the adhesive-bonded joint fails. ing parts made of hard PVC; general
The shear strength "S" in MPa for each adhesive-bonded speci- quality requirements and tests
men is calculated according to the following equation: DIN EN 1464 Adhesives – Determination of the peel
resistance of high-strength adhesive-
F
S = -------- bonded joints – Floating-roller test
πdl
114
DIN EN 1465 Adhesives – Determination of the tensile DIN EN ISO 10365 Adhesives – Designation of the most
shear strength of high-strength adhesive- important fracture patterns
bonded lap joints ISO 4578 Adhesives – Determination of the peel
DIN EN 26922 Adhesives; determination of the tensile resistance of high-strength adhesive bonds
strength of adhesive-bonded butt joints – Floating-roller method
DIN EN 28510-1 Adhesives; peeling test for flexibly/rigidly DVS 2221-1 Qualification testing of plastics adhesive
adhesive-bonded specimens; Part 1: 90° bonders – Qualification Test Group I –
peeling test Pipe/sleeve joints between PVC-U, PVC-C
DIN EN 28510-2 Adhesives; peeling test for flexibly/rigidly and ABS with solvent-based adhesives
adhesive-bonded specimens; Part 2: 180° KRV adhesive Plastic Pipes Association (KRV),
peeling test bonding instructions Kennedyallee 1-5, 53175 Bonn
DIN EN ISO 9311-2 Adhesives for thermoplastic piping sys- for pressurised PVC
tems; Part 2: Determination of the shear piping
strength
DIN EN ISO 9653 Adhesives – Test procedures for the
shear impact strength of adhesive-bond-
ed joints
115
January 2011

FÜR SCHWEISSEN UND Adhesive bonding of thermoplastics Technical Code
DVS 2204-1
Contents: 2 Materials
1 Scope of application The base materials are polymers, copolymers as well as their
2 Materials blends. A list of the materials to be joined, with information about
3 State of the art the adhesive bondability, can be found in Annex 1.
4 Adhesives
4.1 Influencing factors Copolymers and their blends exhibit altered or, to be more exact,
5 Adhesive classification improved properties, e.g. increased impact strength, thermal
5.1 Physically setting adhesives endurance or weathering and media resistance. The materials
5.1.1Contact adhesives are utilised in mouldings and as semi-finished products such as
5.1.2Dispersion adhesives panels, pipes, sections or films.
5.1.3Hot melt adhesives
5.1.4Diffusion adhesives
5.2 Chemically reacting adhesives 3 State of the art
5.2.1General
5.2.2Polymerisation-curing adhesives
Adhesive bonding technology is becoming ever more significant
5.2.3Polyaddition-curing adhesives
5.2.4Polycondensation-curing adhesives in industrial fabrication and in the skilled trades. In the meantime,
6 Joint shapes adhesive-bonded joints can be found in all sectors. A wide selec-
7 Joining part pretreatment tion of adhesives are available for this purpose.
7.1 Surface preparation
With regard to the adhesive bonding of plastics, the surface ener-
7.2 Surface pretreatment
gy (polarity) is a decisive variable. It is responsible for the degree
7.2.1Physical/electrical pretreatment processes of wetting by the adhesive and can be influenced by correspond-
7.2.2Flame pretreatment ing pretreatment methods.
7.2.3Plasma pretreatment
7.2.4Chemical pretreatment processes However, surface pretreatments are often not so effective. There-
8 Adhesive bonding execution fore, no significant improvement in the adhesive-bonded joint is
8.1 Joining with solvent-based adhesives obtained. Moreover, the effectiveness of the pretreatment is often
8.2 Joining with contact adhesives only temporary, depending on the material and the method. In
8.3 Joining with hot melt adhesives the field of the plastics which are easy to adhesive-bond (such as
8.4 Joining with two-component reactive adhesives PVC and ABS), the good solubility of the polymers is exploited
8.5 Joining with one-component reactive adhesives and solvents or solvent-based adhesives are used. The solvents
9 Testing penetrate into the joining face, trigger molecular movements and,
9.1 Testing on test specimens after escaping, lead to strong, permanent joints. It must be borne
9.2 Testing and inspection on finished parts in mind that the solvents may influence the polymer structure and
10 Working hygiene, occupational health and safety and the the composition depending on (for example) the polymer, the
environment time and the temperature. Components with residual stress are
11 Literature particularly susceptible here and corresponding measures (e.g.
11.1 Standards tempering) must be taken.
11.2 Technical rules
Appendix 1: Thermoplastics Polymers with increased polar proportions like ABS can also be
Appendix 2: Adhesive classification joined using adhesives with a purely adhesive effect. Adhesives
which are intended for polyolefins (PE/PP) and achieve notable
strengths also without any special pretreatment of the adhesive
1 Scope of application bonding faces have even been launched on to the market in
recent times.
This technical code deals with the structural adhesive bonding of
thermoplastics exhibiting different chemical compositions with The selection of suitable adhesives is determined by the applica-
themselves or in combination with other thermoplastics. Other tion and the materials and, as a rule, is made in cooperation with
regulations and instructions are not restricted by this technical code. the adhesive supplier or on the basis of a recommendation in a
so-called adhesive table.
As the main focal point, this technical code is oriented to both
manual and mechanical processing. The continuous manufac- Since the base materials may be very different because of the
ture of adhesive-bonded joints (such as large-area coating, com- variation of the components and the mouldings contain additives
posite film manufacture, series fabrication operations and the ad- such as lubricants, preliminary tests are required in addition in
hesive bonding of foams) is not the subject of this technical code. most cases when selecting the adhesive system.
116
4 Adhesives – Proper processing of the selected adhesive (pay attention to

the instructions from the manufacturer).
According to DIN EN 923, any non-metallic substance which can – Loads on the adhesive-bonded joint only after the final strength
join materials, by means of surface bonding (adhesion = bonding or the utilisation strength has been achieved to a great extent
forces at the interface to the substrate to be adhesive-bonded), in (pay attention to the further processing instructions).
such a way that the joint has an adequate internal strength (cohe-
sion = bonding forces of the adhesive constituents amongst Furthermore, sequences in fabrication technology, questions
themselves) is regarded as an adhesive. relating to the economic viability and the latest occupational
health and safety and safety stipulations must be borne in mind
when selecting the adhesive.
Material 1
5 Adhesive classification
Adhesion
Cohesion Adhesive
From classical antiquity to the beginning of the 20th century, the
adhesives were based on natural raw materials such as bone
Adhesion glue, casein or starch which dominated the market. Today, the
Material 2 adhesive market is characterised by the synthetic raw materials.
Due to the variation possibilities resulting from these, the user
has available a large number of most diverse adhesives which
often exhibit distinctly different properties such as the processing,
Figure 1. Structure of an adhesive-bonded layer. the strength, the temperature resistance and the media resistance.
A systematic, binding adhesive classification has not existed until
The basic prerequisites for adhesive bonding are that the adhe- today. The most common adhesive classification is based on the
sive must be liquid or pasty in the application condition and solid setting and curing mechanisms, Annex 2. A classification is made
in the final condition and that the joining parts are wettable with according to physically setting adhesives and chemically reacting
the adhesive. The surface energy of the adhesive must be at adhesives. In the case of the chemically reacting systems, there
least lower than or equal to the surface energy of the material. are differentiations between one-component and two-component
Ideal wetting is obtained when the surface energy of the adhe- systems (1C/2C) as well as between cold-curing and hot-curing
sive is a great deal lower than that of the material. systems. The physically setting systems with chemical solidifica-
tion, e.g. hot melt adhesives with PUR/EP post-curing should be
regarded as a variant in this classification form. Another classifi-
cation possibility is provided by the adhesive bonding forms,
Annex 2.
5.1 Physically setting adhesives

They are defined by the fact that the setting process of the adhe-
sive takes place physically (e.g. by means of drying, solidification
from melts or diffusion processes) without any changes in the
Figure 2. Different wetting. components in the chemical sense.
4.1 Influencing factors 5.1.1 Contact adhesives
For an optimum adhesive bonding result (i.e. a permanent, non- Contact adhesives are characterised by the fact that they contain
positive-locking joint), the following factors must be taken into high-molecular but chemically non-cross-linked polymeric com-
consideration when selecting the adhesive: ponents (e.g. polychloroprene) which, by adding solvent, are
turned into a viscosity state which ensures the optimum wetting
– The application-related material selection must be made taking of the joining part surface.
account of the mechanical, thermal and chemical requirements
as well as the air humidity. Contact adhesives must be applied to both joining parts. The
solidification process (solvent evaporation time) takes place by
– The materials must be pretreated in a material-specific way. means of drying before they are joined together. The adhesive
– The adhesives are selected in relation to the application. bonding layers must feel dry. The joining parts are then pressed
together at a defined pressure within a certain period (contact
– The surfaces to be adhesive-bonded must be dirt/grease-free adhesive bonding time). The level of the pressing pressure, not
and dry. the pressing duration, is decisive for the strength.
– The adhesive bonding faces must be designed with the largest During and after the pressing, an intermeshing process occurs
possible areas. between the adhesive layers on both sides and connects the
joining parts with each other firmly. An improvement in the heat
– Structures appropriate for the adhesive should serve to avoid
resistance and in the creep strength is achieved by utilising slowly
any impermissible peeling loads and to reduce any stress
acting hardeners which lead to spatially wide-meshed cross-
peaks.
linking in the course of a few days.
– The structure must be chosen in such a way that it preferably Because of the high solvent proportion (up to 80 %) of the classi-
results in shear stresses. cal contact adhesives, these are, if possible, replaced by so-
called dispersion adhesives today. In this respect, the polymer
(e.g. PU) is dispersed in water. The substantially longer drying
process and slight initial adhesion are disadvantages in the case
of the aqueous contact adhesives.
Peeling stresses 5.1.2 Dispersion adhesives
These are (synthetic) water-based adhesives on the basis of (for
Figure 3. Types of stresses on the adhesive. example) polyvinyl acetate dispersions (homopolymers/copoly-
mers) in combination with acrylates or functional monomers. The
– A fit-up accuracy of the adhesive-bonded joint which is as high utilisation field of these adhesives is primarily for the adhesive
as possible and is adapted to the adhesive (according to the bonding of wood. As in the case of the hot melt adhesives, there
information from the manufacturer or to standards). is a chemically setting variant here as well, see Section 5.2.
117
5.1.3 Hot melt adhesives strengths are the characteristics of such adhesives. Typical rep-
resentatives are unsaturated polyester diluted with styrene or
Hot melt adhesives are solvent-free systems, preferably on the
methacrylate and polymethyl methacrylates, as gap-filling high-
basis of ethylene vinyl acetate (EVA) copolymers or polyamide
solid products which are utilised as 2C systems.
(PA), which are processed from the melt and form good adhesion
properties due to good wetting with the joining part to be adhe- In addition to the classical curing process caused by organic per-
sive-bonded. After the cooling, the adhesives solidify with corre- oxides, acrylate adhesives can also be made to react using UV
sponding cohesion properties. light.
Moreover, hot melt adhesives on the basis of saturated polyesters, 1C systems are utilised in the form of moisture-curing cy-
polyimides or the styrene butadiene styrene [SBS] or styrene iso- anoacrylates (superglues). The adhesives curing with the exclu-
prene styrene [SIS] block copolymers are available for special sion of oxygen (anaerobic), in the presence of metal ions, constitute
applications. one variant for this purpose. These are utilised preferably in the
The market encompasses not only these hot melt adhesives field of metals. An application in the field of plastics is only possible
which exhibit purely physical setting and may be classed as ther- using suitable activators.
moplastics but also a second category of hot melt adhesives
which form thermoset plastics via chemical post-curing (see Sec- 5.2.3 Polyaddition-curing adhesives
tion 5.2).
The polyaddition-curing adhesives include epoxy resins and poly-
urethanes.
5.1.4 Diffusion adhesives
This group is understood to include solvent-based adhesives (ad- 5.2.3.1 2C epoxy resin adhesives (EP)
hesive solutions) which, as a rule, contain a dissolved polymer
corresponding to the base material to be adhesive-bonded. The EPs are characterised by the fact that the resin component A has
adhesive is applied to both sides and the parts are joined within one or more reactive so-called epoxy groups. Here, two C atoms
the stipulated processing time. are connected together with one oxygen atom in an annular
structure. The utilised hardener component B (e.g. amines) must
The adhesive bonding principle is based on a swelling and disso- be capable of opening the oxygen bond and becoming added to
lution process of the joining parts. The properties of the set adhe- the liberated valencies. Polymer structures (thermoset plastics)
sive (thermal, chemical and mechanical) therefore correspond to which have net-like cross-linking and tightly limited deformation
those of the base material to the greatest possible extent. behaviour and greatly restrict the adhesive bonding of flexible
materials subjected to bending-peeling stresses exist after the
5.2 Chemically reacting adhesives end of the reaction. This behaviour can be improved to a limited
extent by adding elasticisers. With the exception of the polyole-
5.2.1 General fins and the plastics containing fluorine, the adhesion behaviour
Chemically reacting adhesives can be differentiated on the basis is good with all materials. The mixing ratios of A to B are oriented
of different curing mechanisms (Annex 2). They may be available to the number and type of the existing reaction groups. With the
as 1C (one-component) or 2C (two-component) systems. Cold or selection of the A and B components according to the basic
hot curing is possible. chemical structure, it is possible to formulate adhesives whose
curing takes place at room temperature or even only at higher
Polymerisation reactions are characterised by the fact that the temperatures (cold-curing (2C) or hot-curing (1C) adhesives).
polymers are formed from identical/similar monomers/prepolymers.
Depending on the adhesive type, the polymerisation process is
triggered by air humidity, by UV light with the exclusion of oxygen 5.2.3.2 1C epoxy resin adhesives (EP)
(anaerobic) or by adding organic peroxides. The pot life resulting These systems also have two components. They are merely
from this reaction is preferably less than 30 minutes. processed like one-component systems. On the one hand, these
Polyaddition reactions are 2C systems which, in the mixed condition at room tempera-
ture, are too inert to react in this temperature range because of
They are characterised by the fact that two components with
their chemical compositions. They can be processed like one-
different structures (resin A and hardener B) add up to the com-
component systems and the reaction process is triggered (accel-
ponent AB (adhesive). The mixing ratio to be chosen is dependent
erated) by supplying heat. One system variant is based on
on the type and quantity of the reactive groups of both input
admixing to the resin component hardeners (catalysts) which
components. It is imperative to comply with the manufacturer's
only develop their reactivity above certain temperatures. The so-
information about the mixing ratio since the adhesive-bonded
called reactive EP hot melt adhesives work according to the
joint otherwise may not cure completely or may become brittle.
same principle. Here, the curing process is initiated by the high
Polycondensation reactions melting temperature of the hot melt resins and leads to the curing
They are characterised by the fact that decomposition products even after the cooling of the hot melt resin. A substantially higher
(e.g. water or carbon dioxide) arise during the reaction of the heat resistance is achieved compared with the thermoplastic hot
components A+B. Depending on the reaction mechanism, the melt adhesives.
chemical curing processes take place in a more or less intensive-
ly exothermic form, i.e. the reaction process releases heat and 5.2.3.3 Polyurethane adhesives
thus changes the pot life depending on the batch size. This must
The basis of the PU adhesives is formed by isocyanates in one
be taken into consideration during the processing. When the pot
molecular group with high reactivity. The curing takes place via
life has elapsed, the adhesive must not be processed any more.
polyols/polyesters (2C systems) or by means of moisture (1C
The executed adhesive-bonded joints must not be subjected to
system).
any mechanical loads until the curing process has finished (see
the manufacturer's information about the hand strength and the 2C PU adhesives
final strength). The following adhesive descriptions give an over-
These adhesives are characterised by the fact that they contain
view of the various possibilities of the chemical starting basis.
reactive isocyanates (– N = C = 0) which react with hydroxide
Merely the fundamental properties are portrayed herein. They do
(HO) groups, B component, by splitting the double bond and add-
not make any claim to being complete.
ing the B component to polyurethanes. The curing normally takes
place at room temperature and can be controlled across a wide
5.2.2 Polymerisation-curing adhesives
time range from minutes to hours using corresponding catalysts.
These systems are suitable, in particular, for thermoplastics 2C PU systems have a wide application field. They are preferably
which exhibit partial dissolution behaviour with regard to sol- utilised for the large-area adhesive bonding of plastics or plastic-
vents/monomers. Short pot lives / curing times as well as high wood and metal.
118
1C PU adhesives
These systems consist of a polyurethane (the so-called prepoly-
mer) which has already been precured by the supplier and still
has free isocyanate groups for the final cross-linking. Water from
the air humidity is needed as the B component or by means of
direct spraying-on as the hardener. The main area of application
is for the insertion of car windows (as a structural element) by
means of adhesive bonding.
As a rule, 1C systems are offered in cartridges or aerosol cans
and are utilised as foams with good sealing and insulating prop-
erties. As in the case of the EP hot melt resin adhesives, the
possibility of working out the melt (reactive hot melt adhesives) Figure 5. Fig. 5. Compressive (shear) stresses.
exists here too. Higher-molecular, meltable polyisocyanates with
terminal reactive isocyanate groups are utilised in this case.
These are melted completely and applied at 60 – 80°C. Depend-
ing on the time, the free isocyanate groups which are still present
after the cooling react with the existing air humidity. The advan-
tages of this system are to be found in a considerably better
thermal stability.
5.2.4 Polycondensation-curing adhesives Figure 6. Peeling stresses.
The basis of the polycondensation-curing adhesives is formed by

the formaldehyde which reacts with other molecules such as
phenol, melamine or urea with water separation (condensation).
These are then called phenol, melamine or also urea resins.
Because of the water separation in the curing phase, high tem-
peratures and pressures are required for the adhesive bonding of
water-impermeable materials in order to exclude any enlarge-
ment of the volume of the adhesive-bonded joint due to blistering.
Therefore, polycondensation-curing adhesives do not play any
role with regard to the adhesive bonding of thermoplastics. They
are preferably used for the "glueing" (adhesive bonding) of wood,
e.g. for veneering. Here as well, the curing process is carried out
with temperature and pressure. However, wood is capable of
absorbing the water arising in the curing process.
Figure 7. Torsional stresses.

6 Joint shapes
Loading forms
The most favourable joint shapes for an application should
already be stipulated during the planning and the designing, tak-
ing account of the operational parameters. The forces acting on
an adhesive-bonded joint arise as tensile (shear), compressive Figure 8. Bevelled (scarfed) overlap.
(shear), peeling or torsional forces, Figs. 4 to 7.
Favourable joint shapes
From the viewpoint of adhesive bonding technology, the joint
shapes shown on Figs. 8 to 10 (for example) may be classed as
positive. Figure 9. Single cover strap.
Forming of the arising forces
If the design-related starting position is insufficient, an improve-
ment can be achieved by taking supplementary measures.
Stress peaks occurring at the ends of the adhesive-bonded joint
can be reduced (for example) by a scarf joint at the ends of the
substrate, Figs. 11 and 12.
Figure 10. Double cover strap.
The design must be chosen in such a way that peeling loads are
avoided or reduced, Figs. 13 and 14.
In order to avoid any tensile stresses, the joints must be designed
in such a way that the adhesive-bonded joint is subjected to com- Maximum stress
pressive loads in the main load direction.
Mean stress
Figure 4. Tensile (shear) stresses. Figure 11. Stress peaks.
119
with emery cloth or blasting. In the uniformity of the results, sand-

blasting yields the best and most reproducible results but has the
highest dust burdens of all the mechanical processes. In all the
Mean stress Maximum stress processes, the dust residues must be removed before the further
processing. Mechanical pretreatment processes are preferably
used for metallic adhesive-bonded joints.
7.2.1 Physical/electrical pretreatment processes

In contrast with the mechanical processes in which no chemical
changes occur in the surfaces, physical/chemical processes
Figure 12. Reduced stress peaks.
have the objective of chemically changing the surfaces. Physical/
electrical processes are principally used for plastics. Such
pretreatment processes are only temporary and attention must
be paid to the information from the device manufacturers. The
surface tension can be established with test liquids (so-called test
inks).
7.2.2 Flame pretreatment

Here, the plastic surfaces are heated for a short time using a
flame burning with an oxygen surplus. This triggers a surface
Figure 13. Peeling loads (not recommendable). change which exerts an oxidative effect and improves the adhe-
sion properties particularly in the case of non-polar plastics, e.g.
polyolefins.
7.2.3 Plasma pretreatment

Atmospheric plasma
In principle, an ionisable gas (e.g. air) is guided through the
annular gap via an internal electrode (electrically conductive rod)
through a ceramic tube which has a metal powder coating on the
outside wall (outside electrode) and is insulated towards the
outside and the pipe ends. A high-frequency high-voltage field is
Figure 14. Transformation into tensile and compressive loads applied to the electrodes. The gas flowing through is ionised by
(recommendable). the applied alternating electrical field and emerges from the noz-
zle. This process gives rise to a substantial improvement in the
adhesion properties.
7 Joining part pretreatment Low-pressure plasma
The objective of the joining part pretreatment is to optimise the The process chamber necessary for this method is evacuated
adhesion properties of the substrate surfaces. It encompasses when the joining parts have been inserted and is raised to the
three partial aspects: the surface preparation, the surface pre- working pressure by the inflowing process gas. The plasma
treatment and the surface post-treatment. changes the surface with the result of a substantial improvement
in the adhesion properties.
7.1 Surface preparation (as a cleaning process) Corona process
– Cleaning of the surfaces by removing loose or firmly adhering The pretreatment is carried out in the atmosphere between two
contaminations. electrodes to which high-frequency voltage is applied. In this
respect, the air molecules are ionised between the electrodes. If
– Manufacture of joining parts which are as exact-fitting and an insulating material is inserted between the electrodes, the sur-
(plane-)parallel as possible. face is exposed to the high-energy ions which give rise to the
– Degreasing with suitable cleaning agents in order to ensure changes in the adhesion properties.
the problem-free wetting of the joining parts by the adhesive.
The processes described here in an abridged form are applied
– In this respect, the stress cracking behaviour of the respective industrially. They are basically used for the pretreatment of
plastics must be taken into consideration when selecting the components with complicated shapes and of composite film
cleaning agents. materials.
7.2 Surface pretreatment (surface enlargement) 7.2.4 Chemical pretreatment processes

Here, a distinction must be made between mechanical, physical/ The chemical processes are intended for the pretreatment of
electrical and chemical processes. The pretreatment process is metals and of plastics which are difficult to adhesive-bond. The
selected depending on the material. Mechanical pretreatment is following pretreatment processes (amongst others) are possible
mainly applied in the form of grinding, brushing, rubbing-down for plastics which are difficult to adhesive-bond.
120
Pickling Pickling
Material Pretreatment Pickling solution
temperature duration
Polyamide Rubbing-down with emery cloth 20°C 3 min
+
HD polyethylene degreasing 100 g concentrated sulphuric acid 70°C 2 min
+ +
LD polyethylene pickling 5 g potassium dichromate 70°C 10 min
+ +
Polybutene 5 min rinsing 8 g water 70°C 5 min
+
Polypropylene drying 90°C 2 min
Rubbing-down with emery cloth
+
degreasing
+
pickling 23 g metallic potassium in a solution
Polytetrafluoroethylene
+ of 128 g naphthalene in 1 l water-free 20°C 5 – 10 min
(PTFE) rinsing with acetone tetrahydrofuran (< 500 ppm H2O)
+
rinsing with water
+
drying
Rubbing-down with emery cloth Concentrated phosphoric acid
+
degreasing 50°C 5 – 15 sec
Polyoxymethylene +
pickling or
(POM) + 1 g kieselguhr
5 min rinsing 3 g dioxan
+ 0.3 g p-toluene sulphonic acid 90°C 30 sec
5 min drying at 90°C 95.7 g perchloroethylene
In the case of POM, it must be ensured in particular that the a) Melt the hot melt adhesive completely in a suitable device and
rinsing process is carried out properly since a subsequent reac- raise it to the working temperature stipulated by the manufac-
tion is otherwise possible. turer. Pay attention to the maximum temperatures since the
adhesive may otherwise decompose.
8 Adhesive bonding execution b) With suitable appliances (nozzle or roll), apply the hot melt
adhesive to an adhesive bonding face prepared and, if neces-
Each adhesive or each adhesive system has specific processing sary, preheated according to Section 5.
conditions. Therefore, only general instructions can be given at
this juncture. Attention must be paid to the corresponding c) Put the joining parts together immediately. The adhesive bonding
processing instructions, e.g. on packaging and in the technical with hot melt adhesives requires a rapid working method since
bulletins from the adhesive manufacturers. the adhesive already begins to set after slight cooling.
8.1 Joining with solvent-based adhesives 8.4 Joining with two-component reactive adhesives
The adhesive bonding process requires the following operations: The adhesive bonding process requires the following operations:
a) Apply a closed adhesive layer in a uniform thickness to the a) Mix the components homogeneously in the specified quantita-
adhesive bonding faces prepared according to Section 7. tive ratio by stirring them intensively. Always prepare only as
Application on one side is also sufficient in some cases. Pay much mixture as can be processed within the specified pot life.
attention to the maximum permissible processing times, de- b) Apply a uniform layer thickness (pay attention to the informa-
pending on the ambient conditions. tion from the manufacturer!) of the adhesive to one side of the
b) The joining parts become wet, i.e. they are joined immediately adhesive bonding faces prepared according to Section 5, on
after the application of the adhesive. If necessary, they are both sides in special cases.
brought into close contact and fixed by moving them slightly to c) Put the joining parts together. If necessary, bring them into
and fro. During the setting, apply slight pressing-on pressure close contact and fix them by moving them slightly to and fro.
(approx. 1 N/cm²). Remove any surplus adhesive. A pressing pressure is not
8.2 Joining with contact adhesives required. However, a low fixing pressure uniformly effective over
the entire joining face is recommendable during the setting.
The adhesive bonding process requires the following operations:
a) If stipulated, add the required quantity of cross-linking agent to 8.5 Joining with one-component reactive adhesives
the adhesive and mix them well. Prepare only as much mix- The following operations must be carried out:
ture as can be processed within the pot life.
a) Apply a uniform layer of the adhesive to an adhesive bonding
b) Comply with the stipulated minimum solvent evaporation time. face prepared according to Section 5.
It is dependent on the type and quantity of the existing
solvents, on the thickness of the applied adhesive layer, on b) Join the joining parts immediately after the adhesive applica-
the temperature and on the air movement. tion and briefly press them together at a moderate pressure /
fixing pressure.
c) Join the joining faces within the contact adhesive bonding
time and briefly press them together at a high pressing-on c) Pay attention to the manufacturer's information about the
pressure. Thereafter, it is no longer possible to correct the curing mechanism (e.g. UV, heat or moisture).
positions of the joining parts.
8.3 Joining with hot melt adhesives 9 Testing
The adhesive bonding with hot melt adhesives requires the Testing operations on adhesive-bonded joints have various
following measures: objectives, e.g.:
121
– Determination of the adhesive suitable for a certain adhesive

bonding task.
– Determination of the strength values necessary or attainable
for an adhesive bonding task, of their scatter or of the deforma-
tion behaviour of an adhesive-bonded joint with regard to
external forces.
– Determination of the behaviour of the adhesive-bonded joint Figure 16. Tensile shear test specimen, with a double-shear cover strap.
with regard to the ambient temperature and to the ambient
media which subject it to stresses.
Saw Cut 1
– Determination of a suitable pretreatment process appropriate
for production, such as cleaning, roughening, pickling, applica-
tion of a primer etc.
– Determination of suitable working procedures for the adhesive
bonding operation, e.g. handling operations, type of applica-
tion of the fixing and joining pressures, heat application etc. Saw Cut 2
– Refinement of an adhesive formulation for special tasks in
Figure 17. Tensile shear test specimen from a large-area adhesive-bond-
cooperation between the user and the adhesive manufacturer.
ed joint, overlapping length limited by saw cuts.
9.1 Testing on test specimens
Testing methods of various kinds are used in order to establish
the properties and behaviour to be expected from an adhesive-
bonded joint. These methods are the tensile test according to
DIN EN ISO 527-3, the tensile shear or compression shear test
according to DIN EN 1465, the tensile creep test according to
EN ISO 899-1 (possibly at an elevated temperature and in the
medium producing the stresses) as well as the floating-roller test
with reference to DIN EN 1464. Test specimens can either be Extension pieces
Verlängerungsstücke
manufactured in the form of single specimens or be cut out of welded or oder
geschweißt adhesive-bonded
geklebt
large-area trial adhesive-bonded joints, Figs. 15 to 21.
If necessary, fixing jigs are used for the adhesive bonding of
single specimens in order to obtain reproducible adhesive bond-
ing conditions. In the case of the tensile shear test specimen Adhesive-bonded joint
Klebfuge
adhesive-bonded with a single overlap, it is necessary to take
account of the arising bending moment which influences the
measured value due to peripheral peeling forces, Fig. 15. In the
case of the tensile shear test specimen with a double-shear
cover strap, two identical bending moments are effective against
each other so that no additional peeling forces arise, Fig. 16.
Large-area trial adhesive-bonded joints are more efficient and
more reliable to manufacture but require the careful cutting-out of
the tensile shear test specimens. Fig. 17 shows the side view of a
strip-shaped tensile shear test specimen which is cut out of a
large-area adhesive-bonded joint. The two saw cuts which delimit
the testing length lü are characteristic.
In addition to the tensile shear test specimen, mention should be
made here of the traction-adhesive strength test specimen
(DIN EN 15870) with which the bond strength perpendicular to
the adhesive bonding face is measured, Fig. 18. The testing
cross-section may be circular or square.
The strength perpendicular to the adhesive bonding face can Figure 18. Traction-adhesive strength test specimen with a round or
also be established in the pressing-off procedure (press) with rectangular cross-section and boreholes in order to accom-
specimens adhesive-bonded in a cross shape, Fig. 19. The pre- modate the tie rod. The cylindrical test specimen is produced
requisite is a high bending strength of the test strips. The shear from thin-walled adhesive-bonded specimens by attaching
strength according to EN ISO 9311-2 is suitable for adhesive- extension pieces by means of welding or adhesive bonding.
bonded pipe-socket joints with a cylindrical adhesive bonding
face (rotating parts), Fig. 20. In the case of thin, flexible materials,
the testing and the evaluation are frequently carried out using
peeling test specimens (DIN EN ISO 11339, "T peel test"), Fig. 21.
Figure 15. Tensile shear test specimen, adhesive-bonded with an overlap.
Figure 19. Cross-beam test specimen. Test strips with a sufficient bend-
ing strength are adhesive-bonded in a cross shape. The test
is performed by means of "pressing-off" with the pressure
beam of a testing machine or on a press.
122
Compliance Toxic effect

with the
occupational
exposure Transport and
limit (OEL) storage
Order and Mucous membranes,

cleanness Direct skin
skin, contact
Figure 20. Shear test specimen according to DIN EN ISO 9311-2. The
shearing of adhesive-bonded pipe-socket joints or of similar respiratory tracts,
adhesive-bonded components is tested with the pressure Gloves,
hand cream, eyes, Smell and eva-
beam of a testing maschine or on a press.
protective cream, mouth region poration of the
working clothes cleaning agents
and respiratory
mask Application, post-
treatment of the
Exhaust air adhesive-bonded
installations joints and cleaning
and ventilation work
Clamping
Figure 22. Occupational health and safety measures and influences

exerted by the adhesive.
The EU-standardised duty to mark adhesives in the form of warn-

ing symbols (e.g. flame symbol) as well as the marking with
hazard and safety indications (the so-called R and S sets) are
compulsorily stipulated by the legisliation and this information
Figure 21. Peeling test specimen; the bond strength of thin, flexible ma-
terials on an inherently stiff substrate can be tested by means must be affixed to the packages in a way which is clearly visible
of perpendicular pulling-off. to the user. Not only this information but also an abridged version
of the adhesive bonding instructions must be displayed on the
9.2 Testing and inspection on finished parts package.
Frequently, it is not possible to make a correlation between those The exclusion of sources of hazards with regard to working
properties of an adhesive-bonded joint established on test speci- hygiene and occupational health and safety aspects is described
mens and the requirements on an adhesive-bonded component in the also prescribed EU-standardised and product-related safe-
in practice. Therefore, suppliers and customers often agree upon ty data sheets (see SDS according to 91/155/EEC-ISO 11014-1).
service capability and acceptance tests. In the case of the test Operating instructions must be elaborated according to the
specified first, the stresses arising in practice are reconstructed in Hazardous Substances Ordinance. The safety data sheets also
accelerated time in certain circumstances. In general, these are include environmentally relevant information, e.g. about the
destructive tests. The proper execution of adhesive-bonded joints waste disposal.
must be proven by acceptance tests. The following testing The personal protective measures such as the wearing of suita-
methods are customary: visual inspection, leak test and loading ble working clothes (gloves, eye protectors or similar items), the
test with increased nominal loads (e.g. 1.5 times higher). storage of utilised working materials in closed containers as well
Furthermore, any imperfections in the adhesive-bonded joints as the absolute prohibition of eating, drinking and smoking at the
can be detected, amongst other methods, by means of tapping workplace are additional stipulations for reducing hazards. The
(voids and blistering), heat transfer measurements or tempera- assessment variable for the health risk potential is the OEL
ture measurements in the case of large-area adhesive-bonded (occupational exposure limit):
joints, spark induction testing, ultrasonic testing or X-ray testing.
The information about the limiting values is provided in ppm
(parts per million) or in mg/m3.
10 Working hygiene, occupational health and safety and
The OEL value defines the maximum permissible concentration
the environment
of a substance (gas, vapour or suspended matter) in the air at the
Adhesives are based on natural raw materials or are chemical workplace which, according to the present status of knowledge,
products which, in the event of improper use, may constitute a generally does not affect health in the event of repeated and
hazard to health and to the environment. long-term exposure. The higher the ppm or mg/m³ figure, the less
critical a substance should be rated. These define the concentra-
The working hygiene hazard potentials, their effect on people and tion which should be referred to as the basis for the protective
the protective measures to be derived from these are portrayed measures to be taken and their monitoring at the workplace by
on Fig. 22. means of measuring technology.
These risks must be decreased by eliminating and reducing
OEL values only apply to the individual substance in question.
sources of danger as well as by utilising personal protective
Substance mixtures are assessed according to TRGS 900 (Tech-
equipment during the processing. The elimination and reduction
nical Rules for Hazardous Substances) according to which the in-
of sources of danger also represent one of the basic prerequi-
dividual OEL values are added on the basis of the percentage
sites during the development of adhesives. The replacement (as
composition of the mixture. The total OEL value of the mixture is
far as technically possible) of hazardous substances with less
defined in this way.
hazardous substances (substitution precept) decreases the bur-
dens on health and on the environment (e.g. classification in The occupational exposure limits may be checked, for example,
water-endangering classes). by extracting the solvents released during the processing (per-
123
sonal pump system) and absorbing them using activated char- 11 Literature
coal. The existing solvent concentration can be determined in its
total quantity or, for specific substances, by means of gas chro- 11.1 Standards
matography (GC analysis). DIN EN ISO 9311-2 Adhesives for thermoplastic piping sys-
Other data relevant to occupational health and safety (such as tems – Part 2: Determination of the shear
the flash point and the explosion limits) are also specified on the strength
safety data sheets. Additional product-related information with DIN EN ISO 11339 Adhesives – T peel test for adhesive-bond-
regard to the working hygiene, the occupational health and safety ed joints between flexible joining parts
and the environment is also included in the technical bulletins
DIN EN 923 Adhesives – Designations and definitions
from the adhesive manufacturers.
Remark: DIN EN 1464 Adhesives – Determination of the peeling
It is basically true that cleanness at the workplace and during the resistance of high-strength adhesive-
processing contributes to minimising the risks. bonded joints – Floating-roller test
DIN EN 1465 Adhesives – Determination of the tensile
shear strength of adhesive-bonded lap
joints
DIN EN 13887 Structural adhesives – Guidelines for the
surface treatment of metals and plastics
before adhesive bonding
DIN EN 14680 Adhesives for non-pressurised thermo-
plastic piping systems – Stipulations
DIN EN 14814 Adhesives for pressurised piping systems
made of thermoplastics for fluids – Stipula-
tions
DIN EN 14869-1 Structural adhesives – Determination of
the shear behaviour of structural adhesive-
bonded joints – Part 1: Torsion test proce-
dures using hollow cylinders with adhe-
sive-bonded butt joints
DIN EN 14869-2 Structural adhesives – Determination of
the shear behaviour of structural adhesive-
bonded joints – Part 2: Shear test for thick
joining parts
DIN EN 15336 Adhesives – Determination of the time until
the fracture of adhesive-bonded joints sub-
jected to static loads
DIN EN 15337 Adhesives – Determination of the shear
strength of anaerobic adhesives using
bolt-sleeve test specimens
DIN EN 15870 Adhesives – Determination of the tensile
strength of adhesive-bonded butt joints
DIN 16970 Adhesives for the joining of pipes and
piping parts made of hard PVC; general
quality requirements and tests
DIN 53766-1 Testing of apparatus and tanks made of
glass-fibre-reinforced plastics – Determi-
nation of the bond strength in the traction-
adhesive strength test
11.2 Technical rules

made of polyvinyl chloride (PVC-U) (under
preparation)
DVS 2206 Testing of components and structures
made of thermoplastics
124
Appendix 1: Thermoplastics
Materials Code Surface energy E Adhesive bondability

guide values [mN/m]
(method-dependent)
Unplasticised polyvinyl chloride PVC-U 39 ++
Post-chlorinated polyvinyl chloride PVC-C ++
Polyethylene PE 31 0
Cross-linked polyethylene PEX 31 0
Polypropylene PP 29 0
Polybutene PB 0
Acrylonitrile butadiene styrene ABS 35-42 ++
Polystyrene PS 33 ++
Polyamide PA 46 0
Polycarbonate PC 33-37 ++
Styrene butadiene copolymer SB ++
Styrene acrylonitrile copolymer SAN ++
Polyisobutylene PIB 0
Polytetrafluoroethylene PTFE 18.5 0
Polyvinylidene fluoride PVDF 34 0
Polymethyl methacrylate PMMA 33-44 ++
Polyethylene terephthalate PET 47 +
Polyacetal POM 36 0
Polyvinylidene chloride PVDC 49 +
Polyphenylene oxide PPO 0
Polyphenylene sulphide PPS 32 0
++ = readily adhesive-bondable
+ = adhesive-bondable
0 = difficult to adhesive-bond after material-specific pretreatment
125
Appendix 2: Adhesive classification
Adhesive classification according to the setting behaviour
Physically setting Chemically reacting in the form of

– Solvent-free adhesives – Polymerisation
e.g. hot melt adhesives e.g. PMMA (polymethyl methacrylate) systems
– Adhesive solutions whose solvents escape before the – Polyaddition
adhesive bonding e.g. epoxy systems
e.g. contact adhesives
– Polycondensation
– Adhesive solutions whose solvents evaporate during the e.g. urea resin systems
adhesive bonding
e.g. dispersion adhesives (white glues) or diffusion
adhesives
– Pressure-sensitive adhesives
e.g. tapes or films
Adhesive classification according to the adhesive bonding forms
Pressure-sensitive adhesive Contact adhesive bonding Structural adhesive bonding

bonding
Characteristic Material-specific Material-specific Material-specific
Permanently open Solvent evaporation time Limited open assembly time
Adhesive application on Adhesive applicaiton on both sides Application on one side or on two sides
one side
Low adhesive power Limited contact tack
Pressure-dependent and Adhesive power pressure- Strength build-up dependent on the
temperature-dependent dependent ambient conditions
Adhesive bonding Unspecific interaction between Mutual interlocking of the polymer Physical and/or chemical solidification
principle the adhesive and the material layers
Example Adhesive tape Polychloroprene adhesives Adhesive solutions (physical)
EP adhesives
MS adhesives
PU adhesives
(chemical)
126
December 2011
DVS – DEUTSCHER VERBAND Adhesive bonding of pipes and

FÜR SCHWEISSEN UND piping parts made of thermoplastics – Technical Code
VERWANDTE VERFAHREN E.V. Polyvinyl chloride (PVC-U) DVS 2204-4
Contents: based adhesives are applied improperly (e.g. in the event of ex-
cessive dispensing), this may exert seriously negative influences
1 Scope of application on the structure of the plastics in certain circumstances. Above
2 Material all, substantial changes in the strength properties and possibly
3 Adhesives stress cracking may occur in the case of adhesive-bonded joints
4 Requirements on adhesives between parts with high mechanical stresses. These processes
5 Marking of the adhesive packages are promoted, in particular, by high residual stresses, e.g. in in-
6 Shelf life of the adhesives jection mouldings or thermoformed parts.
7 Adhesive bonding instructions
Above all, it must be ensured that only those adhesives which the
8 Testing of adhesives
manufacturer has provided for the adhesive bonding of pipes and
8.1 Test procedures fittings made of polyvinyl chloride and has declared correspond-
8.2 Hygienic evaluation ingly are used. Adhesives which are utilised in the field of pres-
9 Additional indications surised PVC-U pipes must comply with DIN EN 14814.
10 Protective and safety measures
11 Literature When solvent-based adhesives are used, the adhesive bonding
must be carried out "wet in wet", i.e. the joining parts must be
joined immediately after the adhesive has been applied within the
1 Scope of application open assembly time (processing time).
The essential characteristics of these adhesive bonding systems:
This technical code applies to the adhesive bonding of pipes and
short waiting time and quick setting. The cured adhesive-bonded
piping parts made of polyvinyl chloride (PVC-U) according to the
joints (see the information from the manufacturer!) have mechan-
DIN 8061, DIN 8062, DIN 8063 ff., DIN EN 1329-1, DIN EN ISO
ical, thermal and chemical resistances comparable with those of
1452 and DIN EN ISO 15493 standards.
the materials themselves.
When selecting the adhesive, it is necessary to take account of:
2 Material
– dimensions and tolerances
The materials are unplasticised polyvinyl chloride (homopolymer) – mechanical and thermal loads
and blends with an impact-resistant setting. The blends are char- – effects of media
acterised by a higher impact strength. The materials are utilised
as semi-finished products in the form of pipes, fittings, valves,
panels and sections. The adhesive bondability can be checked 4 Requirements on adhesives
by visually inspecting the adhesive bonding faces of the compo-
nents according to the DVS 2221 technical code (Sections 4.3.3 ff.). The adhesives must make it possible to manufacture pipe joints
between PVC-U pipes and fittings, according to the requirements
resulting from the planned intended use of the piping. These include
3 Adhesives the service life, the strength behaviour, the temperature resistance,
the chemical resistance and the hygienic properties demanded in
As a rule, polyvinyl chloride is adhesive-bonded with solvent- the case of pipes for use with food or drinking water. These re-
based adhesives because of the good partial dissolubility of the quirements are defined in the various technical codes. Inquiries
material. The solvents diffuse into the joining faces, trigger molec- about the chemical resistance of adhesive-bonded joints, e.g.
ular movements and, after escaping, lead to solid and permanent when using concentrated inorganic acids, should be addressed
joints between the joining parts. to the manufacturers of the adhesives and of the semi-finished
products. During the processing, adhesives must not cause any
Although other adhesive bonding systems can be applied (e.g. health-related harm while complying with the OEL (occupational
reactive adhesives), this technical code relates to the application exposure limit).
of adhesives which contain solvents and are based on solvents
with rapid solvent action.
Solvent-based adhesives for the specified materials are solutions 5 Marking of the adhesive packages
of PVC-U in organic solvents on the basis of tetrahydrofuran, cy-
clohexanone, methyl ethyl ketone and other solvents with rapid In addition to the statutorily demanded information, the adhesive
solvent action. The choice of the corresponding solvents serves packages must be marked with the following minimum information:
to achieve the optimum partial dissolution of the adhesive bond-
ing faces, the defined open assembly time and the setting speed – designation of the adhesive
appropriate for the processing. Additives such as stabilisers, – name of the manufacturer or supplier
thickening agents, impact strength modifying agents and colouring – reference to the relevant adhesive standard
pigments can be used in order to obtain certain properties. If solvent- – area of application
127
– list of standards relating to thermoplastic piping systems for Table 1. PVC-U pipe joints – Stipulations for the dimension b.
which the adhesive is suitable
– CE marking with an indication of the pressure class according Pipe outside diameter Dimensions for b
to the standards, e.g. DIN EN 14814 mm approx. mm
– instructions for utilisation and storage Up to 16 1–2
– safety precautions with regard to utilisation and storage
– batch number 20 – 50 2–3
– manufacturing or use-by date with an indication of the minimum 63 – 225 3–6
shelf life of at least twelve months
250 – 400 6–8
6 Shelf life of the adhesives The insert depth of the sleeve is marked on the pipe end so that
the required adhesive application and the complete insertion of
The shelf life of an adhesive is understood to be the time in which the pipe into the sleeve can be checked.
the adhesive in an as yet unopened package can be processed
The adhesive bonding faces at the pipe end and in the sleeve of
without any problems after storage in stipulated storage conditions
the fittings are cleaned thoroughly. Clean, unused, absorbent, non-
(information from the manufacturer).
fraying and non-colouring paper and the cleaning agent stipulated
The adhesives must possess a sufficient shelf life in the event of by the adhesive or pipe system manufacturer are used for this
normal storage (min. twelve months). The shelf life depends not purpose. The paper must be replaced after every cleaning operation.
only on the composition of the adhesive but also on the type of The cleaned adhesive bonding faces must be dried off before the
packaging and other external influences, above all the storage adhesive application and must no longer be touched.
temperature. The adhesive manufacturer guarantees a minimum
shelf life in its technical documents. Before the adhesive is used, its processability must be checked.
Using a brush with a suitable size (see the recommendation from
Irrespective of this, the processor must always check the process- the manufacturer!), the adhesive is applied to the whole of the joint
ability of the adhesive! area in the sleeve and to the pipe according to the information
from the manufacturer.
Immediately after the adhesive application, the pipe is pushed
7 Adhesive bonding instructions
into the sleeve as far as the mark without any twisting or tilting, is
aligned if necessary and is fixed there for a few seconds. A uni-
All the adhesives and adhesive systems have specific processing form adhesive surplus on the outside and a small, closed adhesive
conditions. Therefore, only generally applicable indications can ring inside the pipe indicate that the adhesive bonding was carried
be given here. out over the whole area.
The manufacturers or the pipe system suppliers deliver the adhe- Any surplus adhesive is immediately removed with paper so that
sives and the appropriate cleaning agents in the ready-to-use a small throat is formed on the outside of the pipe.
condition. Consumption quantities can be found in the technical
bulletins or can be requested from the manufacturer. Neither dilution The adhesive-bonded joint must not be subjected to any mechan-
nor any miscellaneous changes are permissible. This also applies ical loads during the waiting time until the further processing. The
to the cleaning agents. In principle, attention must be paid to the duration of the waiting time is oriented to the adhesive bonding
adhesive bonding instructions from the adhesive or pipe system system, to the pipe diameter and to the processing temperature.
manufacturer. The pipes and the fittings must be dry and free It is included in the information from the adhesive manufacturer.
from grease or dirt. It is necessary to check the processability of The same applies to the setting time until the pressure test. The
the adhesive. After the stirring, it must run off the diagonally held pipes must not be closed during the drying phase. It is necessary to
rod uniformly and without any lumps. avoid any adhesive accumulations in the joint area.
In the case of larger dimensions as from d200/d225, attention
The adhesive bonding should only be carried out at processing
must be paid to the particular indications made by the adhesive
temperatures between 5°C and 40°C. In the event of any deviations,
and component suppliers!
these processing temperatures must be achieved by taking addi-
tional suitable measures. The open assembly time of the adhesives
decreases at higher temperatures and/or with lower adhesive film 8 Testing of adhesives
thicknesses. The open assembly time is the period between the
adhesive application and the joining of the parts. An overview of the available test procedures for adhesives is given
The following procedure is generally used in order to achieve an below. They are carried out by the adhesive manufacturers.
optimum adhesive-bonded joint:
8.1 Test procedures
– The dimensional accuracy of pipes and fittings must be checked.
– The pipes to be adhesive-bonded are shortened to the required Table 2. Overview of the test procedures.
length.
Solids content DIN EN 827
– The pipes must be cut off at a right angle to the pipe axis.
Viscosity DIN EN 12092
– The pipe ends are bevelled at an angle of approx. 15° on the out-
side (see Fig. 1 and Table 1) and are deburred on the inside. Film properties DIN EN ISO 9311-1
Shear strength DIN EN ISO 9311-2
Internal compressive strength DIN EN ISO 9311-3
8.1.1 Solids content
8.1.1.1 Preliminary remark

The solids content of the adhesive is determined by the content
of dissolved PVC-U and by the quantity of other solid constituents
Figure 1. PVC-U pipe joint, dimension b. in the adhesive.
128
8.1.1.2 Requirement The selection of the measuring devices, the measured specimens
The solids content is a product-specific property and is stipulated and the rotational speed must be adjusted to the adhesive to be
by the manufacturer for every adhesive type. It must be observed tested, must be stipulated and must also be specified along with
with a tolerance of ± 1 % by weight. the viscosity data.
Depending on the utilised spindle, the viscosity of adhesives with
8.1.1.3 Testing a non-thixotropic setting is determined at a rotational speed of
The solids content is determined according to DIN EN 827, Sec- approx. 60 rpm and that of adhesives with a thixotropic setting at
tion 7.6.2 (solids content up to the constant weight). Other methods rotational speeds of approx. 30 rpm. The reading is taken 20 ± 1 s
are permissible if the manufacturer can provide proof of the com- after the viscosimeter has been switched on.
parability and the reproducibility. It is left to the manufacturer to decide the rotational speed at
If required for production technology reasons, the solids content which the measurements are begun. The chosen measuring path
can also be determined by agreement (DIN EN 827, Section must be apparent from the viscosity data.
7.6.1). Depending on the type of the utilised viscosimeter, other rotational
The testing conditions for this purpose are specified in Table 3. speeds can also be stipulated for the tests. These must be docu-
mented in the technical documents.
Two individual determination operations are carried out in each
case. In the test report, the adhesive manufacturer must specify
whether the solids content was determined according to DIN EN 8.1.3 Film properties
827, Section 7.6.1 or according to DIN EN 827, Section 7.6.2.
8.1.3.1 Preliminary remark
8.1.2 Viscosity The adhesive to be tested is applied to a test plate using an appli-
cator (box-type knife) and the flow behaviour and uniformity of
8.1.2.1 Preliminary remark the film are investigated.
The viscosity (here, the dynamic viscosity) is a measure of the
flowability of the adhesives. It is determined with a rotational 8.1.3.2 Requirement
viscosimeter and is specified in mPas.
The flow value is a product-specific property and is stipulated by
8.1.2.2 Requirement the manufacturer. For products with a thixotropic setting, stipulated
maximum values must not be exceeded (e.g. 15 mm on PVC-U).
The viscosity of an adhesive is product-specific. It is dependent on
the storage time and temperature. During the minimum shelf life 8.1.3.3 Testing
specified by the adhesive manufacturer subject to proper storage,
it must be located within the tolerances specified in the technical The testing is carried out according to DIN EN ISO 9311-1 using
bulletin. a procedure stipulated by the adhesive manufacturer. In this respect,
the adhesive is applied to a glass or PVC-U plate using a box-
If the viscosity is the contractual subject of technical terms of
type knife in a defined coat thickness and at a speed of approx.
delivery in the sense of a test certificate according to DIN EN
20 mm/s.
10204, the viscosity data is, unless anything else has been agreed
upon, based on a storage time of 20 ± 4 hours after the manufac- The test report must include information about the utilised test
ture. The nominal value must be observed with a tolerance of procedure as well as about the plate material.
± 20 %. Since products containing solvents may change their
viscosity during the shelf life, it is preferable to agree upon a viscos- 8.1.3.4 Strength tests
ity range.
The strength requirements on thermoplastic pressurised and non-
8.1.2.3 Testing pressurised piping systems are defined in DIN EN 14814 and
DIN EN 14680. The corresponding values for PVC-U are listed in
The testing is performed according to Section 6.2 of DIN EN Tables 4 and 5.
12092 at 23 ± 2°C with a rotational viscosimeter stipulated by the
adhesive manufacturer.
Table 3. Testing conditions for the determination of the solids proportions of adhesives.
Testing conditions
Adhesive type Initial weight Container diameter Temperature Time Heating cabinet
g mm °C min
PVC-U adhesive 1 ± 0.1 60 ± 5 105 ± 1 120 ± 1 Circulating air
Table 4. Shear strength of PVC-U / DIN EN ISO 9311-2.
Pressurised pipe Non-pressurised pipe

DIN EN 14814 DIN EN 14680
Setting time Setting temperature Testing temperature Gap Nominal Nominal
h °C °C mm MPa MPa
1 23 23 0.60 0.40 0.25
24 23 23 0.60 1.50 1.50
480 (+ 96) 23 23 0.60 7.00 3.00
129
Table 5. Internal compressive strength of PVC-U / DIN EN ISO 9311-3.
Setting time Setting temperature Testing pressure / Gap Nominal

h °C temperature mm h
480 + 96 23 + 60 3.2 x PN / 20°C + 0.6 > 1,000
480 + 96 23 + 60 1.3 x PN / 40°C + 0.6 > 1,000 Cold water applications
480 + 96 23 + 60 3.2 x PN / 20°C + 0.6 > 1,000
480 + 96 23 + 60 1.0 x PN / 60°C + 0.6 > 1,000 Industrial applications
8.2 Hygienic evaluation parts tend to be more sensitive to impacts. Moreover, damage to
the pipe system cannot be excluded if solvent vapours take effect
8.2.1 Note for a long time.
The hygienic harmlessness is only tested if the piping to be adhe- Since adhesives of this type set physically, the strength build-up
sive-bonded comes into contact with drinking water. is delayed extremely in certain circumstances. Therefore, particular
laying techniques, e.g. tempering of the joining faces and of the
8.2.2 Requirement adhesive, are required at temperatures below + 5°C. Any present
Since it has not yet been possible to reach any agreement for a condensation water or ice must be removed, for example, using
uniform assessment system (UAS) at the European level, national hot air (pay attention to explosion protection). The necessary
regulations continue to be applicable. In Germany, that is the measures are included in the laying instructions from the manu-
"Plastics in drinking water" (KTW) guideline of the Federal Envi- facturers.
ronmental Office (UBA): "Guideline concerning the hygienic eval- Any surfaces discoloured by UV effects must be carefully rubbed
uation of organic materials in contact with drinking water". down with K80 – K120 emery cloth or non-woven plastic until the
original colour of the pipe material exists once again. Tolerances
8.2.3 Testing must be observed in this respect! General roughening of the joining
In compliance with EN 12873-2, pipes and double sleeves are faces is not recommended.
alternately adhesive-bonded with each other from PVC-U pipes
and double sleeves (d = 32 mm) using the adhesive system to be
tested and according to the adhesive bonding instructions from 10 Protective and safety measures
the adhesive manufacturers or suppliers. The specimen to be
tested should be approx. 100 cm long and should contain 20 ad- A safety data sheet according to (EC) no. 1907/2006 ISO 11014-1
hesive-bonded joints. must be available for every adhesive. The safety regulations and
The period between the adhesive bonding and the beginning of recommendations specified therein must be observed. Adhesives
the testing is max. 20 days. The transport/storage temperature and cleaning agents for adhesive-bonded PVC-U joints are a fire
until the testing should not exceed 23 ± 2°C. Before the testing, hazard. The solvent vapours are heavier than air and may form
the specimens must be stored in water at 80°C for 72 hours at explosive mixtures. Therefore, adequate ventilation must be ensured
the testing agency according to the KTW recommendations. In during the processing and the drying, even after the adhesive
this respect, they are emptied once a day for a short time in order bonding. Smoking is prohibited in the working room and in the
to replace the water in the pipe. Thereafter, the testing is per- adjoining rooms! It is imperative to avoid any welding, naked
formed at 20°C according to the KTW recommendations. light, fire, sparking or formation of explosive gas/air mixtures.
The established values are test values and are converted into Before the commissioning, the piping must be filled with water,
surface/volume values appropriate for practice. They must be below rinsed and/or blown through with air (oil-free). The pipes must be
the corresponding limiting values. kept open during the drying phase.
If the permissible OELs (occupational exposure limits) are exceeded
9 Additional indications over a lengthy period, this may be harmful to health. Any used
cleaning paper must be stored in closed vessels (e.g. a bucket
Before the commissioning, the pipe system must be thoroughly with a lid) in order keep the solvent vapour burdens on the pro-
rinsed with suitable media, e.g. water or air (oil-free), in order to cessors as small as possible. Likewise, the adhesive containers
remove any present solvent vapours from the pipe system. Sub- must be closed in the work breaks.
sequently, the pipe system is subjected to a pressure test. Details
It is recommended to use suitable protective gloves in order to
of this are included in the relevant application standards and regu-
avoid any skin contact with the adhesive or the cleaning agent.
lations, e.g. DVS 2210-1 technical code, Supplement 2. The clean-
Before beginning the work, rub a skin protection ointment into
ing agent and the adhesive exert an effect on polyvinyl chloride.
your hands.
Pipes and fittings must therefore be kept away from any spilled
cleaner or adhesive and from the paper used for the cleaning. After finishing the work, wash your hands well and rub skin care
Reliably close any cleaner or adhesive containers which are not cream into them.
being utilised in order to avoid any solvent losses or thickening.
Any adhesive skin must be removed before the adhesive is used In the event of any eye contact with adhesives or cleaning agents,
once again. Wipe off any thickened adhesive sticking to the your eyes must be rinsed thoroughly with water. Consult a doctor!
brush with dry paper and subsequently clean it with the cleaning Change any clothes soiled with adhesive.
agent recommended by the adhesive manufacturer. Any cleaned
Further indications are included in the accident prevention regu-
brushes must be touch-dry before they are reused (knock them
lations of the commercial employers' liability insurance associa-
out).
tions and in the safety data sheets from the adhesive and pipe
Utmost care is the prerequisite for adhesive bonding at lower system manufacturers. In cases of doubt, consult the manufac-
temperatures. At temperatures below + 5°C, pipes and piping turer.
130
11 Literature DVS 1904-1 Adhesive bonding of plastics in domestic

technical code plumbing; requirements on plants and per-
Set of rules sonnel
DIN EN ISO 1452 Plastic piping systems for the water supply DVS 2204-1 Adhesive bonding of thermoplastics
and for buried and non-buried pressurised technical code
drainage and waste water pipes – Unplas- DVS 2204-5 Adhesive bonding of pipes and fittings made
ticised polyvinyl chloride (PVC-U) technical code of thermoplastics – Chlorinated polyvinyl
DIN EN ISO 9311-1 Adhesives for thermoplastic piping sys- chloride (PVC-C)
tems – Part 1: Determination of the film DVS 2210-1 Industrial piping made of thermoplastics –
properties technical code, Planning and execution – Above-ground
DIN EN ISO 9311-2 Adhesives for thermoplastic piping sys- Supplement 2 pipe systems – Recommendations for in-
tems – Part 2: Determination of the shear ternal pressure and leak tests
strength DVS 2221 Qualification testing of plastics adhesive
DIN EN ISO 9311-3 Adhesives for thermoplastic piping sys- guideline bonders – Pipe joints between PVC-U,
tems – Part 3: Test procedures for the PVC-C and ABS with solvent adhesives
determination of the internal compressive DVS®-EWF 3305 Adhesive bonding practitioner
strength guideline
DIN EN ISO 15493 Plastic piping systems for industrial appli-
cations – Acrylonitrile butadiene styrene
(ABS), unplasticised polyvinyl chloride
(PVC-U) and chlorinated polyvinyl chloride
(PVC-C) – Requirements on piping parts
and the piping system
DIN EN 827 Adhesives – Determination of the solids
content by agreement and up to the con-
stant weight
DIN EN 1055 Plastic piping systems – Piping systems
made of thermoplastics for waste water
pipes inside buildings – Test procedures
for the temperature stressability
DIN EN 1329-1 Plastic piping systems for the discharge of
waste water (at low and high tempera-
tures) inside the building structure – Un-
plasticised polyvinyl chloride (PVC-U) –
Part 1: Requirements on pipes, fittings and
the piping system
DIN EN 10204 Metallic products – Types of test certifi-
cates
DIN EN 12092 Adhesives – Determination of the viscosity
DIN EN 12873-2 Influence of materials on drinking water –
Influence caused by migration – Part 2:
Test procedures for non-metallic and non-
cement-bonded materials applied in situ
DIN EN 14680 Adhesives for non-pressurised thermoplastic
piping systems – Stipulations
DIN EN 14814 Adhesives for pressurised piping systems
made of thermoplastics for fluids – Stipula-
tions
DIN 8061 Pipes made of unplasticised polyvinyl chlo-
ride (PVC-U) – General quality require-
ments and testing
DIN 8062 Pipes made of unplasticised polyvinyl chlo-
ride (PVC-U) – Dimensions
DIN 8063 ff. Pipe joints and piping parts for pressurised
piping made of unplasticised polyvinyl chlo-
ride (PVC-U)
131
March 2013
DVS – DEUTSCHER VERBAND Adhesive bonding of pipes and fittings

VERWANDTE VERFAHREN E.V. Chlorinated polyvinyl chloride (PVC-C) DVS 2204-5
Replaces November 2003 issue as well as

Supplement 1 and Supplement 2 from December 2003
Contents: cyclohexanone, methyl ethyl ketone and other strong solvents.

By selecting the appropriate solvents, optimal partial solution of
1 Scope the bonding surfaces, defined open time and a setting rate that is
2 Material suited to processing can be achieved. In order to obtain certain
3 Adhesives characteristics, additives such as stabilisers, thickening agents,
4 Requirements on adhesives agents to modify impact strength and coloured pigments are in-
5 Labelling of adhesive containers corporated. In the event of incorrect use of solvent adhesives, for
6 Shelf life of adhesives example application of too much adhesive, the structure of the
7 Bonding instructions plastics may suffer serious damage in certain cases. In particular,
8 Testing of adhesives significant changes to the strength properties can result in bonds
8.1 Test method to parts subject to high mechanical stresses, and stress cracks
8.2 Hygiene assessment may form. High residual stresses, for example those on injection-
9 Further information moulded or heat-moulded parts, promote these processes to a
10 Protective measures and safety precautions particularly great extent.
11 References
Particular attention should be paid to the fact that only adhesives
that the manufacturer intended for bonding pipes and fittings
made from chlorinated polyvinyl chloride and declared according-
1 Scope
ly may be used. Adhesives that are used in the field of PVC-C
pressurised pipes must comply with DIN EN 14814.
This guideline applies to the bonding of pipes and pipeline com-
ponents made from chlorinated polyvinyl chloride (PVC-C) in When using solvent adhesives, bonding must take place "wet-in-
accordance with the standards DIN 8079, DIN 8080, DIN 16832 wet", i.e. the joining parts must be joined immediately after apply-
et seq., DIN EN 1566-1, DIN EN ISO 15493 and DIN EN ISO ing the adhesive, during the open time (processing period).
15877.
Key features of these bonding systems: short waiting time, rapid
setting. The hardened adhesive-bonded joints (see manufacturer's
2 Material specifications) have similar mechanical and thermal stability, and
similar chemical resistance, to the materials themselves.
The material is chlorinated polyvinyl chloride (homopolymer) that When choosing the adhesive, the following points must be con-
is free from plasticisers and impact-resistant compounds. The sidered:
compounds are characterised by a high impact strength. The ma-
terial is used as a semi-finished product in the form of pipes, – Dimensions and tolerance
moulded parts, fittings, sheets and profile sections. PVC-C has a – Mechanical and thermal loads
heat resistance of 80°C in pressurised pipeline systems. The
adhesion properties can be checked by means of a visual inspec- – Impact of media
tion of the components' bonding surfaces in accordance with
Guideline DVS® 2221 (Section 4.3.3 et seq. – Visual inspection).
4 Requirements on adhesives
3 Adhesives The adhesives must make it possible to create connections of

PVC-C pipes and fittings in line with the requirements arising from
Due to the good solubility characteristics of the material, polyvinyl the intended use of the pipeline. These requirements include,
chloride is generally bonded using solvent adhesives. The solvents among others, usage duration, strength behaviour, temperature
diffuse into the joint surfaces, trigger molecular movements and, resistance, resistance to chemicals and the necessary hygiene
after their escape, result in solid and durable connections between characteristics for use in contact with foodstuffs/drinking water.
the joining parts. These requirements are defined in the various guidelines and
directives. Enquiries must be made to the adhesive manufacturer
Although it is possible to use other bonding systems, e.g. reactive and/or semi-finished product manufacturer to determine the
adhesives, this guideline concerns itself with the use of adhesives chemical resistance of adhesive-bonded joints, i.e. when using
containing solvents that are based on high performance solvents. concentrated inorganic acids. During processing, adhesives may
Adhesives containing solvents for the specified materials are not cause any damage to health, in compliance with the Occupa-
solutions of PVC-C in organic solvents based on tetrahydrofuran, tional Exposure Limit.
132
5 Labelling of adhesive containers – The pipe ends are chamfered on the outside using an angle of
approximately 15° (see Figure 1 and Table 1), and deburred on
In addition to the information required by law, the adhesive con- the inside.
tainers must be labelled with the following information as a mini-
mum:
– Name of the adhesive
– Name of the manufacturer or supplier
– Reference to the relevant adhesive standard
– Field of application
– List of standards applicable to thermoplastic pipeline systems
for which the adhesive is suitable
– CE label with information on the pressure class in line with the
standards, e.g. DIN EN 14814
Figure 1. PVC-C pipe-fitting measurement b.
– Instructions for usage and storage
– Safety precautions regarding use and storage Table 1. PVC-C pipe-fittings – Stipulations for measurement b.
– Batch number
Pipe outside diameter Approx. measurement for b
– Date of manufacture or expiry, stating the minimum shelf life of [mm] [mm]
at least 12 months.
up to 16 1 to 2
20 to 50 2 to 3
6 Shelf life of adhesives 63 to 225 3 to 6
The shelf life of an adhesive is understood as the time period dur-
The insertion depth of the sleeve is marked on the pipe end, so
ing which the adhesive, in as yet unopened containers, following
that the required application of adhesive and complete insertion
storage in line with the specified storage conditions (manufacturer's
of the pipe in the sleeve can be checked.
instructions), can be worked without problems.
The bonding surfaces on the pipe end and in the sleeve of the
The adhesives must have sufficient shelf life when stored normal-
fittings are cleaned thoroughly. For this, clean, unused, absorbent,
ly (at least 12 months). The shelf life is not only dependent on the
lint-free and non-staining paper is used, together with the clean-
composition of the adhesive, but also on the type of packaging
ing agent prescribed by the manufacturer of the adhesive or pipe
and other external influences, above all the storage temperature.
system. The paper must be replaced after each cleaning opera-
The adhesive manufacturer guarantees a minimum shelf life in its
tion.
technical documentation.
The cleaned bonding surfaces must be dried prior to the applica-
Irrespective of this, the person carrying out the processing must
tion of adhesive, and must not be touched again.
always check the workability of the adhesive.
Prior to use of the adhesive, it must be examined to ensure it is
workable. The adhesive is applied evenly over the whole surface
7 Bonding instructions in the joint area within the sleeve and on the pipe, using a suitably-
sized brush (see manufacturer's specifications and recommenda-
All adhesives and adhesive systems have specific working conditions).
tions. As a result, it is only possible to provide information that is Immediately after application of the adhesive, the pipe is inserted
generally applicable here. into the sleeve, without twisting or tilting, as far as the marking. It
The adhesives and corresponding cleaning agents are supplied is aligned if necessary and fixed in place there for a few seconds.
by the manufacturers or pipe system providers in ready-to-use An even excess of adhesive on the outside and a small complete
condition. Usage quantities can be found in the technical leaflets ring of adhesive within the pipe indicate that bonding has taken
or requested from the manufacturer. Thinning and other changes place over the whole surface.
are not permitted. This also applies to the cleaning agents. As a Excess adhesive is immediately removed with paper so that a
matter of principle, the bonding instructions supplied by the adhe- small fillet forms on the outside of the pipe.
sive or pipe system manufacturer must be observed. The pipes
and fittings must be dry, and free from grease and contamination. The bond location must not be mechanically loaded during the
The adhesive must be examined to ensure it is workable. After waiting time, up until further processing takes place. The duration
stirring, it must run off a bar held at an angle in an even manner, of the waiting time depends on the bonding system, the pipe
without any lumps. diameter and the working temperature. It must be taken from the
adhesive manufacturer's information. The same applies for the
Bonding should only take place at working temperatures between setting time leading up to the pressure test. During the drying
5°C and 40°C. In the event of deviations, these working tempera- phase, the lines must not be sealed. Accumulations of adhesive
tures must be created by additional suitable measures. At higher in the joint area are to be avoided.
temperatures and/or lower thicknesses of adhesive film, the open
time of the adhesives is reduced. The open time is the period With larger dimensions, from d200/d225 upwards, the special
between application of the adhesive and joining the parts. instructions of the adhesive and component suppliers must be
observed.
In general, the following procedure is used to attain the optimal
adhesive-bonded joint:
– The dimensional accuracy of pipes and fittings must be 8 Testing of adhesives
checked.
The following section provides an overview of the test procedures
– The pipes to be bonded are cut to the required length.
that exist for adhesives. The tests are carried out by the adhesive
– The pipes are cut at a right angle to the pipe axis. manufacturers.
133
8.1 Test method If the viscosity constitutes a contractual object of technical deliv-
ery conditions within the meaning of an inspection certificate pur-
Table 2. Overview of test procedures. suant to DIN EN 10204, the statement of viscosity shall be based
on a storage time of 20 ± 4 hours after manufacture, unless
Determination of conventional solids DIN EN 827 agreed otherwise. The target value must be observed to a toler-
content and constant mass solids ance of ± 20% percent by weight. As the viscosity of products
content containing solvents can change during their shelf life, it is prefer-
able to agree a viscosity range.
Adhesives – Determination of viscosity DIN EN 12092
Determination of film properties DIN EN ISO 9311-1 8.1.2.3 Testing
Determination of shear strength DIN EN ISO 9311-2 The test is carried out in accordance with DIN EN 12092, using a
Test method for the determination DIN EN ISO 9311-3 rotational viscometer specified by the adhesive manufacturer in
of resistance to internal pressure line with section 6.2 at 23 ± 2°C.
Thermal stability DIN EN ISO 15908 The selection of the measuring instruments, measuring bobs and
rotational speed must be adapted to the adhesive to be tested
and stated with the information regarding viscosity.
8.1.1 Determination of solids content
Depending on the spindle used, the viscosity of non-thixotropic
8.1.1.1 Preliminary remark adhesives is determined at a rotational speed of approx. 60 rpm,
and the viscosity of thixotropic adhesives at a rotational speed of
The solids content of the adhesive is determined by the content
approx. 30 rpm. The measurement is read off 20 ± 1 s after
of dissolved PVC-C and by the quantity of other solid compo-
switching on the viscometer.
nents in the adhesive.
The manufacturer is free to choose the rotational speed at which
8.1.1.2 Requirement to begin taking measurements. The measuring range selected
must be clear from the viscosity information.
The solids content is a product-specific property and is specified
by the manufacturer for each type of adhesive. It must be ob- Depending on the type of viscometer used, other rotational speeds
served to a tolerance of ± 1% percent by weight. may also be specified for the tests. These are to be set out in the
technical documents.
8.1.1.3 Testing
The solids content is determined in accordance with DIN EN 827 8.1.3 Determination of film properties
(Section 7.6.2 – Solids content up to constant mass). Other
methods are permitted if the manufacturer can provide evidence 8.1.3.1 Preliminary remark
of comparability and reproducibility. The adhesive to be tested is applied to a test plate using an appli-
If necessary for production reasons, the solids content may also cator (case knife) and the flow characteristics and evenness of
be determined by agreement (DIN EN 827, Section 7.6.1). the film are examined.
The test conditions for this are given in Table 3. 8.1.3.2 Requirement
Two individual determinations are carried out in each case. In the The flow value is a product-specific property and is specified by
test report, the adhesive manufacturer must state whether the the manufacturer. For thixotropic products, specified maximum
solids content has been determined in accordance with DIN EN values must not be exceeded. (e.g. 15 mm on PVC-C).
827 – Section 7.6.1 or Section 7.6.2.
8.1.3.3 Testing
8.1.2 Determination of viscosity
The test is carried out in accordance with DIN EN ISO 9311-1
8.1.2.1 Preliminary remark using a procedure specified by the adhesive manufacturer. Here
the adhesive is applied to a glass or PVC-C plate with a case knife
Viscosity, here dynamic viscosity, is a measure for the flowability of defined layer thickness and a speed of approximately 20 mm/s.
of adhesives. It is determined using a rotational viscometer and
given in mPas. The test report must contain information on the test procedure
used and on the plate material.
8.1.2.2 Requirement
8.1.4 Strength tests
The viscosity of an adhesive is product specific. It is dependent
on the storage time and storage temperature. During the mini- The strength requirements for thermoplastic pressurised and
mum shelf life period specified by the adhesive manufacturer with non-pressure piping systems are defined in DIN EN 14814 and
correct storage, it must lie within the tolerances set out in the DIN EN 14680 respectively. The relevant values for PVC-C can
technical leaflet. be found in Tables 4 and 5.
Table 3. Test conditions for determining the solids content of adhesives.
Test conditions
Type of adhesive Weighed sample Container diameter Temperature Time Heating cabinet
[g] [mm] [°C] [min.]
PVC-C adhesive 1 ± 0.1 60 ± 5 105 ± 1 120 ± 1 Circulating air
134
Table 4. Shear strength of PVC-C – DIN EN ISO 9311-2.
Pressurised pipe Pressureless

DIN EN 14814 DIN EN 14680
Setting time Setting temperature Test temperature Gap Target Target
[h] [°C] [°C] [mm] [MPa] [MPa]
1 23 23 0.6 0.4 0.25
24 23 23 0.6 1.5 1.50
480 (+ 96) 23 23 0.6 10.0 3.00
Table 5. Resistance to internal pressure for PVC-C pressurised pipe systems – DIN EN ISO 9311-3.
Setting time Setting temperature Test pressure Test temperature Gap Target
[h] [°C] [PN] [°C] [mm] [h]
480 + 96 23 + 80 0.5 x 80 + 0.6 > 1,000
8.2 Hygiene assessment manufacturer. The cleaned brush must be dry to the touch before
it is reused (shake out).
8.2.1 Note
Bonding at lower temperatures requires extreme care. At temper-
The hygienic safety is only tested if the pipelines to be bonded atures below + 5°C, the sensitiveness to impact of pipes and pipe
come into contact with drinking water. components tends to increase, and with the long-term influence
of solvent fumes, damage to the pipe system cannot be ruled out.
8.2.2 Requirement
As this type of adhesives set physically, the build-up of strength
As no agreement regarding a standardised evaluation system is significantly delayed under certain circumstances. At tempera-
(EAS) has yet been reached at a European level, national regula- tures below + 5°C, special installation techniques are necessary,
tions continue to apply. In Germany, the pertinent regulation is e.g. tempering of the joint surfaces and the adhesive. Any con-
the Guideline on Hygienic Assessment of Organic Materials in densation or ice present must be removed, for example using hot
Contact with Drinking Water (KTW) from the Federal Environment air (observe explosion protection requirements). The necessary
Agency (BDA). measures can be found in the manufacturer's installation instruc-
tions.
8.2.3 Testing
Surfaces discoloured due to the effect of UV light must be rubbed
In accordance with DIN EN 12873-2, PVC-C pipes and double down carefully with emery cloth K80 to K120 or synthetic fleece
sleeves with d = 32 mm are bonded together alternately, using until the original colour of the pipe material is restored. Toleranc-
the adhesive system to be tested and in line with the bonding es are to be observed here. General surface roughening of the
instructions provided by the adhesive manufacturer or supplier. joint surfaces is not recommended.
The specimen to be tested should be approximately 100 cm long
and contain 20 bonding points.
The period between bonding and the start of the test is a maximum 10 Protective measures and safety precautions
of 20 days. Prior to the test, the transport/storage temperature
should not exceed 23 ± 2°C. In line with the recommendations of A safety data sheet pursuant to (EC) No 1907/2006 ISO 11014
the Guideline on Hygienic Assessment of Organic Materials in must be present for each adhesive. The safety provisions and
Contact with Drinking Water, the specimens must be stored in recommendations specified therein must be observed. Adhesives
water at a temperature of 80°C on the premises of the examining and cleaning agents for PVC-C adhesive-bonded joints are
body for 72 hours prior to the test, during which time they must be inflammable. The solvent fumes are heavier than air and may form
briefly emptied once a day to replace the water in the pipe. Fol- explosive mixtures. When working and drying, and after bonding,
lowing this, the test is carried out in line with the recommendations it must therefore be ensured that there is sufficient ventilation.
of the Guideline on Hygienic Assessment of Organic Materials in Smoking is prohibited in the work room and in the adjacent
Contact with Drinking Water, at 20°C und 60°C. rooms. Welding, naked flames, fire, sparking and the formation of
explosive gas/air mixtures must be avoided until all circumstances.
The values determined are test values and are extrapolated to
practical surfaces/volume values. They must lie below the corre- Prior to commissioning, the pipelines should be filled with water,
sponding limit values. flushed and/or blown through with air (oil free). During the drying
phase, the lines must be kept open.
Exceeding the permitted workplace limit values for a longer period
9 Further information
of time may cause damage to health. Used cleaning paper must
be stored in sealed containers (e.g. bucket with lid) so that the
Prior to commissioning, the pipe system must be flushed thoroughly
exposure to solvent fumes is kept to a minimum for those carrying
with suitable media, e.g. water or air (oil free), so as to remove
out processing. Similarly, the adhesive containers must be
any solvent fumes present from the pipe system. After this, the
sealed during work breaks.
pipe system is submitted to a pressure test. Details on this can
be found in the pertinent usage standards and regulations, e.g. The use of suitable protective gloves is recommended, so as to
Guideline DVS 2210-1 Supplement 2. Cleaning agents and ad- avoid the adhesive or the cleaning agent making contact with the
hesives affect polyvinyl chloride. Pipes and fittings should there- skin. Before starting work, you should rub a protective barrier
fore be kept away from any spilt cleaning agent or adhesive, or cream into your hands.
the paper used for cleaning. Cleaning agents and adhesive con-
After finishing work, wash your hands thoroughly and rub in skin
tainers that are not in use must be well sealed, so as to avoid
cream.
leakage of solvent and thickening. Before the adhesive is used
again, an adhesive skin must be removed. Wipe off any thick- In the event that adhesives or cleaning agents come into contact
ened adhesive that is stuck to the brush with dry paper and then with the eyes, flush out the eye thoroughly with water. Seek medical
clean using the cleaning agent recommended by the adhesive attention. Change clothing that is contaminated with adhesive.
135
Further information can be found in the accident prevention regu- DIN EN 10204 Metallic products – Types of test certificates
lations of the commercial employer's liability insurance associa- DIN EN 12092 Adhesives – Determination of viscosity
tions and the safety data sheets of the adhesive and pipe system
manufacturers. In case of doubt, contact the manufacturer. DIN EN 12873-2 Influence of materials on water intended for
human consumption – Influence due to mig-
ration – Part 2: Test method for non-metallic
11 References and non-cementitious site-applied materials
DIN EN 14680 Adhesives for non-pressure thermoplastic
Regulations piping systems – Specifications
DIN EN ISO Adhesives for thermoplastic piping systems – DIN EN 14814 Adhesives for thermoplastic piping systems
9311-1 Part 1: Determination of film properties for fluids under pressure – Specifications
DIN EN ISO Adhesives for thermoplastic piping systems – DIN 8079 Chlorinated polyvinyl chloride (PVC-C) pipes
9311-2 Part 2: Determination of shear strength – Dimensions
DIN EN ISO Adhesives for thermoplastic piping systems – DIN 8080 Chlorinated polyvinyl chloride (PVC-C) pipes
9311-3 Part 3: Test method for the determination of – General quality requirements, testing
resistance to internal pressure DIN 16832 Pipe joints and components of chlorinated
ISO 11014 Safety data sheet for chemical products – et seq. poly(vinyl chloride) (PVC-C) for pipes under
Content and order of sections pressure
DIN EN ISO Plastics piping systems for industrial applica- Guideline Adhesive bonding of plastics in domestic ins-
15493 tions – Acrylonitrile-butadiene-styrene (ABS), DVS 1904-1 tallation; Requirements on plants and person-
unplasticized poly(vinyl chloride) (PVC-U) nel
and chlorinated poly(vinyl chloride) (PVC-C) Guideline Adhesive bonding of thermoplastic materials
– Specifications for components and the sys- DVS 2204-1
tem – Metric series Guideline Adhesive bonding of pipes and piping parts
DIN EN ISO Plastics piping systems for hot and cold DVS 2204-4 made of thermoplastics – Polyvinyl chloride
15877 water installations – Chlorinated poly(vinyl (PVC-U)
chloride) (PVC-C) Guideline Industrial pipelines made from thermoplastics
DIN EN ISO Adhesives for thermoplastic piping systems – DVS 2210-1 – Design and execution – Above-ground pipe
15908 Test method for the determination of thermal Beiblatt 2 systems – Recommendations for the internal
stability of adhesive pressure and leak tests
DIN EN 827 Adhesives – Determination of conventional Guideline Qualification testing of plastics adhesive bon-
solids content and constant mass solids con- DVS® 2221 ders – Pipe joints between PVC-U, PVC-C
tent and ABS with solvent-based adhesives
DIN EN 1055 Plastics piping systems – Thermoplastics Guideline Bonding practitioners
piping systems for soil and waste discharge DVS®-EWF 3305
inside buildings – Test method for resistance
to elevated temperature cycling
DIN EN 1566-1 Plastics piping systems for soil and waste di-
scharge (low and high temperature) within
the building structure – Chlorinated poly(vinyl
chloride) (PVC-C) – Part 1: Specifications for
pipes, fittings and the system
136
January 2015
DVS – DEUTSCHER VERBAND Calculation of tanks and apparatus made

FÜR SCHWEISSEN UND of thermoplastics - Characteristic values Technical code
DVS 2205-1
Replaces September 2013 issue
Contents: Provided the component is used as intended, the partial safety

factors guarantee a sufficiently low probability of component
1 Scope failure at all times during the basic operating/service life.
2 Safety concept
2.1 Partial safety concept In addition to deviations from the anticipated forces (loads) and
2.2 Global safety concept resistances (load-bearing capacities), the partial safety factors
also cover any simplifications made when developing a
3 Strength values
calculable model.
3.1 General
3.2 Creep rupture strength The following applies:
3.2.1 Calculation based on the creep rupture strength
3.2.2 Creep curves S
3.2.3 Intermittent load ------d- ≤ 1 (1)

Rd
3.2.4 Alternating load
3.3 Isochronous stress-strain diagrams where Sd Rated value of the load (e.g. stress from load)
3.4 Young's modulus (creep modulus)
3.4.1 Calculation based on the creep modulus Rd Rated value of the load (e.g. permissible stress)
4 Reduction factors
4.1 Reduction factor (toughness factor) A1 The rated value of the existing load K dexist is calculated from the
4.2 Reduction factor A2, also known as A2B (reciprocal characteristic value of the existing load K exist
k in the component.
resistance factor fCRσ)
vorh vorh
4.3 Reduction factor A2I =
S d K=
d γF ⋅ K k (2)
5 Weld strength reduction factor
6 Explanations Here, the characteristic forces and/or loads are multiplied by the
7 References partial safety factors γF as per Table 1.
Table 1. Partial safety factors for forces.

1 Scope
Force Partial safety factor
This guideline provides processors of semi-finished products
made of thermoplastic materials with instructions on how to Intrinsic weight, filling, assembly γF1 = 1.35
determine characteristic values as the basis for the calculations
involved in designing tanks, apparatus, ventilation and industrial Pressures, wind, snow γF2 = 1.50
pipelines. It is essential that the regulations described in Section Load-reducing intrinsic weight γF3 = 0.90
7 are taken into account when selecting and processing the
materials to be used. The information applies to predominantly Extraordinary load combination γF4 = 1.00
static loads. The respective DVS guidelines and -leaflets as well
as the relevant DIN, EN and ISO standards apply to the Imposed load γF5 = 1.00
calculation, dimensions, design and testing of the various
constructions. Responsibilities with regard to specific fields of law The characteristic resistances and load-bearing capacities are
(for example building law, water law, trade law, etc.) must be divided by partial safety factor γM ≥ 1.31) and reduction factors A1
taken into account. and A2 (Section 4) and multiplied by joint factor f (Section 5) in
the case of analyses in the weld seam.
2 Safety concept The rated strength value K d* is calculated from the characteristic
strength K k* .
2.1 Partial safety concept
K k* ⋅ f
The following stability analyses are always performed in =
R =
K * ---------------------------- (3)
accordance with the partial safety factor concept described d d γM ⋅ A1 ⋅ A2
below:
– Strength analyses, 1) The following applies to DIBt-approved materials in Germany: γM = 1.3.
– Stability analyses
Orders to: DVS Media GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49 (0) 211/1591- 0, Telefax: + 49 (0) 211/1591- 150
137
The following applies: The creep curves are based on the following relationship:
K k* Characteristic strength value (reading value in the creeprupture B C
strength diagram for the calculation temperature and the Igt = A + ---- ⋅ lgσ + ---- + D ⋅ lgσ (4a)
T T
exposure duration of the load)
The following applies:
f Joint factor (if joint connections are to be included) (f = fs in the
case of loads > 1 hour, otherwise f = fz) A, B, C, D Coefficients, shown in the creep diagrams
γM Partial safety factor on the resistance side for the material. T Temperature in Kelvin
The reduction factors are material-dependent and specifically t Service life in hours
include:
The characteristic creep values of the semi-finished products
A1 The influence of toughness used must correspond to the above basic values as a minimum.
A2 The influence of the ambient medium (reciprocal resistance
factor) 3.2.3 Intermittent load
The same partial safety factors apply to stability analyses.
In the case of applications in which alternating (intermittent) loads
The influence of medium is taken into account on the resistance
regularly occur, the theory of linear accumulation of damage
side with reduction factor A2I (Section 4). A greater buckling
(Miner's rule) can be used as the basis for determining
tendency should be accounted for under long-term forces [15].
approximate operating times [1]. Here, the expected service life
(tM) is determined by adding together the damage rates for the
2.2 Global safety concept intermittent operating conditions. Since the permissible service
In order to compare the results with previous calculations, the life of components made of polyolefins is not only dependent on
overall safety factor γg (previously S) is required. This is mechanical load but also on heat aging, the influence of aging
calculated from the product of the two partial safety factors. (tA) must be determined by means of a second calculation.
γ g = γ F2 ⋅ γ M (4) The creep curves (Supplements 1 to 4) and the heat aging limits
of the materials in question (Supplement 1, Section 5 and
Supplement 2, Section 5) are used as the basis for the
3 Strength values calculations. Miner's rule cannot be applied to stability
calculations. The permissible operating time tX is calculated by
3.1 General comparing the calculated service lives tM and tA.
Component calculations are generally made on the basis of long- According to this rule the following applies to the mechanical
term values. Depending on the type of load, the three failure load:
criteria must always be taken into account:
n ai ⋅ tM
1. Strength
2. Deformation (e.g. deflection)  ----------------
100 ⋅ t i
- = 1 (5)
i=1
3. Stability (e.g. buckling and kinking)
1. The calculation can be made with reference to the creep For two loads the following therefore applies:
rupture strength. In most cases multi-axial stress conditions can
a1 ⋅ tM a2 ⋅ tM
be expected. Here, the greatest stresses occurring in the main ---------------------
- + ---------------------
-= 1 (6)
stress directions should be compared with the permissible creep 100 ⋅ t M1 100 ⋅ t M2
rupture strength.
or
The rated values are derived from the material characteristics
based on reduction factors (Section 4), the weld strength 100 ⋅ t M1 ⋅ t M2
reduction factor (Section 5) and safety factors (Section 2). t M = ------------------------------------------- (7)
a 1 ⋅ t M2 + a 2 ⋅ t M1
2. and 3. The determining characteristic value here is the creep
modulus. It can be taken from the creep modulus diagrams as a And in turn the following applies to the influence of aging:
function of time, temperature and tension.
n ai ⋅ tA
 ----------------
The rated values are derived from the material characteristics
- = 1 (8)
based on reduction factors (Section 4) and safety factors 100 ⋅ t i
(Section 2). i=1
The following applies:

3.2 Creep rupture strength
i Number of partial loads
3.2.1 Calculation based on the creep rupture strength
a1, a2 ... an Proportion of partial load times that make up the
The rated strength value1) is calculated from the creep rupture total load time in %
strength, the reduction factors, the weld strength reduction factor
tM1, tM2 ... tMn Service life under the individual operating
and the safety factor. Formula (3) applies.
conditions (constant pressure and temperature)
The strength value K k* to be used as the basis for the calculation
should be taken from the diagrams in Supplements 1 to 4 for a tA1, tA2... tAn Aging times at the relevant temperatures
specific operating time and temperature. tM Calculated service life under mechanical load
3.2.2 Creep curves tA Calculated service life under the influence of aging
The creep curves indicate the strength according to time and tX Permissible operating time, min (tM, tA)
temperature. They have been determined on the basis of years of See also the examples in Supplement 7.
internal pressure tests on pipe specimens filled with water and
should be considered as minimum values (see Supplements 1 to 4).
3.2.4 Alternating load
This topic is beyond the remit of this guideline. Please see the
1) Formerly permissible stress following references [2...4].
138
3.3 Isochronous stress-strain diagrams 3.4.1 Calculation based on the creep modulus
The isochronous stress-strain diagrams show the relationship In the case of stability calculations, the rated value is calculated from
between stress and strain throughout the load time. Sections 1.2, the creep modulus, the reduction factor and the partial safety factor.
2.2 and 3.2 in Supplement 1 show, for example, the isochrones
for 20°C for PE 63, PE 80 and PE 100. For other temperatures E KT°C
E d = ------------------- (11)
the isochrones can be derived from the temperature-based creep A 2I ⋅ γ M
modulus curves based on the following relationship:
In the case of deformations under nominal load, γM is not taken
σ = ε ⋅ EC (9) into account.
ET°C
E d = --------
K (12)
3.4 Young's modulus (creep modulus)
A 2I
Instead of the Young's modulus used in design theory, a creep
modulus (EC) is used for thermoplastics with the exception of a few The following applies:
special cases. This deals with the quotient of stress and total Ed Rated value of the creep modulus in N/mm2
elongation. The creep modulus is dependent on time, stress and T°C
EK Characteristic value of the short-term Young's modulus as
temperature. It may also depend on the medium (particularly in the
per Table 2
case of welling substances; characteristic values for this yet to be
determined). The creep modulus for the materials used can be A2I Reduction factor
taken from the creep modulus curves (Sections 3.3.1 to 3.3.3 in γM Partial safety factor
Supplement 1 for e.g. PE 100) based on the specified parameters or
calculated as a secant modulus from the "Isochronous stress-strain
diagrams" (see Supplement 1, Section 3.2 for e.g. PE 100). 4 Reduction factors
K k* The reduction factors described below apply to stress-based

E cd = ----------------- (10)
( ϑ,σ,t ) ε ( ϑ,σ,t ) calculations as per Section 3.2.1.
The creep modulus is used: 4.1 Reduction factor (toughness factor) A1

– To determine deformations This factor takes into account the toughness of the materials
according to the temperature and is therefore derived from
– For stability calculations, whereby a special safety factor
impact strength values. The known A1 values are listed in the
should be used (see Section 3.4.1)
supplements for PE (Supplement 1, Section 4), for PP
For loads lasting up to 0.1 hours the short-term Young's modulus (Supplement 2, Section 4), for PVC-NI and PVC-RI (Supplement
is used; the temperature-dependent moduli for the primary 3, Section 3), for PVC-C (Supplement 3, Section 4.3) and for
thermoplastics are shown in Table 3. PVDF (Supplement 4, Section 7).
ToC
Table 2. Temperature-dependent short-term Young's moduli E K in N/mm2.
Material ≤ 10°C 20°C 30°C 40°C 50°C 60°C 70°C 80°C 90°C 100°C
PE1) 1,100 800 550 390 270 190 – – – –
PP-H 1,400 1,200 960 770 620 500 400 320 – –
PP-B 1,200 1,000 790 630 500 400 320 250 – –
PP-R 1,000 800 620 490 380 300 230 180 – –
PVC-NI 3,200 3,000 2,710 2,450 2,210 2,000 – – – –
PVDF 1,900 1,700 1,513 1,340 1,188 1,050 926 820 727 650
20 oC
Table 3. Time-dependent long-term Young's moduli E L in N/mm2.
Material 1 year 5 years 10 years 15 years 20 years 25 years
PE1) 308 269 254 245 239 235
PP-H 464 393 365 350 340 330
PP-B 405 334 307 293 283 275
PP-R 322 298 288 283 279 276
PVC-NI 1,800 1,695 1,652 1,627 1,609 1,600
PVDF 810 763 744 733 725 720
1) The Young's moduli for PE can be used for PE 80, PE 100 and PE 100-RC.
139
4.2 Reduction factor A2, also known as A2B (reciprocal During the revision process, aspects of general technical rules
resistance factor fCRσ) defined by other bodies were also taken into account. The
requirement specified in the "Bau- und Prüfgrundsätzen für
Reduction factor A2 quantifies the influence of the operating oberirdische Behälter und Behälterteile aus Thermoplasten"
medium on the creep rupture strength of thermoplastic materials. ["Construction and inspection principles for above-ground tanks
In order to determine reduction factor A2 for PE and PP, internal and tank parts made from thermoplastics"] published by the
pressure creep tests were performed on pipe specimens filled Institut für Bautechnik [German Construction Institute] in Berlin
with medium (pipes used for these A2 factors: 32 × 3 mm, that the product of the safety factor plus the reduction factors for
90 × 8.2 mm, 140 × 12.8 mm). By comparing the resulting creep time, temperature and medium must be at least 4 is satisfied
curves (medium curves) with the creep curve for water, it is within the scope of dimensioning based on the creep curves
possible to determine time- and stress-based reduction factors described in this guideline. An operating temperature of 30°C is
[10; 11]. Supplement 5, Section 1 contains only the decisive used as the basis for this.
stress-based reduction factors (A2σ) for the strength calculation. If
the medium curve runs parallel to the water curve, the A2 factor is The overall safety factor S, which was used throughout the April
the same for all applicable stresses (see Supplement 5, Section 2002 issue, has been replaced by partial safety factors, whereby
1.1). In the case of media curves that are flatter or steeper than S= γ= g γ F2 ⋅ γ M . Reduction factors have been specified in order
the water curve, the stress-dependent A2 factors are applicable to take account of material-specific properties.
to two or more stresses (see Supplement 5, Section 1.2).
Since most components are subjected to multi-axial loads, the
The A2 factor can be found in the tables in Supplement 5, creep diagrams for pipes should be used as the basis for
Sections 1.1 and 1.2 based on strength value K. Linear determining the strength values (see Supplements 1 to 4). These
interpolation may be necessary. Generally speaking, reduction are based on the results of several years of measurements and
factor A2 is virtually the same across various temperatures. For experience [13]. For the above reasons, it is not practical to use
PE, on the other hand, measurements with some media resulted the creep curves of tensile members.
in higher A2 factors (increased attenuation) at decreasing test
temperatures. The most significant change to reduction factors Numerous reduction factors (A2) were considered when
A2 for PE-HD between 80 and 20°C was identified in the determining the influence of the medium while taking into account
presence of 20% chromic acid and 98% acetic acid. Here, the A2 material, stress and temperature.
factors for 20°C were around three times those for 80°C. In order
to define compulsory details for the A2 factor at the respective Reduction factor A2, applicable to the influence of the medium,
operating temperature, tests must be performed at two or more and the weld strength reduction factors fs were determined
different temperatures. independently of one another. The validity of the multiplicative
linking of weld strength reduction factor fs and reduction factor A2
For several media, the reduction factor can only currently be
(reciprocal value of the chemical resistance factor fCRσ) was
specified at an increased test temperature. If the measurement
demonstrated during the course of examinations [14; 15].
values for oxidising media have only been defined for a higher
temperature (e.g. 80°C), the measured A2 factor should be
increased for a lower temperature - in the worst case by up to
three times the 80°C value. For all other media, temperature- 7 References
constant reduction factors A2 can be expected, as there has been
no known damage to date that could be attributed to the use of Regulations
reduction factors measured at higher temperatures.
The most recent issue of the standards and guidelines listed
The media marked 5) in Supplement 5, Section 1 have been
below applies in all cases.
taken from Supplements 1 for DIN 8061, DIN 8075 and
DIN 8078. It can be assumed on the basis of immersion tests and DIN EN 14610 Welding and allied processes – Definitions of
several years of practical experience that these media do not metal welding processes
have a more adverse effect on the creep rupture strength of the DIN 1910-3 Welding; Welding of plastics, Processes
listed materials than water. This means that reduction factor DIN 1910-100 Welding and allied processes – Definitions –
A2 = 1 can be applied. Part 100: Metal welding processes with
additions to DIN EN 14610:2005
When using media for which reduction factors A2 have yet to be
defined, it is advisable to refer to the information provided by the DIN 8061 Unplasticized polyvinyl chloride pipes;
manufacturer of the semi-finished product or raw material. General quality requirements, testing
DIN 8062 Unplasticized polyvinyl chloride (PVC-U) pipes
4.3 Reduction factor A2I – Dimensions
Reduction factor A2I quantifies the influence of the operating DIN 8074 Polyethylene (PE) pipes– PE 63, PE 80, PE
medium on the Young's modulus (creep modulus) of 100, PE-HD – Dimensions
thermoplastic materials (see Supplement 5, Section 2). For all DIN 8075 Polyethylene (PE) pipes – PE 63, PE 80, PE
media with a weaker welling effect than water the value for 100, PE-HD – General quality requirements,
A2I = 1. For welling media the value for A2I can be determined testing
from the mass increase [18]. DIN 8077 Polypropylene (PP) pipes – PP-H, PP-B, PP-
R, PP-RCT – Dimensions
5 Weld strength reduction factor DIN 8078 Polypropylene (PP) pipes – PP-H, PP-B, PP-
R, PP-RCT – General quality requirements,
The weld strength reduction factors (fs and fz) for some materials testing
and welding processes can be found in Supplement 6. These DIN 8079 Chlorinated polyvinyl chloride (PVC-C) pipes –
values have been taken from Guideline DVS 2203-1. Dimensions
DIN 8080 Chlorinated polyvinyl chloride (PVC-C) pipes –
6 Explanations General quality requirements, testing
DIN 16960-1 Welding of thermoplastic materials; Principles
This guideline has been revised by DVS-AG W4.3b (structural
DIN 16961-1 Thermoplastic pipes and fittings with profiled
design/apparatus construction). Although the original guideline
wall and smooth pipe inside – Part 1:
(March 1974 issue) was used widely, advances in knowledge,
Dimensions
experience and material properties called for its revision.
140
DIN 16961-2 Thermoplastic pipes and fittings with profiled [5] Menges G., and R. Taprogge: Denken in Verformungen
wall and smooth pipe inside – Part 2: erleichtert das Dimensionieren von Kunststoffteilen. [Thinking in
Technical delivery specifications terms of deformations simplifies the dimensioning of plastic
DIN EN 12666-1 Plastic piping systems for non-pressure parts] VDI-Z. 112 (1970), E. 6, P. 341/46, and VDI-Z. 112
underground drainage and sewerage – (1970), E. 10, P. 627/29.
Polyethylene (PE) – Part 1: Specifications for
pipes, fittings and the system [6] Menges, G.: Das Verhalten von Kunststoffen unter
Dehnung. {The behaviour of plastics when subjected to
DIN EN ISO Extruded sheets of polyethylene (PE-HD) – strain] Kunststoffe 63 (1973), E. 2, P. 95/100 and
14632 Requirements and test methods Kunststoffe 63 (1973), E. 3, P. 173/77.
DIN EN ISO Plastics – Extruded sheets of polypropylene
15013 (PP) – Requirements and test methods [7] Taprogge, R.: Konstruieren mit Kunststoffen. {Designing
using plastics] VDI-Verlag, Düsseldorf 1971.
DASt guideline Buckling analyses for shells
013
[8] Hessel, J.: Langzeitprüfung von Schweißverbindungen aus
VDI 2003 Machining of plastics Polyethylen bei komplexer Beanspruchung. [Long-term
Guideline DVS Testing of semi-finished products made of testing of polyethylene welded joints in complex stress
2201-2 thermoplastics, weldability; Test methods – situations] Materialwissenschaft und Werkstofftechnik 15
Requirements (1984), P. 153/57.
Guideline DVS Testing of welded joints of thermoplastic [9] Barth. E., and R. Schommer: Messungen der
2203-1 sheets and pipes; Test methods – Langzeitfestigkeit von Schweißverbindungen aus Hart-PVC.
Requirements [Measurements of the long-term strength of welded joints of
Guideline DVS Testing of welded joints of thermoplastic hard PVC] Kunststoffe 74 (1984), E. 9.
2203-2 sheets and pipes; Test methods – Tensile test
Guideline DVS Testing of welded joints made of thermoplastic [10] Diedrich G., B. Kempe and K. Graf: Zeitstandfestigkeit von
2203-3 materials; Tensile impact test Rohren aus Polyethylen hart (HDPE) und Polypropylen (PP)
unter Chemikalieneinwirkung. [Creep rupture strength of
Guideline DVS Testing of welded joints of thermoplastic pipes made of hard polyethylene (HDPE) and polypropylene
2203-4 sheets and pipes; Creep rupture tensile test (PP) under the effects of chemicals] Kunststoffe 69 (1979),
Guideline DVS Testing of welded joints of thermoplastic E. 8, P. 470/76.
2203-5 sheets and pipes; Technological bend test
Guideline DVS Calculation of tanks and apparatus made of [11] Kempe, B.: Prüfmethoden zur Ermittlung des Verhaltens von
2205-2 thermoplastics – Vertical round, non- Polyolefinen bei der Einwirkung von Chemikalien. {Testing
pressurised tanks methods to determine the behaviour of polyolefins under the
effects of chemicals] Materialwissenschaft und
Guideline DVS Calculation of thermoplastic tanks and Werkstofftechnik 15 (1984), P. 157/72.
2205-3 apparatus – Welded joints
Guideline DVS Calculation of thermoplastic tanks and [12] Menges, G., and E. Gaube: Knicken und Beulen von
2205-4 apparatus – Flange connections thermoplastischen Kunststoffen am Beispiel des Hart-
Polyethylens. [Buckling and kinking of thermoplastics
Guideline DVS Calculation of thermoplastic tanks and
exemplified by hard polyethylene] Kunststoffe 58 (1968), E.
2205-5 apparatus – Rectangular tanks
9, P. 642/48.
Guideline DVS Calculation of tanks and apparatus made of
2205-5 thermoplastics – Rectangular tanks; [13] Gaube E., G. Diedrich and W. Müller: Rohre aus
Supplement Rectangular tanks; Structural details thermoplastischen Kunststoffen – Erfahrungen aus 20
Guideline DVS Non-destructive testing of tanks, apparatus Jahren Zeitstandprüfung. [Thermoplastic piping -
2206-1 and piping made of thermoplastics – experiences gained from 20 years of creep testing]
Dimensional checking and visual inspection Kunststoffe 66 (1976), E. 1, P. 2/8.
Guideline DVS Non-destructive testing of tanks, apparatus [14] Kempe, B., and J. Hessel: Zeitstandverhalten von
2206-4 and piping made of thermoplastics – Testing Schweißverbindungen aus HDPE bei der Einwirkung von
with electrical high voltage Chemikalien. [Creep behaviour of HDPE welded joints
Guideline DVS Welding of thermoplastics – Welding fillers – under the effects of chemicals] Materialwissenschaft und
2211 Marking, requirements and tests Werkstofftechnik 14 (1983), P. 37/41.
Guideline DVS Qualification testing of plastics welders;
2212-1 Qualification test groups I and II [15] Hessel J., D. Hausdörfer and B. Kempe: The influence of
oxidizing, surface active and swelling fluids on welded PE-
HD joints. IIW Doc. XVI-453-84.
Bibliography
[16] Tuercke, H.: Zur Stabilität von Behältern aus
[1] Miner, M. A.: Design journal. Dec. 1945, P. 111.
Thermoplasten. [On the stability of thermoplastic tanks]
[2] Alf, E.: Untersuchung zum Verhalten ausgewählter DIBt-Mitteilungen, Heft 5/1995.
Kunststoffe unter schwingender Beanspruchung
[Investigation into the response of selected plastics under [17] Barth, E.: Das Verhalten von PVC hart gegenüber
dynamic loading]. Diss. TH Aachen 1972. Chemikalieneinwirkung, [The behaviour of hard PVC when
exposed to chemicals] Materialwissenschaft und
[3] Menges, G., N. Brand, B. Kleinemeier and G. Wienand: Werkstofftechnik 17 (1986), P. 74-76 and 98-108
Anleitung zur Berücksichtigung der Eigenerwärmung
dynamisch belasteter Kunststoffbauteile. [Guide concerning [18] Barth, E., J. Hessel, and B. Kempe: Die Bestimmung der
the intrinsic warming of dynamically loaded plastic chemischen Widerstandsfähigkeit von Rohren aus
components] Materialprüfung 18 (1976), E. 1, P. 14/19. thermoplastischen Kunststoffen. [Determining the chemical
resistance of thermoplastic pipes] Materials and Corrosion
[4] Brand, N.: Dimensionierungshilfe für dynamisch beanspruchte 48, 1997, P. 1/16
Kunststoffbauteile. [Dimensioning aids for dynamically loaded
plastic components] Diss. TH Aachen 1977.
141
November 2011

Calculation of tanks and apparatus
FÜR SCHWEISSEN UND
made of thermoplastics – Technical Code
Characteristic values DVS 2205-1
of the polyethylene material group Supplement 1
Replaces Supplement 6 (July 1997), Supplement 7 (July 1997), Supplement 8 (July 1997),
Draft Supplement 19 (January 2008), Supplement 23 (August 2007) and Supplement 24 (August 2007).
This supplement includes characteristic values for the PE 63, PE 80 and PE 100 materials.
Contents:
1 PE 63
1.1 Creep curves for pipes
1.2 Isochronous stress/strain diagram for 23°C
1.3 Creep modulus curves
1.3.1 Creep modulus of PE 63 for one year
1.3.2 Creep modulus of PE 63 for ten years
1.3.3 Creep modulus of PE 63 for 25 years
2 PE 80
3 PE 100
4 Reduction coefficients (toughness coefficients) A1 for
moulding materials made of PE
5 Heat ageing limit in the case of PE
6 Coefficients for 2NCT/FNCT for PE
142
1 PE 63
25
20
Creep curves nach
Zeitstandkurven according
DIN 8075to DIN 8075
durch
CreepISO TR 9080
curve part(Juli 1992) abgesicherter
validated Teil der(July
by ISO TR 9080 Zeitstandkurven
1992)
15
10 10°C
9
[N/mm²]
20°C
8
Equivalent stress [N/mm²]
30°C
7
40°C
Vergleichsspannung
6
50°C
5
60°C
70°C
4
80°C
2,5
1,5
1 10 25 50 100
Jahre
Years
1
1 10 100 1000 10000 100000 1000000
Service life[h]
Standzeit [h]
Service life [h]

Straight line equation: log(t) = A + C/T + D  log()
Coefficients of the minimum curves:
Flat branches Steep branches
A1 = – 41.4173 A2 = –19.8823
C1 = 22,008.572 C2 = 8,619.357
D1 = –35.0987 D2 = –3.039
143
1.2 Isochronous stress/strain diagram of PE 63 for 23°C
5
s
e
hrrs ahre
Jeaa yJea
har
0y 225
5
yJae
1
10
1
stress [N/mm²]
4
Zugspannung
3
Tensile
0
0 1 2 3 4 5 6
Elongation [%]
Dehnung [%]
350
* N /m m ²
K = 0 ,5
300 K
250
2
[N/mm²]
modulus[N/mm²]
3
200
4
Kriechmodul
5
150
Creep
100
50
Pay attention
B e g in nende W toäbeginning
rm e a lte ru nheat
g b eageing
i K o n tain
kt the
m i tevent
of
s acontact with
u e rs to ffg e s äoxygen-saturated
ttig te m W a s s e r b ewater
a c h te n
0
20 40 60 80
Temperature
Te m p e ra tu r [°C]
[° C ]
144
300
K K* = 0 ,5 N /m m ²
250
1
[N/mm²]
200
2
modulus[N/mm²]
3
Kriechmodul
150
4
5
Creep
100
50
Pay attention
B e g in n e n d e Wtoä rm
beginning heat
e a lte ru n g b e i ageing
K o n ta ktinmthe
i t event
of
s a contact
ue rs to ffgwith oxygen-saturated
e s ä ttig te m W a s s e r be awater
c h te n
0
20 40 60 80
Temperature [°C]]
Te m p e ra tu r [°C
30 0
25 0
*
KK = 0 ,5 N /m m ²
1
20 0
[N/mm²]
modulus[N/mm²]
2
Kriechmodul
15 0 3
4
Creep
5
10 0
50
Pay
B attentionWtoärm
eginnende beginning
ealterungheat
bei ageing
K ontaktinmthe
i t event
of contact with oxygen-saturated
sauerstoffgesättigtem water
W ass er beac hten
0
20 40 60 80
Tem p e ratu r [°C
Temperature [°C]]
145
2 PE 80
25
20
Zeitstandkurven
Creep curves nach DIN 8075
according to DIN 8075
durch
CreepISO TR 9080
curve part(Juli 1992) abgesicherter
validated by ISO TR Teil der(July
9080 Zeitstandkurven
1992)
15
10°C
20°C
10
9 30°C
[N/mm²]
8
40°C
7
50°C
Vergleichsspannung
6 60°C
70°C
5
80°C
2,5
1,5
1 10 25 50 100
Years
Jahre
1
1 10 100 1000 10000 100000 1000000
Standzeit
Service life[h]
[h]
Service life [h]

A1 = – 40.9578 A2 = –19.9417
C1 = 23,596.350 C2 = 8,804.433
D1 = –37.5758 D2 = –3.3219
146
es
hrar
5
Jaye
2525
se
ahrr
Jea
0y
110
4
[N/mm²]
stress [N/mm²]
eaahr
r
11 yJ
Zugspannung
3
Tensile
0
0 1 2 3 4 5 6
Elongation [%]
Dehnung [%]
350
K K* = 0 ,5 N /m m ²
300
2
250
[N/mm²]
[N/mm²]
5
200
modulus
Kriechmodul
150
Creep
100
50
Pay attention
B e g in n e n d e Wto beginning
ä rm e a lte ru n g heat
b e i K ageing
o n ta kt min
i tthe event
of
s a contact
u e rs to ffgwith oxygen-saturated
e s ä ttig te m W a s s e r b e a cwater
h te n
0
20 40 60 80
Temperature [°C]]
A n mRemark:
e rku n g : DThe
e r N proof
a c h w ewas
is w uprovided
rd e m it H owith
s ta leHostalen
n G M 5 0 1GM
0 T 35010
g e fü hT3
rt
147
350
300
K *K = 0 ,5 N /m m ²
250
[N/mm²]
modulus[N/mm²]
2
200
Kriechmodul
5
150
Creep
100
50
Pay
B e gattention
in n e n d e W toäbeginning heat
rm e a lte ru n g b e i ageing
K o n ta ktin
m the
i t event
ofs acontact with
ttig te m W a s s e r b e awater
c h te n
0
20 40 60 80
Temperature [°C]]
A n mRemark:
e rku n g : DThe
e r N proof
a c h w ewas
is w uprovided
rd e m it Hwith Hostalen
o s ta le n G M 5 0 GM
1 0 T5010
3 g e füT3
h rt
350
300
250
K * = 0 ,5 N /m m ²
[N/mm²]
K
[N/mm²]
200
2
modulus
Kriechmodul
5
150
Creep
100
50
Pay attention
B e g in n e n d e Wto beginning
ä rm e a lte ru n gheat
b e i Kageing
o n ta kt in
m ithe
t event
of
s a contact
u e rs to ffgwith oxygen-saturated
e s ä ttig te m W a s s e r b e awater
c h te n
0
20 40 60 80
Temperature [°C]]
A n mRemark:
e rku n g : DThe
e r Nproof was
achw e is wprovided
u rd e m it Hwith
o s taHostalen
le n G M 5 0GM
1 0 T5010 T3
3 g e fü h rt
148
3 PE 100
25
20
10°C
15
20°C
30°C
10
40°C
9
50°C
8
stress [N/mm²]
[N/mm²]
60°C
7
70°C
6
Vergleichsspannung
80°C
5
Equivalent
2,5
2
Zeitstandkurven
Creep nach DIN 8075
curves according to DIN 8075
Creep curve
durch ISO part (Juli
TR 9080 validated by ISO TR 9080
1992) abgesicherter Teil der(July 1992)
Zeitstandkurven
1,5
1 10 25 50 100
Years
Jahre
1
1 10 100 1000 10000 100000 1000000
Service life
Standzeit [h] [h]
Service life [h]

A1 = –38.9375 A2 = –20.3159
C1 = 24,482.467 C2 = 9,342.693
D1 = –38.9789 D2 = – 4.5076
149
e
5
hsr
Jaar
25ye
es
harr
25
Jyae
1100
4
Tensile stress [N/mm²]
hr r
Jeaa
11y
Zugspannung
0
0 1 2 3 4 5 6
Dehnung [%]
Elongation [%]
350
K * = 0 ,5 N /m m ²
K
300
2
250
[N/mm²]
[N/mm²]
5
200
modulus
Kriechmodul
150
Creep
100
50
Pay
B e gattention
in n e n d e Wtoä rmbeginning
e a lte ru n gheat
b e i Kageing
o n ta kt min
i t the event
ofs contact
a u e rs to ffg e s ä ttig
with te m W a s s e r b e a cwater
oxygen-saturated h te n
0
20 40 60 80
Te m p e ra tu r[°C]
Temperature [° C ]
Remark:
Anm e rk u n g : DThe
e r N proof
a c h w ewas
is w uprovided
rd e m it H owith Hostalen
s ta le n C R P 1 0 0CRP
g e fü h100
rt
150
350
300
K *K = 0 ,5 N /m m ²
250
[N/mm²]
2
[N/mm²]
200
modulus
Kriechmodul
150
Creep
100
50
Pay attentionWtoärm
B eginnende beginning
ea lterungheat
bei Kageing
ontakt in
m ithe
t event
of contact
s aue with ttigtem
rs toffgesä oxygen-saturated
W a ss er beacwater
hten
0
20 40 60 80
Te m p e ra tu [°C]
Temperature r [°C ]
Remark:
A nm erkun g: D er The proof
N ac hw eis was provided
w urde with Hostalen
m it H ostalen C R P 100CRP 100
g eführt
350
300
250
K K* = 0 ,5
[N/mm²]
N /m m ²
modulus[N/mm²]
200 2
Kriechmodul
5
150
Creep
100
50
Pay
B e gattention
in n e n d e W toäbeginning
rm e a lte ru n heat
g b e i ageing
K o n ta ktinmthe
i t event
ofs acontact with
ttig te m W a s s e r b e awater
c h te n
0
20 40 60 80
Temperature
Te m p e ra tu r[°C]
[°C ]
A n m e rkuRemark: The
ng: Der N a c hproof
w e is wwas
u rd eprovided with
m it H o s ta Hostalen
le n C R P 1 0 0 gCRP
e fü h rt100
151
4 Reduction coefficients (toughness coefficients) A1 for moulding materials made of PE
Material description:
Moulding material PE 63 PE 80 PE 100

Notched impact strength [kJ/m²] at 23°C  12  13  13
Modulus in tension [N/mm²] at 23°C –  800  800  1,000
according to prEN ISO 15013
Requirement on the creep strength DVS 2205-1, Supplement 1, DVS 2205-1, Supplement 1, DVS 2205-1, Supplement 1,
according to Section 1.1 Section 2.1 Section 3.1
Testing standards:
Modulus in tension: ISO 527-2
Notched impact strength: DIN EN ISO 179-1/1eA (Charpy) Test specimens: DIN EN ISO 1873-2
Creep strength: ISO 1167
Reduction coefficients:
Moulding material Temperature [°C]

-10 0 0 201) 30 40 50 60 80
PE 63 1.2 1.1 1 1 1 1 1 1 1
PE 80 1.1 1 1 1 1 1 1 1 1
PE 100 1.1 1 1 1 1 1 1 1 1
1)This value also applies to the normal temperature of 23°C.
Explanation: The notched impact strength was established by means of tests on both injected and pressed test specimens.
The stipulation of the reduction coefficient A1 is based on the lowest value of the notched impact strength.
5 Heat ageing limit in the case of PE
3,6
10
3,5
20
3,4
(y)
1/T*1,000 (y)
temperature 1/T*1000
3,3 30
°C
Temperaturein[°C]
3,2 40
abs. Temperatur
Temperatur
3,1 50
rez. abs.
3 60
Rec.
70
2,9
80
2,8
95 Function
2,7 of the straight lines:
0,2 1 10 100 1000 y = a + b *(Inx)
0,5 5 50 500 5000 a = 2.83835
Ageing time in
Alterungszeit inJahren
years (x)
(x) b = 0.08939
152
6 Coefficients for 2NCT/FNCT for PE
Minimum requirements for the resistance to slow crack growth1)

in the case of PE
Material PE 63 PE 80 PE 100 PE 100-RC*)

Requirement2) 30 100 300 8,760
(hours)
*) "RC": Resistant to Cracking
Remarks 1:
All the above characteristic values apply to PE 100.
The reduction factors for media influence A2B can be lowered for
media which induce stress cracking.
Remarks 2:
Test specimens: Pressed panels or extruded panels (testing
transverse to the extrusion direction).
Remarks 3:
If any deviating testing conditions are applied, the following require-
ments are set:
A correlation must be proven between the testing conditions
"80°C; 2 % Arkopal N-100; 4 N/mm²" and the deviating testing
conditions.
The correlation must be validated over min. 60 testing series in
three decades. The target variable (e.g. 8,760 hours) must be in-
cluded in this respect. The correlation coefficient must be > 0.9.
The minimum requirement must be proven with a "lower confi-
dence limit" of 2.5 %. The correlation must be accredited according
to EN ISO/IEC 17025.
The fracture faces of the tested specimens (2NCT or FNCT)
must exhibit a brittle fracture (see also ISO 16770).
1) Testing according to DIN EN 12814-3

2) Testing conditions: 80°C; 2 % Arkopal N-100; 4 N/mm²
153
September 2013
DVS – DEUTSCHER VERBAND Calculation of tanks and apparatus

VERWANDTE VERFAHREN E.V. values of the polypropylene material group DVS 2205-1
Supplement 2
Replaces DVS 2205-1, Supplement 1 (August 1996),

Supplement 2 (August 1996), Supplement 3 (August 1996) and Supplement 10 (July 2005).
This supplement includes characteristic values for the PP-H, PP-B and PP-R materials.
Contents:
1 PP-H, polypropylene homopolymer

1.3 Creep modulus
1.3.1 Creep modulus curves for one year
1.3.2 Creep modulus curves for ten years
1.3.3 Creep modulus curves for 25 years

2 PP-B, polypropylene block copolymer
2.3 Creep modulus
3 PP-R, polypropylene random copolymer
3.3 Creep modulus
4 Reduction coefficients A1 for moulding materials made of PP
5 Heat ageing limit in the case of PP
6 Coefficients for 2NCT/FNCT in the case of PP
7 Literature
154
1 PP-H, polypropylene homopolymer
30
25
20
15
10°C
20°C
10
9 30°C
[N/mm²]
8
40°C
7
50°C
Vergleichsspannung
5 60°C
70°C
3
2,5 80°C
2
90°C
110°C 95°C
1,5
120°C
E = 140 N/mm²
C
bei 120° C,1
at 120°C, N/mm² und
1 N/mm² and 1000
1,000hh
1 2 5 10 20 50
1 Jahre
Years
0,8
1 10 100 1.000
1,000 10.000
10,000 100.000
100,000 1.000.000
1,000,000
Standzeit
Service life[h]
[h]
Straight line equations:

log(t) = A + B/T log() + C/T + D  log() log(t) = a + b  log()
Coefficients of the straight lines at 10 - 95°C Coefficients of the straight lines:
Flat branches Steep branches Flat branches Steep branches
A1 = -46.3645 A2 = -18.387 110°C
B1 = -9,601.1 B2 = 0 a1 = 8.06631 a2 = 5.15457
C1 = 20,381.55 C2 = 8,918.5 b1 = -10.8149 b2 = -4.13903
D1 = 15.24 D2 = -4.1 120°C
a1 = 7.4989 a2 = 4.6841
b1 = -10.7284 b2 = -4.0779
155

6
hre
0eaJras
10 1Y
5
ahre
s
hYrear
25eJar
25 Y
4
1 J1a
[N/mm]²
stress [N/mm²]
Zugspannung
3
Tensile
0
0 1 2 3 4
D e hn un g [%]
Dehnung
Elongation [%
[%]]
1.3 Creep modulus

500
K K* [N /m m ²]
0,5
1
450
2
3
4
400
5
[N/mm²]
350
modulus
Kriechmodul [N/mm²]
300
Creep
250
200
150
100
20 40 60 80 100
Tem peratur[°C]
Temperature
Temperatur [°C ]
[°C]
156
400
K K* [N /m m ²]
0,5
1
350
2
3
4
300 5
[N/mm²]
modulus[N/mm²]
250
Kriechmodul
200
Creep
150
100
Beginnende
Beginnende
Pay attention W beginning
to ärmealterung
Wärmealterung bei
heat bei K ontakt
Kontakt
ageingmit mitevent
in the
ofsauerstoffgesättigtem
sauerstoffgesättigtem W asser
Wasser beachten
beachten
contact with oxygen-saturated water
50
20 40 60 80 100
Temperature
Tem peratur[°C]
[°C ]

400
K K* [N/mm²]
350
0,5
1
2
300 3
4
5
modulus [N/mm²]
250
Kriechmodul
200
Creep
150
100
Beginnende Wärmealterung
Pay attention
Beginnende to beginningbei
Wärmealterung Kontakt
heat
bei mi
mittin the event
ageing
Kontakt
sauerstoffgesättigtem
sauerstoffgesättigtem Wasser
Wasser beachtenwater
beachten
50
20 40 60 80 100
Temperature
Temperatur [°C]
[°C]
157
2 PP-B, polypropylene block copolymer

30
25
20
15
10°C
10
20°C
9
[N/mm²]
8
30°C
7
40°C
Vergleichsspannung
50°C
4
3
60°C
2,5
2 70°C
80°C
1,5
EE = =140140 2
CC N/mm N/mm² 90°C
atbei
120°C, 111N/mm² 2 und1,000
bei 120°C,
120° C, N/mm²and
N/mm 1000hhh
und 1000
95°C
120°C 110°C 100°C
1
1 2 5 10 20 50
Years
Jahre
0,8
1 10 100 1,000
1.000 10,000
10.000 100,000
100.000 1,000,000
1.000.000
Standzeit
Service life[h][h]
Coefficients of the straight lines at 10 - 95°C: Coefficients of the straight lines:
A1 = -56.0862 A2 = -13.699 100°C
B1 = -10,157.8 B2 = 0 a1 = 8.45725 a2 = 4.88603
C1 = 23,971.71 C2 = 6,970.3 b1 = -14.0472 b2 = -3.794
D1 = 13.32 D2 = -3.82 110°C
a1 = 7.98862 a2 = 4.51668
b1 = -14.0595 b2 = -3.61563
120°C
a1 = 7.18348 a2 = 4.06677
b1 = -13.64801 b2 = -3.71798
158

6
res
5
aha
es
YJ e
har
JYae
2255
r
110
ahr
1 Je
1Y
[N/mm²]
4
stress [N/mm²]
Zugspannung
3
Tensile
0
0 1 2 3 4
Elongation
Dehnung [%][%]
Dehnung
2.3 Creep modulus

500
K K* [N /m m ²]
450
1
400
[N/mm²]
350
3
[N/mm²]
300
modulus
5
Kriechmodul
250
Creep
200
150
100
50
0
20 40 60 80 100
Temperature
Temperatur
Tem [°C]
peratur [°C]
[°C ]
159

400
K * [N /m m ²]
K
350
1
[N/mm²] 300
3
modulus[N/mm²]
250
5
Kriechmodul
200
Creep
150
100
50
B eginnende
Pay Wto
attention
Beginnende ärmealterung bei Kontakt
beginning heat
Wärmealterung bei Kontaktin
ageing mi t event
the
mit
sauerstoffgesättigtem W asser beachten
beachten
sauerstoffgesättigtem Wasser water
0
20 40 60 80 100
Temperature
peratur [°C]
Temperatur
Tem [°C ]

400
350
K * [N /m m ²]
K
300 1
[N/mm²]
modulus[N/mm²]
250
3
Kriechmodul
200
5
Creep
150
100
50
Beginnende
B eginnende
Pay Wärmealterung
Wto
attention ärm bei
beiKontakt
ealterungheat
beginning mit
K ontaktin
ageing mi
thet event
sauerstoffgesättigtem W asserbeachten
sauerstoffgesättigtem Wasser beachten
water
0
20 40 60 80 100
Temperature
Temperatur
Tem [°C]]
peratur [°C]
[°C
160
3 PP-R, polypropylene random copolymer
25
20
15
10°C
20°C
10
9 30°C
8
[N/mm²]
40°C
7
6 50°C
Vergleichsspannung
5 60°C
4
70°C
3
80°C
2,5
2
90°C
95°C
1,5 110°C 100°C

ECC==70
E 70N/mm
N/mm² 2
at 120°
bei120°C,
120°C, N/mm2and
C,11N/mm²
N/mm² und 1000
1000hhh
und1,000
120°C
1
1 2 5 10 20 50
Years
Jahre
0,8
1 10 100 1.000
1,000 10.000
10,000 100.000
100,000 1.000.000
1,000,000
Service life
Standzeit [h][h]
Coefficients of the straight lines at 10 bis 100°C: Coefficients of the straight lines:
A1 = -55.7247 A2 = -19.98 110°C
B1 = -9,484.1 B2 = 0 a1 = 10.0045 a2 = 4.9264
C1 = 25,502.18 C2 = 9,507.0 b1 = -17.6073 b2 = -3.6416
D1 = 6.39 D2 = -4.11 120°C
a1 = 8.40722 a2 = 3.8390
b1 = -18.8014 b2 = -1.3955
161

6
arre
s
Ye h
0 Ja
110
5
hrsre
JYaea
Ye h r
ar
1 a
2255
1J
[N/mm²]
2]
stress[N/mm²] 4
Zugspannung
Zugspannung [N/mm
3
Tensile
0
0 1 2 3 4
Elongation
DDehnung [%]
[%]
e hnung [% ]
3.3 Creep modulus

400
350 K K* [N/mm²]
2
300
[N/mm²]
3
250
modulus[N/mm²]
5
Kriechmodul
200
Creep
150
100
50
0
20 40 60 80 100
Temperature [°C]
Temperatur [°C]
162

400
350
K K* [N/mm²]
300
2
[N/mm²]
250 3
[N/mm²]
modulus
5
Kriechmodul
200
Creep
150
100
50
Pay attention bei Kontakt
to beginning heat ageing inmit
the event
of contact with oxygen-saturated water
0
20 40 60 80 100
Temperature
Temperatur [°C]
[°C]

400
350
K K* [N/mm²]
300
2
[N/mm²]
250
[N/mm²]
3
modulus
Kriechmodul
200
5
Creep
150
100
50
Pay attention bei Kontakt
to beginning heat ageing mit
in the event
of contact with oxygen-saturated water
0
20 40 60 80 100
Temperature
Temperatur [°C]
[°C]
163
4 Reduction coefficients A1 for moulding materials made of PP
1. Material description
Moulding material PP-H PP-B PP-R

Notched impact strength [kJ/m²] at 23°C 6  30  20
Modulus in tension [N/mm²] at 23°C,
 1,200  1,000  700
according to prEN ISO 15013
Requirement on the creep strength according to Section 1.1 Section 2.1 Section 3.1
Testing standards:
Notched impact strength: DIN EN ISO 179-1/1eA (Charpy)
Test specimens: DIN EN ISO 1873-2
Creep strength: ISO 1167
2. Reduction coefficients A1
Temperature [°C]
Moulding material
-10 0 10 201) 30 40 50 60 80
PP-H 1.8 1.7 1.5 1.3 1.1 1.0 1.0 1.0 1.0
PP-B 1.6 1.5 1.0 1.0 1.0 1.0 1.0 1.0 1.0
PP-R 1.8 1.6 1.3 1.0 1.0 1.0 1.0 1.0 1.0
1) This value also applies to the normal temperature of 23°C.
Explanation:
The notched impact strength was established by means of tests
on both injected and pressed test specimens. The stipulation of
the reduction coefficient A1 is based on the lowest value of the
notched impact strength.
164
5 Heat ageing limit in the case of PP
3,6
10
3,5
Für
For Temperaturen
temperatures > 95°C,
95° C siehe Informationen
see
in DVSinformation in DVS 5
2201-1 Beiblatt 2201-1 Supplement 5
20
3,4
(y)
1/T*1,000 (y)
3,3 30
temperature1/T*1000
°C
in °C
Temperatur in
3,2 40
abs.Temperatur
Temperature
3,1 50
Rec.abs.
3 60
rez.
70
2,9
80
2,8
90
95
2,7
0,2 1 10 100 1000
1,000
0,5 5 50 500 5,000
5000
Alterungszeit
Ageing time ininyears
Jahren
(x)(x)
Function of the straight lines:
y = a + b  (Inx)
a = 2.39171
b = 0.15604
165
6 Coefficients for 2NCT/FNCT1) in the case of PP 7 Literature
Minimum requirements for the resistance to slow crack growth in Set of rules
the case of PP DIN EN 179-1 Plasti.cs – Determination of the Charpy im-
pact properties – Part 1: Non-instrumented
Material PP-H2) PP-B3) PP-R2) impact strength test
Requirement ISO 527-2 Plastics; determination of the properties from
 250  250  500
(hours) the tensile test; Part 2: Testing conditions for
injection and extrusion moulding materials
Test specimens: ISO 1167-1 Pipes- fittings and component combinations of
Pressed panels or extruded semi-finished products (testing trans- thermoplastics for the transport of liquids –
verse to the extrusion direction). Determination of the resistance to internal
If any deviating testing conditions are applied, the following re- overpressure – Part 1: General test procedure
quirements are set: Validation over min. 60 testing series in three DIN EN ISO Plastics – Extruded panels made of polypro-
decades. The target variable (e.g. 500 hours) must be included in 15013 pylene (PP) – Requirements and testing
this respect. The correlation coefficient must be > 0.9. The mini- DIN EN ISO Plastics – Polypropylene (PP) moulding mate-
mum requirement must be proven with a "lower confidence limit" 1873-2 rials – Part 2: Manufacture of test specimens
of 2.5 %. The correlation must be accredited according to and determination of properties
EN ISO/IEC 17025.
DIN ISO/IEC General requirements on the competence of
17025 testing and calibration laboratories
1) DIN EN 12814-3 Testing of welded joints between thermoplas-
DIN EN 12814-3
tics – Part 3: Tensile creep test
166
September 2013

FÜR SCHWEISSEN UND
Characteristic values of the DVS 2205-1
polyvinyl chloride material group Supplement 3
Replaces DVS 2205-1, Supplement 9 (September 2005),

Supplement 11 (March 2002), Supplement 12 (March 2002) and Supplement 14 (September 2005).
This supplement includes characteristic values for the PVC-NI, PVC-RI and PVC-C materials.
Contents:
1 PVC-NI, polyvinyl chloride, normal impact strength

1.3 Creep modulus curves for one, ten and 25 years for the
stress range from 2.5 N/mm² to 10 N/mm²
2 PVC-RI, polyvinyl chloride, increased impact strength

3 Reduction coefficients A1 for moulding materials made of
PVC
4 PVC-C, polyvinyl chloride, chlorinated
4.1 PVC-C for pipes
4.1.1 Creep curves
4.2 PVC-C for fittings
4.2.1 Creep curves
4.3 Reduction coefficients A1 for moulding materials made of
PVC-C
5 Literature
167
1 PVC-NI, polyvinyl chloride, normal impact strength
60
50
40
30
20°C
25
30°C
20
[N/mm²]
40°C
15
Vergleichspannung
50°C
10
9
8
7
60°C
6
3
1 10 25 50 100
Jahre
Years
2
1 10 100 1,000
1.000 10.000 100,000
10,000 100.000 1,000,000
1.000.000
Standzeit
Service life[h][h]
Straight line equation:
log(t) = A + B/T log() + C/T + D  log()
A = -164,647
B = -29,378.37
C = 60,161.4
D = 75,2053
168

12
11
rs re
Jeaa h
10
Y
1100
9
arse
JYaeh
8
255
rr
stress [N/mm²]
Jeaah
[N/mm²]
11Y
Zugspannung
6
Tensile
0
0 0,2 0,4 0,6 0,8 1
Elongation
Dehnung [% [%]
]
1.3 Creep modulus curves for one, ten and 25 years for the stress range from 2.5 N/mm² to 10 N/mm²
,
2.000
11Year
Jahr
,
1.500
[N/mm²]
modulus [N/mm²]
10
10 Jahre
Years
Years
25 Jahre
Kriechmodul
,
1.000
Creep
500
20 40 60 80
Temperature
Temperatur[°C]
[°C]
169
2 PVC-RI, polyvinyl chloride, increased impact strength
60
50
40
30
25
20
[N/mm²]
15 20°C
Vergleichsspannung
30°C
40°C
10
9 50°C
8
60°C
7
6
3
1 10 25 50 100
Years
Jahre
2
1 10 100 1,000
1000 10,000
10000 100000 1,000,000
100,000 1000000
Service life[h][h]
Standzeit
log(t) = A + B/T log() + C/T + D log()
A = -20.726
B = -720.5232
C = 13,573.95
D = -14.8729
170
3 Reduction coefficients A1 for moulding materials made of PVC
The four groups correspond to the information in ISO 11833-1.
PVC-NI PVC-RI
Moulding material or
Plates Pipes Plates Pipes
semi-finished product
Extruded Pressed Extruded Pressed
Notched impact strength [kJ/m²] at 23°C >2 >3 >5 > 10
Vicat softening temperature [°C]  75  78  72  75
Modulus in tension [N/mm²] at 23°C  3,000  3,000  2,500  2,500
Creep strength, according to ISO 11833-11) ISO 11833-11) Section 1.1 ISO 11833-11) ISO 11833-11) Section 1.1
1) Creep curves are not available. Therefore, ISO 11833-1 is used.
Testing standards:
Notched impact strength: ISO 179-1/1eA (Charpy)
Vicat softening temperature: DIN EN ISO 306, procedure. B 50
Creep strength: ISO 1167-1
Semi-finished Notched impact strength Temperature [°C]

Material designation
product kJ/m² -10 0 10 202) 40 50 60
Plates, extruded <2 1.8 1.8 1.8 1.8 1.6 1.6 1.5
Plates, pressed PVC-NI <3 1.7 1.7 1.7 1.6 1.4 1.3 1.2
Pipes
Plates, extruded <5 1.7 1.6 1.5 1.4 1.2 1.0 1.0
Plates, pressed PVC-RI < 10 1.5 1.3 1.1 1.0 1.0 1.0 1.0
Pipes
171
4 PVC-C, polyvinyl chloride, chlorinated
4.1 PVC-C for pipes
4.1.1 Creep curves

60
50
40
10°C
30
20°C
25
30°C
20 40°C
[N/mm²]
50°C
Equivalent stress [N(mm²]
15
60°C
Vergleichsspannung
10
9 70°C
8
7 80°C
4
95°C
1 5 10 25 50 100
Jahre
Years
1,5
1 10 100 1.000
, 10.000
, 100.000
, 1.000.000
, ,
Service life [h]
Standzeit [h]
A = -109.95
B = -21,897.4
C = 43,702.87
D = 50.742
172
4.2 PVC-C for fittings
4.2.1 Creep curves
60
50
40
30
25 10°C
20°C
20
30°C
40°C
[N/mm²]
15
50°C
Vergleichsspannung
10 60°C
9
8
70°C
7
6
80°C
5
4
90°C
2 1 5 10 25 50 100
Jahre
Years
1,5
1 10 100 1.000
, 10.000
, 100.000
, 1.000.000
, ,
Standzeit
Service life[h]
[h]
A = -121.699
B = -25,985
C = 47,143.18
D = 63.0351
173
4.3 Reduction coefficients A1 for moulding materials made of PVC-C

Semi-finished product Plates Pipes Fittings and mountings

Notched impact strength [kJ/m²] at 23°C 2 >3 >3 >5
Vicat softening temperature [°C]  105  103  110  103
Modulus in tension [N/mm²] at 23°C  3,200  2,500  2,750  2,500
Creep strength, according to Section 2.1 Section 2.1 Section 1.1 Section 2.1
Testing standards:
Notched impact strength: ISO 179-1/1eA (Charpy)
Vicat softening temperature: DIN EN ISO 306, procedure: B 50
Creep strength: ISO 1167-1
2. Reduction factors A1
Manufacturing process / Notched impact strength Temperature [°C]

Semi-finished product
modification kJ/m² -10 0 10 201) 40 50 60 80
Film-pressed, without any
Plates 2 1.9 1.9 1.9 1.8 1.7 1.7 1.6 1.5
impact strength modification
Film-pressed or extruded,
Plates with impact strength  32) 1.8 1.7 1.7 1.6 1.3 1.0 1.0 1.0
modification
Extruded, with impact
Pipes 3 1.8 1.7 1.7 1.6 1.3 1.0 1.0 1.0
strength modification
Injected, with impact
Fittings and mountings 5 1.7 1.6 1.5 1.3 1.1 1.0 1.0 1.0
strength modification
1)
This value also applies to the normal temperature of 23°C.
2)
The A1 values may only be used if the other characteristic values (e.g. elastic modulus, creep modulus, creep strength and welding factor) are also
available by the time that the white paper is published.
5 Literature
Set of rules
DIN EN ISO 306 Plastics – Thermoplastics – Determination of
the Vicat softening temperature (VST)
DIN EN 179-1 Plastics – Determination of the Charpy impact
properties – Part 1: Non-instrumented impact
strength test
ISO 527-2 Plastics; determination of the properties from
the tensile test; Part 2: Testing conditions for
injection and extrusion moulding materials
ISO 1167-1 Pipes, fittings and component combinations of
thermoplastics for the transport of liquids –
Determination of the resistance to internal
overpressure – Part 1: General test procedure
ISO 11833-1 Plastics – Unplasticised polyvinyl chloride
panels – Types, dimensions and properties –
Part 1: Panels with a thickness of min. 1 mm
174
September 2013

FÜR SCHWEISSEN UND
Characteristic values of the fluoropolymer DVS 2205-1
material group Supplement 4
Replaces DVS 2205-1, Supplement 4 (August 1996), Supplement 15 (September 2005),

Supplement 18 (February 2006), Supplement 20 (August 2007), Supplement 21 (January 2008) and Supplement 25 (August 2007).
This supplement includes characteristic values for the PVDF, PVDF(-C), E-CTFE and PTFE materials.
Contents:
1 PVDF (polyvinylidene fluoride homopolymer, PVDF)

1.1 Creep curves of PVDF for pipes
1.2 Isochronous stress/strain diagram of PVDF for 20°C
1.3 Creep modulus curves of PVDF for one, ten and 25 years for the stress range from 2 N/mm² to 5 N/mm²
2 PVDF (polyvinylidene fluoride copolymer, PVDF-C, Type 1 and Type 2)
2.1 Creep curves of PVDF-C, Type 2 for pipes
2.2 Isochronous stress/strain diagram of PVDF-C, Type 1 for 20°C
2.3 Creep modulus curves of PVDF-C, Type 1 for one year for the stress range from 1 N/mm² to 8 N/mm²
2.4 Creep modulus curves of PVDF-C, Type 1 for ten years for the stress range from 1 N/mm² to 8 N/mm²
2.5 Creep modulus curves of PVDF-C, Type 1 for 25 years for the stress range from 1 N/mm² to 8 N/mm²
3 Coefficients for 2NCT/FNCT in the case of PVDF
4 PVDF / E-CTFE media list
5 E-CTFE (ethylene chlorotrifluoroethylene)
5.2 Isochronous stress/strain diagram of E-CTFE for 20°C
5.3 Creep modulus curves of E-CTFE for one year
5.4 Creep modulus curves of E-CTFE for one year; range from 50°C to 120°C
5.5 Creep modulus curves of E-CTFE for ten years
5.6 Creep modulus curves of E-CTFE for ten years; range from 50°C to 120°C
5.7 Creep modulus curves of E-CTFE for 25 years
5.8 Creep modulus of E-CTFE for 25 years; range from 50°C to 120°C
6 PTFE (polytetrafluoroethylene)
7 Reduction coefficients A1 for moulding materials made of fluoropolymers
8 Literature
175
1 PVDF (polyvinylidene fluoride homopolymer, PVDF)
1.1 Creep curves of PVDF for pipes
40
35
30 20°C
25 30°C
40°C
20 50°C
60°C
70°C
15
80°C
[N/mm²]
Equivalent stres [N/mm²]
10
9 90°C
Vergleichsspannung
8
95°C
7
100°C
6
5
4,5 110°C
4
3,5 120°C
3 130°C
2,5
140°C
1,5
1 10 25 50
Years
Jahre
1
1 10 100 1.000
1,000
, 10.000
10,000 100,000
100.000 1,000,000
1.000.00
Service life[h]
Standzeit [h]
Straight line equation::
lg(t) = A + B/T lg() + C/T + D  lg()
Flat part Steep part
A1 = –165.4959 A2 = –23.19426
B1 = –36,518.671 B2 = –1,611.687
C1 = 78,465.650 C2 = 12,100.011
D1 = 57-04670 D2 = –0.40473
176
1.2 Isochronous stress/strain diagram of PVDF for 20°C
se
5
ahrr
YJea
100
hraers
4
[N/mm²]
JaYe
stress [N/mm²]
rr
aeha
2525
11JY
Zugspannung
3
Tensile
0
0 0,2 0,4 0,6 0,8 1
Dehnung [%]
Elongation [%]
1.3 Creep modulus curves of PVDF for one, ten and 25 years for the stress range from 2 N/mm² to 5 N/mm²
1.000
800
1 JY
[N/mm²]
modulus[N/mm²]
aeha
rr
600
Kriechmodul
1100
25 JYaeh
25Ja arres
Yher
aers
400
Creep
200
0
20 40 60 80 100 120
Temperature [°C]
Temperatur [°C]
177
2 PVDF (polyvinylidene fluoride copolymer, PVDF-C, Type 1 and Type 2)
2.1 Creep curves of PVDF-C, Type 2 for pipes
40
30
20
15 20°C
[N/mm²]
10 40°C
9
8
Vergleichsspannung
7 60°C
6
80°C
5
95°C
Remark:
Anmerkung: Der Nachweis wurde mit Rohren aus
The proo was Kynar
provided withgeführt.
2800 pipes made of Kynar 2800.
Prüfanforderung:
Testing requirement:80°C
80°C// 66 N/mm² 200 hh
N/mm² / 200 1 5 10 25 50
JahreYears
1
1 10 100 1.000
, 10.000
, ,
100.000 , ,
1.000.000
Service life[h]
Standzeit [h]
lg(t) = A + B/T lg() + C/T + D  lg()
A = –39.318107
B = 3,301.80773
C = 24,874.3781
D = –46.436897
Creep curves are currently being prepared for PVDF-C, Type 1. Until these curves are published, reference can be made to the curve
of PVDF-C, Type 2 for the calculation of components made of PVDF-C, Type 1.
178
2.2 Isochronous stress/strain diagram of PVDF-C, Type 1 for 20°C
10
20 °C
harr
res e
harrs
Jae
har
11 Y
JYae JYae
10 2255
8
[N/mm²]
stress [N/mm²]
6
Zugspannung
Tensile
0
0 1 2 3 4 5
Elongation [%]
Dehnung [%]
2.3 Creep modulus curves of PVDF-C, Type 1 for one year for the stress range from 1 N/mm² to 8 N/mm²
700
Jahr
1 Year
650
1 N/mm²
600
550
500
2
[N/mm²]
modulus[N/mm²]
450
400 3
Kriechmodul
350 4
5
300
Creep
8
250
200
150
100
50
0
20 40 60 80
Temperature
Temperatur [°C][°C]
179
2.4 Creep modulus curves of PVDF-C, Type 1 for ten years for the stress range from 1 N/mm² to 8 N/mm²
700
10
10 Jahre
Years
650
600
550
1 N/mm²
500
[N/mm²]
modulus[N/mm²]
450
400
2
Kriechmodul
350
3
300 4
Creep
250 5
8
200
150
100
50
0
20 40 60 80
Temperature
2.5 Creep modulus curves of PVDF-C, Type 1 for 25 years for the stress range from 1 N/mm² to 8 N/mm²
700
25
25Jahre
Years
650
600
550
500
[N/mm²]
1 N/mm²
modulus[N/mm²]
450
400
Kriechmodul
350 2
300 3
4
Creep
250 5
200 8
150
100
50
0
20 40 60 80
Temperature [°C]
Temperatur [°C]
180
3 Coefficients for 2NCT/FNCT1) in the case of PVDF 4 PVDF / E-CTFE media list
Minimum requirements for the resistance to slow crack growth Preliminary remarks
Material PVDF2) PVDF-C, Type 1 und Type 23) This media list applies to the semi-fluorinated materials (PVDF /
E-CTFE) with proven minimum properties according to the re-
Requirement 200 200 quirements of the German Institute for Construction Technology
(hours) (DIBt) or according to the DVS 2205 technical code. The follow-
ing media list has been agreed upon with the raw material manu-
Test specimens: facturers Arkema and Solvay Solexis.
Pressed panels or extruded semi-finished products (testing trans- The numerical values specified in the column with the material
verse to the extrusion direction) properties in the media list constitute the maximum utilisation
If any deviating testing conditions are applied, the following re- temperature at which the media influence is not expected to affect
quirements are set: the material. This means that, for the creep strength, reference
Validation over min. 60 testing series in three decades. The tar- can be made to the creep diagram established in the test with
get variable (e.g. 200 hours) must be included in this respect. water (A2B = 1 and A2I = 1). A reduction in the elastic modulus,
The correlation coefficient must be > 0.9. The minimum require- i.e. in the stiffness (as a result of swelling), is not to be expected
ment must be proven with a "lower confidence limit" of 2.5 %. The either.
correlation must be accredited according to EN ISO/IEC 17025.
This list is only applicable to the individual media specified on it
up to the stipulated concentrations. If mixtures exist, it is neces-
sary to contact the manufacturers of the semi-finished products.
For PVDF, attention must generally be paid to the inclination of
all aqueous media to permeation at operating temperatures
> 60°C. In the case of composite structures with PVDF liners, it
must be borne in mind that the permeation through the external
load-bearing coat is usually lower than that through the PVDF
liner. This circumstance must be taken into consideration when
the bonding agent is selected. In the same operating conditions
and particularly at elevated temperatures, the inclination of E-CTFE
to the permeation of water vapour is substantially lower than that
of PVDF.
1) DIN EN 12814-3
2) For PVDF, additional media (with which a chemical influence is to
Testing conditions: 95°C; 2 % Arkopal N-100; 11 N/mm²
3)
be expected) are specified in Media List 40-1.3 from DIBt with the
Testing conditions: 95°C; 2 % Arkopal N-100; 6 N/mm² relevant reduction factors.
Explanations about the following table:

1) I: inorganic substance
O: organic substance
M: mixture of inorganic and organic substances
2) SS: saturated (at 20°C), aqueous solution
TP: technically pure medium
CA: commercially available composition or as occurring in nature
S: suspension
DS: diluted solution
3) 88.25 parts of water, 10 parts of sodium perchlorate, 1 part of sodium hydroxide,
0.25 parts of aniline, 0.25 parts of monochlorobenzene and 0.25 parts of toluene diamine.
3.1) Not transferable to other waste waters.
4) Here, attention must be paid to the distinct inclination of the medium to permeate
the PVDF material already at operating temperatures  60°C.
181
5) Pay attention to the danger of the formation of explosive mixtures.
PVDF-C PVDF-C
1) PVDF E-CTFE
Proportion2) Type 1 Type 2
Medium
%
Max. operating temperature [°C]
1, 3, 5 trimethylbenzene, C6H3(CH3)35) O 100 80 80 65
Acetic acid, CH3COOH O 10 60 60 60 100
Air, O2/N24) I 100 145 135 125 150
Aluminium chloride, AlCl3 I  SS 140 130 110 140
Aluminium fluoride, AIF3 S 100 100 100 140
Aluminium hexafluorosilicate, Al2(SiF6)3  SS 100 100 100 140
Aluminium iron(II) sulphate, Al2Fe(SO4)4  SS 100 100 100 140
Aluminium metaphosphate, Al(PO3)3  SS 100 100 100 140
Aluminium nitrate, Al(NO3)3  SS 100 100 100 140
Aluminium oxide (corundum), Al2O3 S 100 100 100 140
Aluminium sulphate, Al2(SO4)3 I  SS 140 130 110 140
Alums (Me(I)/Me(III) sulphates) I  SS 140 130 110 140
I 3 40 40 40 140
Ammonia licquor, NH3 + H2O
I < 30 140
Ammonium acetate, CH3COONH4 M  SS 80 65 65 65
Ammonium aluminium sulphate, NH4Al(SO4)2  SS 100 100 100 140
Ammonium bromide, NH4Br I < SS 120 110 110 140
Ammonium carbonate, (NH4)2CO3 I < SS 135 130 110 140
Ammonium chloride, NH4Cl I  SS 135 130 110 140
Ammonium citrate, (NH4)2C6H6O7 DS 100 100 100 120
Ammonium fluoride, NH4F I > 10 135 130 110 140
Ammonium formate, NH4HCOO  SS 100 100 100 100
Ammonium hexafluorosilicate, (NH4)2SiF6  SS 100 100 100 140
Ammonium hydrogen(di)fluoride, NH4 HF24)
.  50 60 60 60 100
Ammonium hydrogencarbonate, (NH4)HCO3 I  SS 135 130 110 140
Ammonium hydrogensulphite, NH4HSO3  SS 100 100 100 140
Ammonium hydroxide, (NH4OH) 140
Ammonium nitrate, NH4NO3 I  SS 135 130 110 140
Ammonium oxalate, (NH4OOC)2  SS 100 100 100
Ammonium peroxodisulphate, (NH4)2S2O8  SS 100 100 100 100
Ammonium phosphate, (NH4)3PO4 I  SS 135 130 110 140
Ammonium sulphate, (NH4)2SO4 I  SS 135 130 110 140
Ammonium sulphide, (NH4)2S I  SS 50 50 50 140
Ammonium tetrafluoroborate, NH4BF4  SS 80 80 80 80
Ammonium thiocyanate, NH4SCN  SS 100 100 100 140
Apple juice O CA 140 130 110 140
Barium carbonate, BaCO3 I  SS 140 130 110 120
Barium chloride, BaCl2 I  SS 140 130 110 140
Barium hydroxide, Ba(OH)2  SS 120
Barium nitrate, Ba(NO3)2 I  SS 140 130 110 140
Barium sulphate, BaSO4 I  SS 140 130 110 140
Barium sulphide, BaS I  20 80 80 80 120
Beer O CA 140 130 110 140
Benzene sulphonic acid O 40 50 50 50 65
Benzoic acid, C6H5COOH  SS 100 100 100 120
Beryllium sulphate, BeSO4  SS 100 100 100 140
Borax, Na2B4O7 I  SS 135 130 110 140
Boric acid (borated water), H3BO3 I TP 135 130 110 140
182
PVDF-C PVDF-C
1) PVDF E-CTFE
Medium
%
Bromic acid, HBrO3 DS 40 40 40 50
Buttermilk O CA 140 130 110 140
Cadmium chloride, CdCl2 I  SS 140 130 110 140
Cadmium cyanide, Cd(CN)2 I  SS 60 60 60 65
Cadmium sulphate, CdSO4 I  SS 140 130 110 140
Calcium acetate, (CH3COO)2Ca M  SS 80 65 65 65
Calcium bromide, CaBr2 I  SS 140 130 110 140
Calcium carbonate, CaCO3 I  SS 80 80 80 140
Calcium chloride, CaCl2 I  SS 140 130 110 140
Calcium fluoride, CaF2 I  SS 140 130 110 140
Calcium hydrogencarbonate, Ca(HCO3)2  SS 100 100 100 140
Calcium hydrogensulphide, Ca(HS)2  SS 100 100 100 140
Calcium hydrogensulphite, Ca(HSO3)2  SS 100 100 100 140
Calcium hydroxide, Ca(OH)2 < SS 130
Calcium lactate, Ca(C3H5O3)2  SS 100 100 100 140
Calcium nitrate, Ca(NO3)2 I  SS 140 130 110 140
Calcium phosphate, Ca3(PO4)2 S 100 100 100 140
Calcium sulphate (gypsum), CaSO4 I  SS 140 130 110 140
Calcium sulphite, CaSO3 I  SS 140 130 110 140
Carbon dioxide, gaseous, CO24) I Any 140 120 110 140
Carbon tetrachloride, CCl4 O TP 75 75 75 75
Carbonic acid, CO2 + H2O  SS 100 100 100 140
Casein TP 140 130 110 140
Chloroform, CHCl3 O 100 50 50 50
10 110 110 110 120
Chromic acid, CrO3 + H2O I
20 110 110 110 110
Chromium(II) chloride, CrCl2  SS 100 100 100 140
Chromium(III) chloride, CrCl3  SS 100 100 100 140
Chromium(III) nitrate, Cr(NO3)3  SS 100 100 100 140
Chromium(III) sulphate, Cr2(SO4)3  SS 100 100 100 140
Chromosulphonic acid, CrO3 + H2SO4 + H2O I 100 65 70 70 70
Cider O CA 140 130 110 140
Citric acid, (COOH)3 C3H4OH O  10 140 130 110 140
Common salt solution, NaCl I 25 140 130 110 140
Copper electrolytic solution, CuSO4 + H2SO4 I 20/5 140 130 110 140
Copper(I) chloride, CuCl  SS 100 100 100 140
Copper(I) cyanide, CuCN I  SS 140 130 110 140
Copper(II) chloride, CuCl2 I  SS 140 130 110 140
Copper(II) cyanide, CuCN2 S 100 100 100 140
Copper(II) fluoride, CuF2 DS 100 100 100 140
Copper(II) nitrate, aqueous, Cu(NO3)2 I  30 140 130 110 140
Copper(II) sulphate, CuSO4 I  SS 140 130 110 140
Decane, C10H225) O 100 140 130 110 140
Dextrose O  20 140 130 110 140
Dichloroethylene, CH2 = CCl2 O 100 100 90 80 20
Ethanolamine < 99 80
Ethylene glycol M 100 140 130 110 140
Formaldehyde, CH2O O 40 50 50 50 90
183
PVDF-C PVDF-C
1) PVDF E-CTFE
Medium
%
Fructose (fruit sugar) O > 10 140 130 110 140
Fruit drinks and juices O CA 140 130 110 140
Glycerin, C3H5(OH)3 TP 100 100 100 140
Grape sugar, aqueous I  20 140 130 110 140
Heating oil5) O 100 140 130 110 140
Hexafluorosilicic acid, H2SiF6  50 40 40 40 140
Hexanol, C6H13OH O 100 80 70 65 140
Hydraulic oil O 100 140 130 110 140
Hydrobromic acid, HBr  50 40 40 40 140
Hydrochloric acid, HCl4) I  33 100 100 100 140
 50 100 100 100 120
Hydrofluoric acid, HF4) O
 70 50 50 50 50
Hydrogen sulphide, H2S4) I TP 140 130 110 140
Hydroxyl ammonium sulphate, (NH2OH)2 H2SO4 I  12 140 110 110 140
Iron(I) sulphate, FeSO4 I  SS 140 130 110 140
Iron(II) chloride, FeCl2 I  SS 140 130 110 140
Iron(II) nitrate, Fe(NO3)2  SS 100 100 100 140
Iron(III) chloride, FeCl3 I  SS 140 130 110 140
Iron(III) nitrate, Fe(NO3)3  SS 100 100 100 140
Iron(III) sulphate, Fe2(SO4)3 I  SS 100 100 100 140
Lactic acid O CA 50 50 50 140
Lead acetate, Pb(CH3COO)2 I  30 90 90 90 140
Lead nitrate, Pb(NO3)2 I  SS 140 130 110 140
Lead sulphate, PbSO4 I  SS 140 130 110 140
Lead tetrafluoroborate, Pb(BF4)2  50 100 100 100
Linoleic acid, C17H31COOH TP 100 100 100 120
Lithium bromide, LiBr  SS 100 100 100 140
Lithium hydroxide, LiOH  SS 100
Lithium sulphate, Li2SO4 I  SS 140 130 110 140
Magnesium carbonate, MgCO3 I  SS 70 70 70 140
Magnesium chloride, MgCl2 I  SS 140 130 110 140
Magnesium hydrogencarbonate, MgHCO3 I  10 60 60 60 140
Magnesium nitrate, Mg(NO3)2  SS 100 100 100 140
Magnesium sulphate, MgSO4 I  SS 140 130 110 140
Mercury(II) chloride, HgCl2  SS 100 100 100 140
Mercury(II) cyanide, Hg(CN)2  SS 100 100 100 140
Mercury(II) nitrate, Hg(NO3)2 S 100 100 100 140
Methanol, CH3OH5) O 100 75 65 50 130
Milk O CA 140 130 110 140
Mineral water I CA 135 130 110 140
Natural gas (main constituent: CH4)4)5) O 100 140 130 110 140
Natural gas condensate (mixture of aromatics and aliphatics)5) O 100 140 130 110 140
Nickel chloride, NiCl2  SS 100 100 100 140
Nickel nitrate, Ni(NO3)2  SS 100 100 100 140
Nickel(II) sulphate, NiSO4 I  SS 140 130 110 140
Nicotinic acid, NC5H4COOH O TP 120 120 110 120
Nitrating acid4)
6.5 parts by volume of 96 % sulphuric acid + 2 parts by volume 80 80 80 80
of 65 % nitric acid + 1.5 parts by volume of water
184
PVDF-C PVDF-C
1) PVDF E-CTFE
Medium
%
Nitric acid + hydrofluoric acid, HNO3 + HF4) I 15 + 4 60 65 65 65
Nitric acid, HNO3 I 15 80 90 90 115
N-methylpyrrolidone TP 50
Octanol, C6H17OH5) O 100 110 100 75 120
Oleic acid O TP 140 130 110 140
Olive oil O CA 140 130 110 140
Oxalic acid, (COOH)2 O  SS 45 45 50 65
Oxygen, O24)5) I 100 140 130 110 140
Palm oil O CA 140 130 110 140
Peanut oil O 100 140 130 110 140
Petrol, C5H12 to C12H265) O 100 140 130 110 140
 60 140 130 110 140
Phosphoric acid, H3PO4 I
75 100 110 110 140
Phosphorus trichloride, PCl34) TP 40 40 40 40
Potassium aluminium sulphate4), KAI(SO4)2 I > 10 140 130 110 140
Potassium borate, K2B4O7 I  SS 140 130 110 140
Potassium bromate, aqueous, KbrO3 I  10 140 130 110 140
Potassium bromide, KBr  SS 100 100 100 140
Potassium carbonate < SS 130
Potassium chlorate, KclO3 I  SS 90 95 95 140
Potassium chloride, KCI  SS 100 100 100 140
Potassium chromium(III) sulphate (chrome alum), KCr(SO4)2  SS 80 80 80 140
Potassium cyanide, KCN I  0.5 40 40 40 140
Potassium fluoride, KF I  SS 140 130 110 140
Potassium hexacyanoferrate(II) (yellow prussiate of potash),
K4[Fe(CN)]6
I  SS 140 130 110 140
Potassium hexacyanoferrate(III) (red prussiate of potash),

K3[Fe(CN)]6
I  SS 140 130 110 140
Potassium hydrogencarbonate, KHCO3 I  10 70 70 70 140

Potassium hydrogensulphate, KHSO4  SS 100 100 100 140
Potassium hydrogensulphite, KHSO3  SS 100 100 100 140
Potassium hydroxide, KOH < 50 120
Potassium iodide, KI I  SS 140 130 110 140
Potassium nitrate, KNO3 I  SS 140 130 110 140
Potassium nitrite, KNO2  SS 100 100 100 140
Potassium permanganate, KMnO4  SS 80 80 80 120
Potassium persulphate I  SS 50 60 70 120
Potassium phosphate, K3PO4 I  SS 140 130 110 140
Potassium sulphate, K2SO4 I  SS 140 130 110 140
Potassium tartrate, K2(CHOHCOO)2  SS 100 100 100 140
Sea water I CA 140 130 110 140
Silicic acid, SiO2(H2O)n  SS 100 100 100 140
Silver nitrate, AgNO3 I  SS 140 130 110 140
Soda, Na2CO3, also sodium carbonate I  10 40 40 40 140
Sodium acetate, CH3COONa M  10 80 80 80 80
Sodium bisulphite I  SS 140 130 110 140
Sodium bromide, NaBr I  SS 140 130 110 140
Sodium carbonate < SS 130
Sodium carbonate, aqueous, Na2CO3, also soda I  10 40 40 40 140
185
PVDF-C PVDF-C
1) PVDF E-CTFE
Medium
%
Sodium chloride, NaCl I  SS 140 130 110 140
Sodium cyanide, NaCN I 1 40 40 40 140
Sodium disulphite, Na2S2O5 I  10 140 130 110 140
Sodium fluoride, NaF  SS 100 100 100 140
Sodium hydrogencarbonate, NaHCO3 I  10 60 60 60 140
Sodium hydrogensulphate, NaHSO4 I  SS 140 130 110 140
Sodium hydrogensulphite, NaHSO3 I > 10 140 130 110 140
Sodium hydroxide, NaOH < 50 120
Sodium hypochlorite, NaOCl <5 100
Sodium iodide, NaI  SS 100 100 100 140
Sodium nitrate, NaNO3 I  SS 140 130 110 140
Sodium nitrite, NaNO2 I  SS 140 130 110 140
Sodium perborate, NaBO2 I  SS 140 130 110 140
Sodium phosphate, Na3PO4 I  SS 140 130 110 140
Sodium sulphate, Na2SO4 I  SS 140 130 110 140
Sodium sulphite, aqueous, Na2SO3 I  40 140 130 110 140
Sodium tetraborate, Na2B4O7 I  SS 100 100 100 140
Sodium thiosulphate, Na2S2O3 I  SS 140 130 110 140
Spirits of all kinds O CA 90 90 80 140
Starch O Any 140 130 110 140
Stearic acid O TP 140 130 110 140
Succinic acid O TP 140 130 110 140
Sugar syrup O CA 140 130 110 140
Sulphuric acid, H2SO4 I 40 100 100 90 140
Tartaric acid O  10 140 130 110 140
Tetramethyl ammonium hydroxide (TMAH), (CH3)4NOH 50 80
Tin(II) chloride, SnCl2 I  SS 140 130 110 140
Tin(IV) chloride, SnCl4 I  SS 140 130 110 140
Toluene, C6H5CH35) O 100 80 80 65
Transformer oil O 100 140 130 110 140
Trichlorofluoromethane (CFC), CCl3F4) O TP 100 100 100 65
Unfractionated petroleum (mixture of aromatics and aliphatics) O 100 140 130 110 140
Urine CA 140 130 110 140
Waste water from a cellulose factory, acidic3) M 100 95 95 95 95
Waste water from a dairy installation3.1) M 100 140 130 110 140
Water with wetting agent M 2 140 130 110 150
Water, H2O I 100 140 130 110 150
Wines M CA 140 130 110 140
Yeast O Any 140 130 110 140
Zinc carbonate, ZnCO3  SS 100 100 100 140
Zinc chloride, ZnCl2  SS 100 100 100 140
Zinc nitrate, Zn(NO3)2  SS 100 100 100 140
Zinc oxide, ZnO S 100 100 100 140
Zinc phosphate, Zn3(PO4)2 S 100 100 100 140
Zinc stearate, Zn(C17H35COO)2 S 100 100 100 140
Zinc sulphate, ZnSO4 I  SS 140 130 110 140
186
5 5E-CTFE (ethylene chlorotrifluoroethylene)

30
25
20
20°C
15
40°C
10
[N/mm² ]
9 60°C
8
7
Vergleichsspannung
80°C
6
5 95°C
4
120°C
3
Remark: The Der

Anmerkung: proofNachweis
was provided
wurdewith
mitpipes made
Rohren ausofHalar
Halar901
901geführt
1 5 10 25 50
Years
Jahre
1
1 10 100 1.000
, 10.000
, 100.000
, 1.000.000
, ,
Service life[h]
Standzeit [h]
lg(t) = A + B/T lg() + C/T + D  lg()
A = –149.9727
B = –30,448.284
C = 63,064.546
D = 56.9484
187
5.2 Isochronous stress/strain diagram of E-CTFE for 20°C
14
20 °C
r
ehar
JYa
1
12
arres
YJaeh
1100 e
hrrs
JYaea
Zugspannung [N/mm²]
Tensile stress [N/mm²]
10 2255
2
Established on Halar 901
Ermittelt an Halar 901
0
0 0,5 1 1,5 2
Dehnung [%]
Elongation [%]
5.3 Creep modulus curves of E-CTFE for one year
2.000
,
1 N/mm² 11Year
Jahr
,
1.900
1.800
,
1.700
,
1.600
,
1.500
,
2
1.400
,
[N/mm²]
modulus[N/mm²]
1.300
,
3
1.200
,
1.100
, 4
Kriechmodul
1.000
, 5
900
8
800
Creep
700
600
Creep modulus
Kriechmodul established
ermittelt on Halar
an Halar 901 901
500
400
300
200
100
0
20 40 60 80 100 120 140
Temperatur [°C]
Temperature [°C]
188
5.4 Creep modulus curves of E-CTFE for one year; range from 50°C to 120°C
500
1 N/mm² 11 Year
Jahr
400
2
[N/mm²]
modulus[N/mm²]
3
300
4
Kriechmodul
Creep modulus established

Kriechmodul onHalar
ermittelt an Halar 901
901
5
200
Creep
100
0
60 80 100 120
Temperature [°C]
Temperatur [°C]
5.5 Creep modulus curves of E-CTFE for ten years

,
2.000
1 N/mm² 10
10Years
Jahre
,
1.900
,
1.800
,
1.700
,
1.600
,
1.500
,
1.400
[N/mm²]
2
modulus[N/mm²]
,
1.300
,
1.200
3
,
1.100
Kriechmodul
,
1.000
4
900
5
800
Creep
700
8
600
Creep modulus ermittelt
Kriechmodul established
an on Halar
Halar 901901
500
400
300
200
100
0
20 40 60 80 100 120 140
Temperature [°C]
Temperatur [°C]
189
5.6 Creep modulus curves of E-CTFE for ten years; range from 50°C to 120°C
500
1 N/mm² 1010 Years
Jahre
400
[N/mm²]
modulus[N/mm²]
2
300
3
Kriechmodul
Kriechmodul
Creep ermittelt anon
modulus established Halar 901
Halar 901
4
200 5
Creep
100
0
60 80 100 120
Temperature [°C]
Temperatur [°C]
5.7 Creep modulus curves of E-CTFE for 25 years
2.000
,
1 N/mm² 25
25Years
Jahre
1.900
,
1.800
,
1.700
,
1.600
,
1.500
,
1.400
,
[N/mm²]
modulus[N/mm²]
1.300
, 2
1.200
,
1.100
,
3
Kriechmodul
1.000
,
900 4
800 5
Creep
700
8
600
Creep modulus ermittelt
Kriechmodul established on Halar
an Halar 901901
500
400
300
200
100
0
20 40 60 80 100 120 140
Temperature
190
5.8 Creep modulus of E-CTFE for 25 years; range from 50°C to 120°C
500
1 N/mm² 2525
Jahre
Years
400
[N/mm²]
modulus[N/mm²]
300 2
Kriechmodul
Creep modulus established

Kriechmodul ermittelt anonHalar
Halar901
901
3
200 4
Creep
100
0
60 80 100 120
Temperature [°C]
Temperatur [°C]
191
6 PTFE (polytetrafluoroethylene)
30
25
Anmerkung: DerThe
Remark: Nachweis wurde
proof was mit Rohren
provided aus
with pipes
made TF
Dyneon of Dyneon TF 2025
2025 PTFE PTFE.
geführt.
20
15
20°C
10
[N/mm² ]
9
50°C
8
7
Vergleichsspannung
80°C
6
5 120°C
4
175°C
3
235°C
Testing requirement:
Prüfanforderung: 80°C
80°C / 7,0/ N/mm²
7.0 N/mm²
/ 200/h200 h
1 5 10 25 50
Years
Years
Jahre
1
1 10 100 1.000
, 10.000
, 100.000
, 1.000.000
, ,
Standzeit
Service life[h]
[h]
lg(t) = A + B/T lg() + C/T + D  lg()
A = –31.6933
B = –1,949.34
C = 33,222.6864
D = –66.46132
192
7 Reduction coefficients A1 for moulding materials made of fluoropolymers
Moulding material PVDF PVDF-C, PVDF-C, E-CTFE PTFE

Type 1 Type 2
Notched impact strength [kJ/m²] at 23°C
Without Without Without
according to DIN EN ISO 179-1/1eA 6* 12*
fracture fracture fracture
(Charpy)
Modulus in tension [N/mm²] at 23°C
1,900 950 600 1,600 400
according to DIN EN ISO 527-2
DVS 2205-1 DVS 2205-1 DVS 2205-1 DVS 2205-1 DVS 2205-1
Requirement on the creep strength according
Supplement 4 Supplement 4 Supplement 4 Supplement 4 Supplement 4
to ISO 1167
Section 1.1 Section 2.1 Section 2.1 Section 5.1 Section 6.1
* Extrusion moulding materials may exhibit higher values.
Temperature [°C]
Formmasse
–10 0 10 201) 30 40 50 60 80
PVDF 1.6 1.5 1.4 1.3 1.1 1.0 1.0 1.0 1.0
PVDF-C, Type 1 1.5 1.4 1.2 1.1 1.0 1.0 1.0 1.0 1.0
PVDF-C, Type 2 1.2 1.1 1.0 1.0 1.0 1.0 1.0 1.0 1.0
E-CTFE 1.2 1.1 1.0 1.0 1.0 1.0 1.0 1.0 1.0
PTFE 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0 1.0
Explanation:
The notched impact strength was established by means of tests
not only on injected test specimens but also on pressed and ex-
truded test specimens. The stipulation of the reduction coefficient
A1 is based on the lowest value of the notched impact strength.
8 Literature
Set of rules
DIN EN ISO 179-1 Plastics – Determination of the Charpy impact
properties – Part 1: Non-instrumented impact
strength test
erties – Part 2: Testing conditions for
moulding and extrusion materials
EN ISO/IEC 17025 General requirements on the competence
of testing and calibration laboratories
ISO 1167-1 Pipes, fittings and component combinations
of thermoplastics for the transport of liquids
– Determination of the resistance to internal
overpressure – Part 1: General testing pro-
cedure
DIN EN 12814-3 Testing of welded joints between thermo-
plastics – Part 3: Tensile creep test
DIBt Media List 40
193
September 2013

VERWANDTE VERFAHREN E.V. Reduction coefficients in the case DVS 2205-1
of a media influence Supplement 5
Replaces DVS 2205-1, Supplement 15 (September 2005)
This supplement includes reduction coefficients in the case of a media influence.
Contents:
1 Reduction coefficients A2 in the case of a media influence for PE, PP and PVC
1.1 Media with stress-independent A2 values
1.2 Media with stress-dependent A2 values
2 Reduction coefficients A2I in the case of proof of the stability with a media influence for PE and PP
Footnotes for Sections 1.1 and 1.2:

1) I: inorganic substance
O: organic substance
M: mixture of inorganic and organic substances
3) Not transferable to other waste waters.
4) 88.25 parts of water, 10 parts of sodium perchlorate, 1 part of sodium hydroxide, 0.25 parts of aniline,
0.25 parts of monochlorobenzene and 0.25 parts of toluene diamine.
5) On the basis of many years of experience in practice, A2 = 1 (also see the DVS 2205-1 technical code, Section 4.2).
6) Extrapolated values according to ISO/TC 138 SC 3 N 382.
7) For further information, see:
Kempe, B.: Testing methods for the determination of the behaviour of polyolefins subjected to the effect of chemicals.
Materialwissenschaft und Werkstofftechnik 15 (1984), pp. 157/72.
8) For further information, see:
Barth, E.: The behaviour of hard PVC subjected to the effect of chemicals.
Materialwissenschaft und Werkstofftechnik 17 (1986), pp. 74-76 and 98-108.
1 Reduction coefficients A2 in the case of a media influence for PE, PP and PVC
1.1 Media with stress-independent A2 values
Concentra- PE-HD PP PVC-NI

Medium Chemical formula 1) tion2)
% 20°C 40°C 60°C 80°C 20°C 40°C 60°C 80°C 95°C 20°C 40°C 60°C
Air O2N2 I 100 1 1 1 1 1 1 1 1 1 1 1

Alkaline solutions4) M 100 2
Aluminium chloride5) AlCl3 I  SS 1 1 1 1 1 1 1 1 1
Aluminium
Al2(SO4) I  SS 1 1 1 1 1 1 1 1 1
sulphate5)
Alums (Me(I)/Me(III)
I  SS 1 1 1 1 1 1 1 1 1
sulphates)5)
194

% 20°C 40°C 60°C 80°C 20°C 40°C 60°C 80°C 95°C 20°C 40°C 60°C
Ammonia licquor5) NH4OH I  SS 1 1 1 1 1 1 1 1 1

Ammonia,
NH3 I TP 1 1 1 1 1 1 1 1 1
gaseous5)
Ammonia, liquid5) NH3 I TP 1 1 1 1
 SS 1 1 1 1 1 1 1 1 1
Ammonia solution5) NH4OH I 15 1.67
 30 1 1 1
Ammonium
CH3COONH4 M  SS 1 1 1 1 1 1
acetate5)
Ammonium
NH4Br I  SS 1 1 1 1 1 1 1 1 1
bromide5)
Ammonium
(NH4)2CO3 I  SS 1 1 1 1 1 1 1 1 1
carbonate5)
Ammonium
NH4Cl I  SS 1 1 1 1 1 1 1 1 1
chloride5)
Ammonium fluoride5) NH4F I > 10 1 1 1 1 1 1 1 1 1
Ammonium hydro-
(NH4)HCO3 I  SS 1 1 1 1 1 1 1 1 1
gencarbonate5)
Ammonium nitrate5) NH4NO3 I  SS 1 1 1 1 1 1 1 1 1 1 1
Ammonium
(NH4)2SO4 I  SS 1 1 1 1 1 1 1 1 1 1 1
sulphate5)
Ammonium
(NH4)2S I  SS 1 1 1 1 1 1 1 1 1
sulphide5)
Ammonium-
dihydrogen- NH4H2PO4 I  SS 1 1 1 1 1 1 1 1 1 1 1
phosphat5)
Amyl alcohol8) C5H11-OH O TP 2.36
Apple juice5) O CA 1 1 1 1 1 1 1 1 1 1 1
2 1.28
Arkopal N 1008) O
5 2.17
Barium carbonate5) BaCO3 I  SS 1 1 1 1 1 1 1 1 1
Barium chloride5) BaCl2 I  SS 1 1 1 1 1 1 1 1 1
Barium hydroxide5) Ba(OH)2 I  SS 1 1 1 1 1 1 1 1 1 1 1
Barium nitrate5) Ba(NO3)2 I  SS 1 1 1 1 1 1 1 1 1
Barium salts5) I/M  SS 1 1 1 1 1 1 1 1 1 1 1
Barium sulphate5) BaSO4 I  SS 1 1 1 1 1 1 1 1 1
Barium sulphide5) BaS I  SS 1 1 1 1 1 1 1 1 1
Battery acid
H2SO4 I  51 1 1 1 1 1 1 1 1 1
(see sulphuric acid)
Beer5) O CA 1 1 1 1 1 1 1 1 1 1 1
Benzene sulphonic
O 40 1 1 1
acid5)
Benzyl alcohol8) C6H5CH2OH O TP 4.54
Boric acid5) I TP 1 1 1
Butanol – butyl
C4H9OH O TP 2.5
alcohol8)
Buttermilk5) O CA 1 1 1 1 1 1 1 1 1 1 1
Cadmium chloride5) CdCl2 I  SS 1 1 1 1 1 1 1 1 1
195

% 20°C 40°C 60°C 80°C 20°C 40°C 60°C 80°C 95°C 20°C 40°C 60°C
Cadmium cyanide5) Cd(CN)2 I  SS 1 1 1 1 1 1 1 1 1

Cadmium sulphate5) CdSO4 I  SS 1 1 1 1 1 1 1 1 1
Calcium acetate5) (CH3COO)2Ca M  SS 1 1 1 1 1 1 1 1 1
Calcium bromide5) CaBr2 I  SS 1 1 1 1 1 1 1 1 1
Calcium carbonate5) CaCO3 I  SS 1 1 1 1 1 1 1 1 1 1 1
Calcium chloride5) CaCl2 I  SS 1 1 1 1 1 1 1 1 1 1 1
Calcium fluoride5) CaF2 I  SS 1 1 1 1 1 1 1 1 1
Calcium hydroxide5) Ca(OH)2 I  SS 1 1 1 1 1 1 1 1 1
Calcium nitrate5) Ca(NO3)2 I  SS 1 1 1 1 1 1 1 1 1
Calcium sulphate5) CaSO4 I  SS 1 1 1 1 1 1 1 1 1
Calcium sulphide CaS I  SS 1 1 1 1 1 1 1
Calcium sulphite5) CaSO3 I  SS 1 1 1 1 1 1 1 1 1
Carbon dioxide,
CO2 I Any 1 1 1 1 1 1 1 1 1
gaseous5)
Casein5) TP 1 1 1
Chlorine water Cl2  H2O I Any 1.4 1.4 1.4 1.4 1 1
Chrome alums I  SS 1 1 1
Chromosulphonic H2SO4 +
I 100  100
acid8) H2SO4 + H2O
Chromosulphonic 50% H2SO4 + 15%
I 4.76
acid8) H2SO4 + 35% H2O
Cider5) O CA 1 1 1 1 1 1 1 1 1
Citric acid5) (CO2H)CH2CO2H 10 CA 1 1 1 1 1 1 1 1 1 1 1 1
Citric acid5) (CO2H)CH2CO2H O  10 1 1 1 1 1 1 1 1 1 1 1
Common salt
NaCl I  SS 1 1 1 1 1 1 1 1 1 1 1 1
solution5)
Copper(I) cyanide5) CuCN I  SS 1 1 1 1 1 1 1 1 1
Copper(II) chloride5) CuCl2 I  SS 1 1 1 1 1 1 1 1 1
Copper(II) nitrate Cu(NO3)2 I  SS 1 1 1 1 1 1 1
Copper(II)
CuSO4 I  SS 1 1 1 1 1 1 1 1 1
sulphate5)
Detergents, various M
Dextrose5) O  20 1 1 1 1 1 1 1 1 1
Dichloroethane C2H4Cl2 O 100 1.11
1.1 dichloroethylene CH2 = CCl2 O 100  100
Diethylenetriamine
pentaacetic acid O 100 1.4 1.4 1.4 1.4
(e.g. Trilon C)
Dimethylsulphate (CH3)2SO4 O 100 1.15
Disinfectant M 100 1.54
Ethanol
CH3-CH2-OH O 1.88
(ethyl alcohol)8)
Ethylene dichloride C2H4Cl2 O 100 1.11
Ethylene glycol CH2OHCH2OH O TP 1.1 1.1 1 1.1 1 1 1
Ethylenediamine
O CA 1.4 1.4 1.4 1.4
tetraacetic acid
196

% 20°C 40°C 60°C 80°C 20°C 40°C 60°C 80°C 95°C 20°C 40°C 60°C
Fatty acid O TP 1 1 1
Fertilising salt5) I  SS 1 1 1 1 1 1 1 1 1
Fluoroboric acid HBF4 I  50 1.4 1.4 1.4 1.4
Formaldehyde CH2O O 40 1.61
 60 1 1 1.4 1.4 1 1 18)
Formic acid HCOOH O
 85 1.4
Fructose5) O  10 1 1 1 1 1 1 1 1 1 1 1
Fruit drinks and
O C 1 1 1 1 1 1 1 1 1 1 1
juices5)
Glyconic acid5) O 30 1.1 1.1 1 1 1
Grape sugar,
I  20 1 1 1 1 1 1 1 1 1 1
aqueous5)
Heating oil, heavy8) O 100 5.55
Hydraulic oil O 100 2.33
Hydrazine hydrate N2H4  H2O O  24 1 1 1 1 1 1
30 1.75 1.75 1.75 1.75 2.13 1 1 1
Hydrochloric acid HCl I
 37 1.2 1.2 1.33 1.2 1 1 18)
Hydrofluoric acid HF I  75 1.4 1.4 1.4 1.4
Hydrogel emulsion (pH value = 9.5) 100 1
Hydrogen peroxide H2O2 I  70 1 1
Hydrogen sulphide I TP 1 1 1
Hydroxyethylene-
diamine triacetic acid O CA 1.4 1.4 1.4 1.4
(e.g. Trilon D)
Hydroxyl ammonium
(NH2OH)2  H2SO4 I  12 1 1 1 1 1 1 1 1 1
sulphate5)
Iron(II) and iron(III)
FeCl2 FeCl3 I  SS 1 1 1 1 1 1 1 1 1
chlorides5)
Iron(II) sulphate5) FeSO4 I  SS 1 1 1 1 1 1 1 1 1 1
Iron(III) chloride
Fe3(ClSO4)2 I  SS 1 1 1 1 1 1 1 1 1 1
sulphate5)
Lactic acid5) O CA 1 1 1
Lead acetate5) Pb(CH3COO)2 I  SS 1 1 1 1 1 1
Lead nitrate5) Pb(NO3)2 I  SS 1 1 1
Lead sulphate5) PbSO4 I  SS 1 1 1 1 1 1 1 1 1 1
Liquid fertiliser CA 1 1 1 1
Lithium sulphate5) Li2SO4 I  SS 1 1 1
Magnesium
MgCO3 I  SS 1 1 1 1 1 1 1 1 1
carbonate5)
Magnesium
MgCl2 I  SS 1 1 1 1 1 1 1 1 1 1 1
chloride5)
Magnesium hydro-
MgHCO3 I  SS 1 1 1 1 1 1 1 1 1
gencarbonate
Magnesium salt5) I/M  SS 1 1 1 1 1 1 1 1 1
Magnesium
MgSO4 I  SS 1 1 1 1 1 1 1 1 1 1 1
sulphate5)
Mercury chloride HgCl2 I  SS 1 1 1 1 1 1 1
197

% 20°C 40°C 60°C 80°C 20°C 40°C 60°C 80°C 95°C 20°C 40°C 60°C
Mercury nitrate Hg(NO3)2 I  SS 1 1 1 1 1 1 1

Mercury Salts5) I/M  SS 1 1 1 1 1 1 1 1 1
Mercury sulphates HgSO4 I  SS 1 1 1 1 1 1
Methyl acetoacetate CH3COCH2COOCH3 O 100 1.18
Milk O CA 1 1 1 1 1 1 1 1 1 1 1
Mineral water5) H2O IA CA 1 1 1 1 1 1 1 1 1 1 1 1
Monoethylamine CH3CH2NH2 O 100 1
Natural gas Main constituent: CH4 O 100 1 1 1 1
Nickel nitrate Ni(NO3)2 I  SS 1 1 1 1 1 1 1 1 1 1
Nickel(II) sulphate5) NiSO4 I  SS 1.1 1.1 1 1 1
Nicotinic acid5) O TP 1 1 1
50 3.13 1.2 1.2 18)
Nitric acid HNO3 I 53 2 2 3.3
65 3.3
Nitric acid and I 15 + 4 2

HNO3 + HF
hydrofluoric acid 20 1.11 1 1 1.48)
Nitrilotriacetic acid
I CA 1.4 1.4
(e.g. Trilon A)
Oleic acid5) O TP 1 1 1
Olive oil5) O CA 1.1 1.1 1 1 1
Oxalic acid5) O  SS 1 1 1
100 1 1 1 1
40 1 1 1 1
Oxygen O2 I
78 1.4 1 1 1.4 1.67 1 1 1
80 1.268)
Palm oil5) O CA 1 1 1
Peanut oil O 100 1.37
 SS 1 1 1 1 1 1 1 1 1
Phosphates5) I
 30 1 1 18)
75 1 1.43
Phosphoric acid H3PO4 I
 95 1.2 1 1.2 1.43 1.1 1.68)
Photochemicals I CA 1.1 1.1 1.1 1.1 1 1
Polysulphides Me2S I 100 1.33 1 1 1 1 1 1
Potassium alumi-
KAl(SO4)2 I  10 (> 50) 1 1 1
nium sulphatet5)
Potassium borate5) K3BO3 I  SS 1 1 1 1 1 1 1 1 1
Potassium bromate,
KBrO3 I  10 1 1 1 1 1 1 1 1 1
aqueou5)
Potassium
KBr I  SS 1 1 1 1 1 1
bromide5)
Potassium chlorate5) KClO3 I  SS 1 1 1 1 1 1 1 1 1
Potassium chloride5) KCl I  SS 1 1 1 1 1 1 1 1 1
Potassium cyanide5) KCN I  10 1 1 1 1 1 1 1 1 1
Potassium cyanide5) KCN I  10 1 1 1 1 1 1 1 1 1
198

% 20°C 40°C 60°C 80°C 20°C 40°C 60°C 80°C 95°C 20°C 40°C 60°C
Potassium fluoride5) KF I  SS 1 1 1 1 1 1 1 1 1
Potassium
K4Fe(CN)6
hexacyanoferrate I  SS 1 1 1 1 1 1 1 1 1
K3Fe(CN)6
(II) and (III)5)
Potassium hydro-
KHCO3 I  SS 1 1 1 1 1 1 1 1 1
gencarbonate5)
Potassium
KOH I  50 1 1 1 2 2 2 2 1 1
hydroxide5)
Potassium
KOCl I  12.5 1.9 1.9 1.9 1.9
hypochlorite
Potassium iodide5) KJ I  SS 1 1 1 1 1 1 1 1 1
Potassium nitrate5) KNO3 I  SS 1 1.1 1 1.1 1 1 1
Potassium
K2S2O8 I  SS 1 1 1
persulphate5)
Potassium
K3PO4 I  SS 1 1 1 1 1 1 1 1 1
phosphate5)
Potassium
K2SO4 I  SS 1 1 1 1 1 1 1 1 1 1
sulphate5)
Potassum carbonate K2CO3 I  SS 1 1 1 1 1 1 1 1 1
Sea water5) I CA 1 1 1 1 1 1 1 1 1 1 1
Silver nitrate5) AgNO3 I  SS 1 1 1 1 1 1 1 1 1
Silver salt5) M  SS 1 1 1 1 1 1 1 1 1
Soda5) Na2CO3 I  50 1 1 1 1 1 1 1 1 1
I 40 1 1
Soda lye NaOH  50 1 1 1 1 2 2 2 2 1 1 1
I 60 1.28)
Sodium acetate5) CH3COONa M  SS 1 1 1 1 1 1 1 1 1 1 1
Sodium aluminium
NaAl(SO4)2 I  10 1 1 1
sulphate5)
Sodium bromide5) NaBr I  SS 1 1 1 1 1 1 1 1 1
Sodium carbonate,
Na2CO3 I  50 1 1 1 1 1 1 1 1 1
aqueous5)
Sodium chlorate5) NaClO3 I  SS 1 1 1 1 1 1 1 1 1
Sodium chloride5) NaCl I  SS 1 1 1 1 1 1 1 1 1 1 1 1
Sodium chlorite NaClO2 I  SS 1.4 1.4 1.4 1.4 1.2 1.2
Sodium cyanide5) NaCN I  SS 1.1 1.1 1 1 1
Sodium cyanide5) NaCN I  SS 1 1 1 1 1 1 1 1 1 1
Sodium dichromate5) Na2Cr2O7 I  SS 1 1 1 1 1 1
Sodium disulphite5) Na2S2O5 I  SS 1 1 1
Sodium hydro-
NaHSO4 I  SS 1 1 1 1 1 1 1 1 1
gensulphate5)
Sodium hydrogen-
NaHSO3 I  10 1 1 1 1 1 1 1 1 1
sulphite
Sodium
12.5
hypochlorite8) NaOCl 1.2 1.56
act. Cl
(bleaching lye)
Sodium nitrate5) NaNO3 I  SS 1 1 1 1 1 1 1 1 1
Sodium nitrite5) NaNO2 I  SS 1 1 1 1 1 1 1 1 1
199

% 20°C 40°C 60°C 80°C 20°C 40°C 60°C 80°C 95°C 20°C 40°C 60°C
Sodium perborate5) I  SS 1 1 1
Sodium phosphate5) Na3PO4 I  SS 1 1 1 1 1 1 1 1 1 1 1
Sodium silicate5) Waterglass I  10 1 1 1 1 1 1 1 1 1
Sodium sulphate5) Na2SO4 I  SS 1 1 1 1 1 1 1 1 1
Sodium sulphide5) Na2S I  SS 1 1 1 1 1 1 1 1 1
Sodium sulphite,
Na2SO3 I  40 1 1 1 1 1 1 1 1 1 1 1
aqueous5)
Sodium sulphite,
Na2SO3 I  40 1 1 1 1 1 1 1 1 1 1 1
aqueous5)
Sodium tetraborate5) Na2B4O7 I  SS 1 1 1 1 1 1 1 1 1
Sodium I  SS 1 1 1 1 1 1 1 1 1
Na2S2O3
thiosulphate5) 30 1.43 1 1 1
Spirits of all kinds5) O CA 1 1 1 1 1 1 1 1 1
Starch5) O Any 1 1 1 1 1 1 1 1 1
Stearic acid5) O TP 1 1 1
Succinic acid5) O TP 1 1 1
Sugar syrup5) O CA 1 1 1 1 1 1 1 1 1
40 1 1 1 1 1 1 1 1
Sulphuric acid H2SO4 I 51 1 1 1 1.1 1.1 1.1
78 1 1
Tannic acid8) 30 1
Tartaric acid5) O CA 1 1 1 1 1 1 1 1 1
Tin(II) chloride5) SnCl2 I  SS 1 1 1 1 1 1 1 1 1
Tin(IV) chloride5) SnCl4 I  SS 1 1 1 1 1 1 1 1 1
Toluene C6H5CH3 O 100 1.057)
Triacetin6) Glycerin triacetate O 100 1.1 1.1 1 1 1
Trichlorofluoro-
CCl3F O 100 16) 1.126) 1.43 1.82
methane
Urea5) CO(NH2)2 O  SS 1 1 1 1 1 1 1 1 1
Urine5) CA 1 1 1
Vegetable oil O TP 1.1 1 1 1 1
Vinegar5) CA 1 1 1 1 1 1 1 1 1 1 1
Waste water from a 4) M 100 1.05
cellulose factory
Waste water from a Alkaline M 100 1

cellulose factory4) Acidic M 100 1
Waste water from a
chemical fibre M 100 1.33
factoryk3)
Waste water from a
M 100 1.37
dairy installation3)
Water H2O I 100 1 1 1 1 1 1 1 1 1 1 1 1
Water with wetting
M 2 1.67
agent
Wines5) M CA 1 1 1 1 1 1 1 1 1
Yeast5) O Any 1 1 1 1 1 1 1 1 1
200

% 20°C 40°C 60°C 80°C 20°C 40°C 60°C 80°C 95°C 20°C 40°C 60°C
Zinc chloride ZnCl2 I  SS 1 1 1 1 1 1 1

Zinc nitrate Zn(NO2)2 / Zn(NO3)2 I  SS 1 1 1 1 1 1 1
Zinc salts5) I/M  SS 1 1 1 1 1 1 1 1 1
Zinc sulphate5) ZnSO4 I  SS 1 1 1 1 1 1 1 1 1 1
1.2 Media with stress-dependent A2 values
Testing PE Testing PP PVC

1) Concentration2)
Medium stress stress
%
N/mm2 80°C 60°C 40°C 20°C N/mm2 80°C 60°C 40°C 20°C
40 1.478)
50 1.038)
5...2 1.72
60
4...2 1.25 1.43 1.646) 1.856)
Acetic acid
5 3.85 5
CH3COOH
4 1.67 3.45 4.76 5.56
98
3 1.67 5.0 5.56 6.67
2 1.67 7.69 8.33 8.33
99.5 1.428)
100 5...3 1
Antifreeze agent 5 1.67
50
3 1
4 1.33 1.37 1.456)
Benzene
O 100 3 1.16 1.09 16)
C6H6
2 1 1 16)
4 1.43 1.54 1.676) 1.796)
Carbon tetrachloride
O 100 3 1.25 1.43 1.676) 1.856)
CCl4
2 1.05 1.25 1.496) 1.756)
4 2.22
Chloroform
O 100 3 2.1
CHCl3
2 1.82
10 4...2 1.43 1.61 2.046) 7.698)
5 4.76
4 1.72 2.38 5.56
Chromic acid 20
I 3 2.0 2.78 6.67
H2Cr2O4
2 2.63 3.57 9.1
30 5.888)
40 1.698)
Decane 4 1.39
O 100
C10H22 2 1.05
4 1,25
Ethyl acetoacetate
CH3COCH2COOC2H5 O 100 3 1
2 1
201

1) Concentration2)
%
N/mm2 80°C 60°C 40°C 20°C N/mm2 80°C 60°C 40°C 20°C
4 1.43
Heating oil, EL O 100 3 1.25
2 1.06 2.78)
4 1.11
Hexanol
O 100 3 1
C6H13OH
2 1
4 1.49 1.47 1.456) 1.436)
Methylene chloride
CH2CH2 O 100 3 1.25 1.28 1.326) 1.356)
2 1.05 1.06 1.086) 1.096)
5 Service life > 7a
Natural gas condensate 4 1.28
(mixture of aromatics and O 100
alphatics) 3 1.11
2 1
5 1
Octanol 4 1 1 1
O 100
C8H17OH 3 1 1 1
2 1 1 1
4 1.47 1.59 1.856)
Petrol
O 100 3 1.28 1.33 1.456)
C5H12 to C12H26
2 1.06 1.08 1.16)
3 1
85 3...1.5 1.67 1 1
2 3.3
3 2.0
90
2 9.09 1 1
3 10
Sulphuric acid 95
I 2 >100 1.2 1.1 1
H2SO4
96 1.028)
5 2.86
4 2.44 3.33 5.56
98
3 20 3.85 4.17 7.14
2 > 100 7.69 5.56 10 98)
4 1.54
Toluol
O 100 3 1.33
C6H5CH3
2 1.05
4 1.33 1.18 1.046) 16)
Transformer oil O 100 3 1.19 1 16) 16)
2 1 1 16) 16)
4 1.54
1,3,5 trimethylbenzene
O 100 3 1.33
C6H3(CH3)3
2 1.11
202

1) Concentration2)
%
N/mm2 80°C 60°C 40°C 20°C N/mm2 80°C 60°C 40°C 20°C
Service
4.5 1.35 > 25a
life
Unfractionated petroleum 4 1.25
(mixture of aromatics and O 100
alphatics) Service
2.8 1 > 25a
life
2 1
2 Reduction coefficients A2I in the case of proof of the stability with a media influence for PE and PP
The following table shows reduction factors A2I of media which exert a swelling effect and exhibit a value of  1.0.
(Source: Media Lists 40-1.1 and 40-1.2 from the German Institute for Construction Technology (DIBt), January 2004 edition)
Reduction coefficients
A2I (stability)
Concentration
Medium % PE PP
20°C 40°C 20°C 40°C
 60 1.1 1.1 1.2 1.2
Acetic acid, CH3COOH
 60  80 1.1 1.1 1.2 1.2
Diesel fuel, DIN EN 14214 CA 1.2 1.2

Fatty acid / methyl ester (biodiesel)
Diesel fuel, DIN EN 590-DK CA 1.1 1.1
Diethylenetriamine pentaacetic acid (e.g. Trilon C) CA 1.1 1.1 1.2 1.2
Ethylenediamine tetraacetic acid (e.g. as Trilon B),
CA 1.1 1.1 1.4 1.4
C2H4N2(CH2COOH)4
 60 1.1 1.1 1.2 1.2
Formic acid, HCOOH
 60  85 1.1 1.1
Glycolic acid, HOCH2COOH  SS 1.1 1.1 1.1 1.1
Heating oil, EL, DIN 51 603-1 CA 1.1 1.1
Hydrochloric acid  10  30 1.0 1.0 1.2 1.2
Lubricating oils (fresh oils or used2); hydraulic oils,
heat transfer oils Q, doped or undoped, fresh or CA 1.2 1.2
used2); aromatic-free
Synthetic resin dispersion CA 1.4 1.4 1.4 1.4
Triacetin (glycerin triacetate), (CH3COO)3C3H5 TP 1.0 1.1
Vegetable oil TP 1.2 1.2 1.2 1.2
In the case of all other aqueous media: A2I = 1.
Footnotes for Section 2:

2) The operator must be able to prove the origin and the flash point.
203
February 2013

VERWANDTE VERFAHREN E.V. Welding factors DVS 2205-1
Supplement 6
Replaces DVS 2205-1 Supplement 17 (February 2006)
Short-time (fZ) and long-time (fS) welding factors
Materials Welding factors,

PE1) PP2) PVC-U PVC-C PVDF
Processes short-time / long-time
Heated tool butt welding fZ 0.9 0.9 0.9 0.8 0.9
HS fS 0.8 0.8 0.6 0.6 0.6
Hot gas extrusion welding, discontinuous fZ 0.8 0.8 – – –
WE fS 0.4 0.4 – – –
Hot gas extrusion welding, continuous fZ 0.8 0.8 – – –
WE fS 0.6 0.6 – – –
Hot gas welding fZ 0.8 0.8 0.8 0.7 0.8

WZ/WF fS 0.4 0.4 0.4 0.4 0.4
IR welding for pipes, fZ – 0.9 – – 0.9
pressure-controlled fS – 0.8 – – 0.8
IR welding for pipes, fZ 0.9 0.9 – – 0.9
displacement-controlled fS 0.7 0.8 – – 0.8
1) Applies to PE 63, PE 80 and PE 100
2) Applies to PP-H, PP-B and PP-R
The prerequisites for the specified values are the command of the
corresponding welding processes and the execution by qualified
and certified personnel.
The short-time factors apply to loading times up to one hour. In
the case of other materials and/or joining processes, the values
must be proven individually.
The prerequisite for computation with higher welding factors than
stipulated in the above table is proof which is provided on the ma-
terial combination to be welded and must not be more than two
years' old.
204
February 2013

VERWANDTE VERFAHREN E.V. Application examples DVS 2205-1
Supplement 7
Examples which describe the determination of the material parameters or the permissible operating times for various applications are
listed in this supplement.
Contents: 2 Determination of the service life with intermittent stresses
1 Strength parameter with constant stresses Remarks:

2 Determination of the service life with intermittent stresses The creep curves have been established with the absolute tem-
o
2.1 Changing temperatures with constant stresses perature T =   C + 273  in kelvin.
2.2 Changing stresses at a constant temperature
In order to estimate the computational service life tX with intermit-
2.3 Changing stresses and changing temperatures
tent stresses, the material parameter Kvorh S assigned in each
3 Determination of isochrones at a higher temperature
case is initially established with the existing stresses Kvorh
K of the
individual partial stresses and the stipulated reduction coeffi-
cients A1 and A2 as well as with the safety coefficients and, if
1 Strength parameter with constant stresses
necessary, the welding factor fS.

Sought: Strength parameter K K* vorh
vorh K K  F  I  M  A1  A2
Given: Operating temperature  = 50°C KS = ----------------------------------------------------------------
 fS 
Service life t = 15 years
Filling material Water With this parameter, the relevant service life with partial stresses
The strength parameter K K is obtained from the creep strength is read off the creep curves of the utilised material for the temper-
diagram for pipes, e.g. made of PE 80 (Fig. 1). The line for a service ature in question. Thus, the resulting service life tM can be calcu-
life of 15 years intersects the 50°C creep curve for water at the P1 lated with the aid of Miner's rule (Equation (5) in DVS 2205-1).
point. A line parallel to the abscissa through the P1 point results in In order to establish the influence of the ageing, the beginning
the P2 point on the ordinate at which K K* = 4.6 N/mm² can be ageing with partial stresses can be read off the heat ageing limits
read off. for the temperature in question (for PE and PP, see DVS 2205-1,
Supplement 1, Section 5 and Supplement 2, Section 5). A sec-
ond calculation with Miner's rule (Equation (8) in DVS 2205-1)
Characteristic strength KK* [N/mm²]
leads to the resulting ageing time tA. The lower value of tM and tA
is the permissible operating time tX.
In Sections 2.1 to 2.3, the handling for the various stress cases is
50°C creep curve for water portrayed using simple examples.
2.1 Changing temperatures with constant stresses

Sought: Permissible service life tX
vorh
Given: Stresses KS
Operating temperatures 1 and 2
Corresponding to the time proportions at the individual tempera-
15 years tures, the computational service life tM is located between the
service lives of the partial stresses tM1 and tM2. With the given
stresses K vorh
S , the line parallel to the strength axis through tM
results in the P point. P is located on a creep curve which would
result between 1 and 2 at a constant temperature X.
1,000 10,000 100,000 1,000,000
Service life t [h]
Figure 1. Determination of the strength parameter K K* with constant
stresses.
205
2.2 Changing stresses at a constant temperature

Creep curves for the Sought: Permissible service life tX
vorh vorh
operating temperatures 1 and 2 Given: Stresses K S1 and K S2
Operating temperature 
Corresponding to the time proportions with the individual stresses,
the computational service life tX is located between the service
lives of the partial stresses tM1 and tM2. The line parallel to the
strength axis tM intersects the creep curve at the P point. This results
vorh
in the equivalent stresses K SM .
Creep curve for one

operating temperature 
Figure 2. Service life at changing temperatures with constant stresses.
Example for PE 63
Operating conditions and damage proportions
life with partial stresses
Computational service
Damage proportion
Time proportion
Partial stresses
Figure 3. Service life with changing stresses at a constant temperature.

Temperature
Example for PP-B

Stresses

Kvorh
S
tM
%


1 30°C 90 % 314.593 years 2.6
Damage proportion
5 N/mm²
2 42°C 10 % 0.946 years 97.4
Partial stresses
Temperature
(Values from DVS 2205-1, Supplement 1, Section 1.1)

Zeitanteil
Stresses
According to Equation (5) in DVS 2205-1, the service life to be

expected on the basis of the mechanical stresses is:
KSvorh
100  314.593  0.946
tM
%
1

=
----------------------------------------------------------------
-
a
tM 9.21 years
90  0.946 + 10  314.593 1 3.5 N/mm² 20 % 16.3 years 2.6
1) vorh 60°C
The same service life would be achieved with K S = 5 N/mm² at a con- 2 2 N/mm² 80 % 138 years 97.4
stant temperature of 37.6°C.
Ageing and damage proportions According to Equation (5) in DVS 2205-1, the service life to be
expected is:
Damage proportion
100  16.3  138 2

=tM =
-------------------------------------------------
- 55.35 years
Time proportion
Partial stresses
20  138 + 80  16.3
Temperature
heat ageing
2) The same service life would be achieved at a temperature of 60°C with

Beginning
a constant stress of KSM = 2.54 N/mm².
Ageing and damage proportions

%
tA

1 30°C 90 % 175.6 years 68.8

Damage proportion
Time proportion
2 42°C 10 % 43 years 31.2

Partial stresses
Temperature
heat ageing
(Values from DVS 2205-1, Supplement 1, Section 5)

Beginning

expected on the basis of the ageing is:
%
tA
100  175.6  43

=tA -------------------------------------------------
= - 134.2 years
90  43 + 10  175.6 1 60°C 100 % 50 Jahre 100
tM < tA, the permissible operating time is thus tX = 9.21 years. (Values from DVS 2205-1, Supplement 2, Section 5)
The service life to be expected on the basis of the ageing is 50 years.
tA < tM, the permissible operating time is thus tX = 50 years.
206
2.3 Changing stresses and changing temperatures 3 Determination of isochrones at a higher temperature
Sought: Permissible service life tX
vorh vorh
In order to be able to portray the isochrone determination for oth-
Given: Stresses K S1 and K S2 er temperatures, the creep modulus values are taken from the
Operating temperature 1 and 2 creep modulus diagram, in the case of the corresponding temper-
Corresponding to the time proportions at the individual tempera- ature and time, for the respective stresses. The relevant strains
tures, the computational service life tM is located between the can be calculated from these with the relationship below:
service lives of the partial stresses tM1 and tM2. 
=
 -------
EC
Creep curves for the
Example for PE 63, 40°C and one year
operating temperatures 1 and 2
 [N/mm²] 5 4 3 2 1
EC [N/mm²] 95 110 125 145 170
 [%] 5.26 3.64 2.40 1.38 0.59
(Values from DVS 2205-1, Supplement 1, Section 1.3.1)
Figure 4. Service life with changing stresses at changing temperatures.
Example for PP-H

Damage proportion
Time proportion
Partial stresses
Temperature
Stresses
Kvorh
S
tM
%

1 6 N/mm² 50°C 75 % 33.3 years 82

2 2 N/mm² 80°C 25 % 50.25 years 18

expected on the basis of the mechanical stresses is:
100  33.3  50.25
tM ------------------------------------------------------
= - 36.4 years
75  50.25 + 25  33.3
Ageing and damage proportions

Damage proportion
Time proportion
Partial stresses
Temperature
heat ageing
Beginning
%
tA

1 50°C 75 % 91.23 Jahre 35.7

2 80°C 25 % 16.9 Jahre 64.3
(Values from DVS 2205-1, Supplement 2, Section 5)

expected on the basis of the ageing is:
100  91.23  16.9
tA ------------------------------------------------------
= - 43.45 years
75  16.9 + 25  91.23
tM < tA, the permissible operating time is thus tX = 36.4 years.
207
Draft January 2015
DVS – DEUTSCHER VERBAND Calculation of tanks and apparatus made

FÜR SCHWEISSEN UND of thermoplastics – Vertical round, non- Technical code
VERWANDTE VERFAHREN E.V. pressurised tanks DVS 2205-2
Objections to be submitted by 30 April 2015
Replaces draft edition from February 2014

Intended as replacement for issue dated January 2011
This draft is being published for review and comment purposes. Suggestions for additions or modifications should be submitted to DVS
e.V., Postfach 10 19 65, 40010 Düsseldorf.
Contents: The cylindrical casing with continuously equal or graduated wall

thickness can be welded from panels, or consists of a wound
1 Scope pipe or an extruded pipe.
2 Calculation variables
In addition to the hydrostatic loads, short and long-term
3 Stresses
pressures must be taken into consideration. The following
3.1 Constant loads
minimum values have been determined:
3.1.1 Total dead load GE
3.1.2 Load of the filling material GF Positive pressure: 0.0005 N/mm2 (0.005 bar)
Negative pressure: 0.0003 N/mm2 (0.003 bar)
3.1.3 Internal and external pressure pü, pu

3.2 Medium-term loads The long-term pressures should only be applied if they can
3.2.1 Snow load GS actually take effect.
3.2.2 Summer temperature
3.3 Short-term loads Restriction of the main dimensions:
3.3.1 Internal and external pressure püK, puK Container diameter: d≤4m
3.3.2 Traffic loads on the roof Ratio: h/d ≤ 6
3.3.3 Wind loads Minimum thicknesses: s = 4 mm
3.3.4 Radially symmetrical equivalent load as a result of wind
pressure Responsibilities with regard to specific fields of law (for example
3.3.5 Negative pressure due to wind suction building law, water law, Occupational Health and Safety Law,
3.3.6 Assembly loads etc.) must be taken into account.
3.4 Temperature
4 Stability analysis
4.1 Strength analysis 2 Calculation variables
4.1.1 Effects
4.1.2 Superposition of the effects a mm Thickness of the weld seam
4.1.3 Casing A1 – Reduction factor for the influence of the
4.1.4 Base specific strength (corresponds to A4 according
4.1.5 Base/casing welded joint to guideline DVS 2205-1)
4.1.6 Conical roof A2 – Reduction factor for the liquid during strength
4.1.7 Connecting pieces analyses
4.1.8 Anchors A2I – Reduction factor for the liquid for stability and
4.1.9 Lifting lugs deformation analysis
4.2 Stability analysis
AB m2 Area of the base
4.2.1 Superposition of the effects
4.2.2 Casing ABü mm2 Area of the scaffolding
4.2.3 Axial stability next to the cylinder connecting pieces AD m2 Area of the roof
4.2.4 Conical roof Aj m2 Area exposed to wind (partial area)
5 Appendix AZ m2 Casing area of the cylinder
5.1 Explanations
5.2 References bPr mm Width of the lug
5.3 Temperature and time-dependent Young's modulus for bÖ mm Width of the lifting lug
stability calculations and deformation calculations C – C1 ⋅ C2
5.4 Structural details cf – Aerodynamic force factor
C1 – Stress increase factor
1 Scope C2 – Material-specific form factor
C* – Factor for the circular cylinder which is
The following structure and calculation rules apply to vertical, subjected to external load
cylindrical, factory-fabricated flat base tanks made of d mm Nominal internal diameter
thermoplastics, in particular dA mm Connecting piece outside diameter
– Polyvinyl chloride (PVC), dL mm Hole diameter in the lifting lug
– Polypropylene (PP),
dmax mm Largest cylinder diameter
– Polyethylene (PE),
– Polyvinylidene fluoride (PVDF). dmin mm Smallest cylinder diameter
Orders to: DVS Media GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49(0)211/1591- 0, Fax: + 49(0)211/1591-150
208
dSch mm Diameter of the shackle pstat,i N/mm² Overpressure per bottom edge gradation due
N/mm2 Young's modulus during short-term loading for to the filling medium
ET°C
K pu N/mm² Constant external pressure (and/or internal
T°C
N/mm2 Young's modulus for short-term loading at negative pressure)
E K20°C puK N/mm² Short-term external pressure (and/or internal
20°C
negative pressure)
E20°C N/mm2 Young's modulus for long-term loading at 20°C
L pü N/mm² Constant internal pressure
fs – Long-term weld strength reduction factor püK N/mm² Short-term internal pressure
fsD – Long-term weld strength reduction factor for pus N/mm² Negative pressure due to wind suction
roof pV N/mm² Traffic load (surface load)
fz – Short-term weld strength reduction factor pw,d N/mm² Auxiliary quantity
fzD – Short-term weld strength reduction factor for p1 N/mm² Auxiliary quantity
roof pσ,d N/mm² Auxiliary quantity
g m/s 2 Acceleration due to gravity (9.81 m/s2) PV N Traffic load (concentrated load)
gA N/mm² Equivalent surface load for connecting pieces, q kN/m² Velocity pressure
including on roof
qj kN/m² Velocity pressure on partial area Aj
gD N/mm² Surface-related weight of the roof
qLö kN/m² Velocity pressure at the ventilation line
GA N Dead load as additional weight on the roof opening
GB N Dead load of the base qmax kN/m² Larger velocity pressure affecting the tank
GD N Dead load of the roof r mm Radius of the cylinder
GE N Total dead load
Rd N/mm² Rated value of the stress capacity
GF kN Load of the filling material
s mm Minimum thickness
GS N Snow load
sa mm Actual thickness of the basic component
GZ N Dead load of the cylinder
sB mm Wall thickness of the base
h mm Height of tank
sD mm Thickness of the roof
hF mm Fill height
Sd N/mm² Rated value of the stress
hF,i mm Fill height of section i
sÖ mm Wall thickness of the lifting lug
hRF mm Remaining fill height
sZ mm Wall thickness of the cylinder
hZ,i mm Height of section i
sZF mm Wall thickness of the bottom section
hZ mm Cylindrical height
hZF mm Height of the bottom section s*ZF mm Minimum thickness of the lowest section
based on calculations
kf – Concentration factor according to [4]
sZm mm Average wall thickness of the cylinder
exist N/mm² Stress in the case of short-term effect
KK sZ,1 mm Wall thickness of the top section
exist N/mm² Rated value of a short-term stress sZ,i mm Wall thickness of section i
K K,d
so mm Wall thickness of the upper section of the
exist N/mm² Rated value of a long-term stress
K L,d substitute cylinder
exist N/mm² Rated value of a stress in the case of medium TA °C Average ambient temperature (according to
K M,d
effective duration Miner, see DVD 2205-1)
K *K N/mm² Creep rupture strength for 10-1 hours TAK °C Maximum ambient temperature
TD °C Average roof temperature
K* N/mm² Rated value of creep rupture strength for 10-1
K,d Design °C Maximum calculation temperature for conical
hours T KD
roofs
K* L,d
N/mm² Rated value of the creep rupture strength for
the mathematical service life at the average TDK °C Highest roof temperature with indoor
effective temperature installation
K *M,d N/mm² Rated value of the creep rupture strength for T*D °C Average roof temperature for summer load
medium effective duration (e.g. with snow for 3 case
months at 0°C) TM °C Average media temperature (according to
lo mm Length of the upper section of the substitute Miner, see DVS 2205-1)
cylinder TMK °C Maximum media temperature
MW Nm Bending moment in the event of wind load TZ °C Average temperature of the cylinder wall
nla – Number of load introduction points TZK °C Highest temperature of the cylinder wall
nZ,d N/mm Rated value of the membrane tensile force at u % Permissible ovality
the lower edge of the cylinder V m³ Filling volume
exist N/mm² Short-term rated value of the influences on the vA – Weakness value
pD
K, d roof according to Table 4/5.
wgr mm Permitted lifting distance
exist N/mm² Rated value of the influences on the roof
pD Wj kN Wind load
L,M,d according to Tables 4 and 5
z – Number of anchors
peu N/mm² Radially symmetrical equivalent load as a
α – Auxiliary quantity
result of wind pressure
pkM,d N/mm² Rated value of the critical casing buckling αD Degree Inclination angle of roof
pressure s
pmax N/mm² Auxiliary quantity β – Factor
pS N/mm² Snow load on the roof δ – Factor
pstat N/mm² Overpressure on the tank base due to the δB – Factor for base calculation
filling medium δw – Factor
209
δσ – Factor
ε % Acceptable extreme fibre expansion
γF Partial safety factor of the action/stress
γM Partial safety factor of the resistance/stress
capacity
ηA,i – Utilisation of the axial stability in section i
ηM – Utilization of the casing compressive stability
κ Degree Angle of roof to solder
s
ρ g/cm³ Material density (γ = ρ ⋅ g)
ρF g/cm³ Density of liquid
σd
exist N/mm² Rated value of the decisive compressive
stress in the conical roof
σk,d N/mm² Rated value of the critical buckling stress in
the conical roof
exist
σ i,d N/mm² Rated value of the decisive axial compressive
stress in section i
σk,i,d N/mm² Rated value of the critical axial buckling stress
in section i
σV N/mm² Equivalent compressive stress in cylinder from
traffic load
Figure 2. Open flat base tank with graduated thickness.
σW N/mm² Membrane compressive stress from the wind
load
3 Stresses
3.1 Constant loads

Depending on application, tanks are designed for a mathematical
operating time of up to 25 years (2 ⋅ 105 hours).
The mathematical fill height hF is determined by the operating
conditions present.
Figure 1. Open flat base tank with non-graduated thickness.
Figure 3. Flat base tank with conical roof and non-graduated thickness.
210
The exceptional snow load on the North German Plain must be
taken into account.

The roofs can heat up significantly in summer. For installation in
Germany, a wall temperature of T Design
KD = 50 °C must be taken
into consideration.
3.3 Short-term loads

The effective duration of short-term loads is defined as 10-1
hours.
Pressure surges that may occur during filling procedures must be
prevented by adopting appropriate measures.
3.3.1 Internal and external pressure püK, puK

Where no higher pressures can occur due to the operating
method, the minimum pressures stated in Section 1 must be
taken into consideration. The definition of püK gives püK ≥ pü (see
Figure 5). The same applies to puK.
Figure 4. Flat base tank with conical roof and graduated thickness.
3.1.1 Total dead load GE

GE = GD + GZ + GB+ GA N (1)
Dead load of the roof GD
GD= AD ⋅ sD ⋅ ρ ⋅ g N (2) Figure 5. Definition of püK.
Dead load of the cylinder GZ
3.3.2 Traffic loads on the roof
GZ = AZ ⋅ sZ ⋅ ρ ⋅ g N (3)
The roofs must not be accessed without measures to distribute the
Dead load of the base GB load. Appropriate precautions must be taken for assembly and
inspection work.
GB = AB ⋅ sB ⋅ ρ ⋅ g N (4)
GA is an additional weight (e.g. from scaffolding), that applies 3.3.3 Wind loads
axial load introduction units, distributed equidistantly, to the
cylinder over nla. The load bearing capacity of scaffolding must be The wind loads Wj should be calculated as follows:
demonstrated separately. Wj = c f · q · A j kN (6)
3.1.2 Load of the filling material GF The symbols have the following meanings:
GF = V ⋅ ρF ⋅ g kN (5) Wj Wind load of the partial area Aj
3.1.3 Internal and external pressure pü, pu cf Aerodynamic force factor

Higher pressures than those stated in the range must be taken q Velocity pressure
into consideration in the height specified by the operator.
Aj Associated exposed area in m² (for the tank: Diameter times
If safety fittings such as overfill prevention devices or ventilation total height hG including roof)
systems are connected and these result in higher pressures,
these pressures must be taken into account. These pressures must The aerodynamic force factor does not need to be calculated
not take effect when the tank is completely empty, as otherwise precisely if the following force factors are applied:
the base will be at risk or the tank will rise up.
Tank cf = 0.8 circular cylinder and roof; this takes all
3.2 Medium-term loads connecting pieces and row formations into
account
The effective duration is 3 months.
Scaffolding cf = 1.2 Scaffolding and platforms with 40% visible
3.2.1 Snow load GS area
The snow load according to DIN EN 1991-1-3/NA must be Ladder cf = 1.6 Ladders with 20% of the visible area
calculated cumulatively over the mathematical service life at a
wall temperature of 0°C for the roof. The mathematical snow load Fittings cf = 1.2
is calculated from the shape coefficient μ and the characteristic
The velocity pressure q is dependent on the wind zone, the terrain
value of the snow load sk according to the map of snow load
category, the height of the terrain above sea level and the height of
zones and the height above sea level.
the tank above the terrain according to DIN EN 1991-1-4/NA.
For conical and flat roofs, μ = 0.8 can be used as the shape Up to a height of 25 m above ground, the simplified assumptions
coefficient. of paragraph NA.3.3.2 can be used for calculations.
211
The stress resulting from the wind moment MW may be simplified In the case of outdoor installation, the wall temperature of the roof
and calculated as follows should be calculated as at least T KD Design
= 50°C due to solar
3 radiation. A reduced ambient temperature TAK - 5°C applies to
4 ⋅ M W,x ⋅ 10
σ W,i = ----------------------------------- N/mm2 (7) stability analyses in the cylinder for outdoor installation (wind effect).
2
π ⋅ d ⋅ s Z,i
Mw,x at a height x above the tank base can be calculated using

an equivalent clamped rod.
2
( hG – x )
- + c f2 ⋅ q ⋅  ( A j ⋅ a j )
M W, x = c f1 ⋅ q ⋅ d ⋅ ----------------------- Nm (8)
2
whereby aj is the lever arm of the area exposed to wind Aj of the
structures and fittings in relation to the height x.
3.3.4 Radially symmetrical equivalent load as a result of

wind pressure
The pressure load generated due to the wind blowing on the
cylindrical casing is determined using the equivalent load peu.
peu = δ ⋅ qmax ⋅ 10-3 N/mm² (9)
The symbols have the following meanings:
 r r 
δ = 0.46 ⋅  1 + 0.1 ⋅ C * ⋅ ------ ⋅ ---------- ≤ 0.6 (10)
 h Z s Zm
C* = 1.0 for the closed tank

without tray collector with tray collector
C* = 0.6 for the open tank
TD = (TM+TA)/2 TD = (TM+TA)/2
 ( hZ,i ⋅ s Z,i ) TZ = (TM+TA)/2 TZ = (3 · TM+TA)/4
s Zm = --------------------------------- (11)
hZ
The same applies to TDK and TZK with TMK and TAK.
3.3.5 Negative pressure due to wind suction Figure 6. Definition of the effective temperatures.
In the case of ventilated tanks, an internal negative pressure is 4 Stability analyses

generated due to the suction effect.
The stability analyses are carried out according to the partial
pus = 0.6 ⋅ qmax ⋅ 10-3 N/mm² (12)
safety factor concept. The following applies:
In the case of ventilation through a pipeline leading to the Sd
outside, the following applies: pus = 0.4 ⋅ q Lö ⋅10-3 N/mm². (12a) ------- ≤ 1 (12b)
Rd
3.3.6 Assembly loads
with Sd rated value of the stress
The tank must be designed for load states that arise during Rd Rated value of the stress capacity
transport and assembly. When doing so, 1.5 x mounting loads Here, the characteristic forces and/or loads are multiplied by the
(impact factor) are used for calculation. γF1 is applied as a partial partial safety factors γF as per Table 1.
safety factor. The short-term weld strength reduction factor must
be taken into account according to DVS 2205-1. Table 1. Partial safety factors for forces.
Force Partial safety factor

3.4 Temperature
Intrinsic weight, filling, assembly γF1 = 1.35
The effective wall temperature is decisive when dimensioning
components. In the case of long-term forces, parts in contact with Pressures, wind, snow γF2 = 1.5
liquid must be analysed with the average liquid temperature TM Load-reducing intrinsic weight γF3 = 0.9
and, in the case of short-term forces, with the highest liquid
temperature TMK. The average temperature is the temperature The rated value of the available stress results from γFtimes the
that, according to Miner, causes the same damage to the characteristic value of the available stress in the component.
material as the changing temperatures during actual operation
exist exist
(e.g. according to Miner, 10% of the time at 30°C and 90% at K K,d = γ F ⋅ K K (12c)
20°C gives TM = 26.3°C; TMK = 30°C). A simplified calculation
using the average of the two neighbouring air temperatures can The characteristic resistances and/or the stress capacities are
be performed for non-wetted parts. The liquid temperature is divided by the partial safety factor γM ≥ 1.31).
used as the air temperature within the tank. In the case of For example, the rate value of the short-term strength K *K,d results
ambient temperature, a distinction is made based on the from the characteristic short-term strength value K *K divided by γM
installation location and effective duration. The following according to the rupture strength diagrams of DVS 2205-1.
minimum values apply for installation in Germany:
K *K
Minimum values Short-term Long-term *
K K,d = ---------- (12d)
γM
Indoor installation TAK = 20°C TA = 20°C
Outdoor installation TAK = 35°C TA = 20°C
1) The following applies to DIBt-approved materials in Germany: γM = 1.3.
212
The rated factors for stress capacity must be divided by the K K,dexist
reduction factors A1 and A2 and multiplied by the weld strength -------------- ≤ 1 (15)
reduction factor for analyses in the seam. As it is shorter to K*K,d
depict, however, the rated values for the existing stress in the
following section are multiplied by the reduction factors A1 and A2 exist exist A 1 ⋅ A 2
where: K K,d = σ K,d ⋅ ------------------ N/mm2 (15a)
and divided by the weld strength reduction factor, which gives the fz
same result.
and
4.1 Strength analyses * = Rated value of the creep rupture strength for 10-1
K K,d
hours at the temperature associated with this load
4.1.1 Effects combination.
Loads due to connecting pieces and pipelines that are connected The less favourable of the two analyses is always decisive for
are not covered by this calculation and must be taken into dimensioning of the components.
account separately by means of structural measures (e.g.
buffers). Note:
The most unfavourable combination of all the effects must always For the strength analysis of the roof, it must be established
be sought for each component. Two cases must be examined for whether taking the snow load into account leads to a more
the effects of wind and snow: unfavourable result, as although the total load is increased, the
creep rupture strength also rises due to the effective wall
1. Full snow load
temperature of 0°C.
2. 0.7 of the snow load + full wind load
Short-term load cases do not need to be combined with each 4.1.3 Casing
other. The height of the bottom section hZF must be at least
1.4 ⋅ d ⋅ s ZF . In the case of graduated tanks, a maximum wall
4.1.2 Superposition of the effects thickness ratio for neighbouring sections of 3 is permitted without
further analysis. If there are thickness inconsistencies with a wall
A distinction must be made between three load categories
thickness ratio greater than 2, then the casing seam formation
according to the effective duration:
according to DVS 2205-3 Figure 2.2 a), 2.2 c) or 2.2 c1) must be
– Short-term loads (K) used.
e. g. puK, püK, pus, peu, wind
Note: In the case of thickness inconsistencies above 2, clearly
– Effects of medium effective duration (M) identifiable projections occur at the lower edge of the thinner
e.g. snow ps or summer temperatures section. These may worry operators, but they do not constitute a
– Long-term loads (L) hazard.
e.g. intrinsic weight, liquid load, pu, pü
In the event that, during the mathematical service life of the tank, 4.1.3.1 Analysis in circumferential direction
filling is not constant with regard to filling height and temperature,
For each section i, an analysis must be carried out to check that
a representative equivalent load can be calculated for such
the ring tensile load from filling and positive pressures can be
intermittent loads using Miner's rule. On the other hand, use of
withstood on its lower edge. According to Section 4.1.2, the
Miner's rule is not very practicable for superposition of the loads
double analysis must be carried out with
from the three load categories.
For this reason, a double analysis must always be carried out. exist ( γ F1 ⋅ p stat,i + γ F2 ⋅ p ü ) ⋅ d A 1 ⋅ A 2
K L,d = ----------------------------------------------------------------- ⋅ ------------------ N/mm2 (16)
2 ⋅ s Z,i fs
1. It must be shown that the stress from long-term loads
superposed with the effects of medium effective duration, but
A1 with effective wall temperature TM
without short-term loads, does not exceed the creep rupture
strength. and
exist exist
K L,d
--------------------
K M,d
-≤1
+ ---------------------- exist ( γ F1 ⋅ p stat,i + γ F2 ⋅ p üK ) ⋅ d A 1 ⋅ A 2
(13) K K,d = -------------------------------------------------------------------- ⋅ ------------------ N/mm2 (17)
K*L,d K*M,d 2 ⋅ s Z,i fz
where: A1 with effective wall temperature TMK
exist exist A1 ⋅ A2 where:
K L,M,d = σ L,M,d ⋅ ------------------ N/mm2 (14)
fs –6
p stat,i = ρ F ⋅ g ⋅ h F,i ⋅ 10 N/mm2 (18)
and
whereby hF,i denotes the height of the liquid level above the
exist lower edge of section i.
σ L,M,d = Rated value of the existing stresses
K*L,d = Rated value of the creep rupture strength for the Stresses from effects of medium effective duration do not arise in
mathematical service life at the average effective this analysis
temperature exist
(K M,d = 0) .
K*M,d = Rated value of the creep rupture strength for
medium effective duration (e.g. with snow for 3 In the case of cylinders made from plates, the weld strength
months at 0°C for the roof) reduction factor of the casing seam fs or fz must be taken into
account. Heated plate welding is preferred, based on the current
2. It must be shown that at the end of the mathematical service
state of the art. fs = 1 and fz = 1 applies for wound tanks.
life, the stress from short-term loads superposed with the other
effects does not exceed the residual strength of the material. The residual stresses from the panels bending at room
Here, the creep rupture strength for 10-1 hours is set as the temperature can be ignored if the extreme fibre expansions
residual strength. ε = s/d ξ 100 [%] in line with Table 2 are not exceeded.
213
Table 2. Acceptable extreme fibre expansions. Note: The values for PE-HD may be used for PE 63, PE
80 and PE 100.
Material Extreme fibre expansion ε
There is no need for an analysis of the weld stresses in the seam
PE-HD 1.00 if the conditions in Section 4.1.5 are met.
PP-H 0.50 The stress increase factor C1 = 1.2 assumes that the base is not
PP-B 0.75 thicker than the thickness of the bottom section (sB ≤ sZF) and no
base plate distance ü is greater than those shown in Figure 11.
PP-R 1.00
PVDF 0.50 4.1.4 Base
PVC-U 0.20
4.1.4.1 Analysis for the filling loading case
PVC-C 0.10
If the base and cylinder are connected with fillet welds (Fig. 11 in
Section 5.4), the required base thickness may be determined as
Note: The value for PE-HD may be used for PE 63, PE 80
follows
and PE 100.
δ B ⋅ s *ZF ≤ s B ≤ s ZF (21a)
4.1.3.2 Analysis in longitudinal direction
with sZF actual thickness
The largest tensile stresses must be secured. Only 90% of the
δB in line with Figure 7 and
constant compressive stresses relieving the tensile stresses may
be taken into consideration here. s *ZF = max ( s ZF,L * )
* , s ZF,K mm (22)
For analysis of the stress in the longitudinal direction, only the
lowest section at the transition to the base needs to be examined. d d
where: s *ZF,L= C ⋅ ( γ F1 ⋅ p stat + γ F2 ⋅ p ü ) ⋅ --- + γ F2 ⋅ p ü ⋅ ---
Stresses from the bending disturbance moment occur here and 2 4
must be superposed with the longitudinal stresses from the
γ F3 ⋅ ( G E – G B ) A 1 ⋅ A 2
intrinsic weight, pressures and wind. – ---------------------------------------- ⋅ ------------------ mm (22a)
π⋅d K L,d*
The double analysis must be carried out according to Section
4.1.2 with A1 and K*L,d with effective wall temperature TM
exist d d
K L,d = C ⋅ ( γ F1 ⋅ p stat + γ F2 ⋅ p ü ) ⋅ --- + γ F2 ⋅ p ü ⋅ --- d d
2 4 and s *ZF,K= C ⋅ ( γ F1 ⋅ p stat + γ F2 ⋅ p üK ) ⋅ --- + γ F2 ⋅ p üK ⋅ ---
2 4
γ F3 ⋅ ( G E – G B ) A 1 ⋅ A 2
– ---------------------------------------- ⋅ ------------------ N/mm2 (19) γ F3 ⋅ ( G E – G B ) A 1 ⋅ A 2
π⋅d s ZF – ---------------------------------------- ⋅ ------------------ mm (22b)
π⋅d K K,d*
A1 with effective wall temperature TM
* with effective wall temperature TMK
A1 and K K,d
–6
with p stat = ρ F ⋅ g ⋅ h F ⋅ 10 N/mm (20)
The base of the tank must be fully bedded on a level, rigid
exist
supporting plate.
K M,d = 0
Note: With other structural forms, e.g. inclined or conical bases,
and the base, its support and the cylinder restraining torque must be
analysed.
exist d d
K K,d = C ⋅ ( γ F1 ⋅ p stat + γ F2 ⋅ p ü ) ⋅ --- + γ F2 ⋅ p ü ⋅ ---
2 4
3
γ F2 ⋅ 4 ⋅ M W ⋅ 10 γ F3 ⋅ ( G E – G B ) A 1 ⋅ A 2
+ --------------------------------------------- – ---------------------------------------- ⋅ ------------------ N/mm2 (21)
π⋅d
2 π⋅d s ZF
A1 with effective wall temperature TMK.
The factor C for the welded transition of the base-casing
connection is the product of the stress increase factor C1= 1.2
and a material-specific form factor C2 as per Table 3 3.
Table 3. Material-specific form factor C2 and factor C for

thermoplastics.
Material C2 C = C 1 ⋅ C2
PE-HD 1.00 1.20
PP-H (type 1) 1.17 1.40 Figure 7. Diagram for determining the base thickness, derived for PE-HD
PP-B (type 2) 1.00 1.20 (for C > 1.2, this diagram is on the safe side).
PP-R (type 3) 1.00 1.20 4.1.4.2 Analysis of unanchored tank with overpressure
PVC-NI (normal impact 1.25 1.50 If an overpressure is applied to an unanchored tank (e.g. a tank
resistance) in a tray collector), the base of the tank curves outwards, which
PVC-RI (raised impact 1.08 1.30 leads to the entire tank rising up and to bending stresses in the
resistance) base. When calculating this rise, a filling remainder to be
PVC-HI (high impact 1.00 1.20 guaranteed is taken into account with the fill height hRF.
resistance) Short and long-term pressures are dealt with in the same
PVC-C 1.33 1.60 manner, as it can be postulated that the state of long-term
pressure and remaining fill height will only be present for a limited
PVDF 1.17 1.40 period of time. The effective pressure is therefore
214
p1 = pük N/mm² (due to pük ≥ pü) (23) If one of these conditions is not met, then a detailed analysis of
the stresses in the seam must be carried out (e.g. FE
In addition to the strength analysis, an analysis regarding limiting
calculation).
the lifting distance under nominal loads to wgr = 10 mm is carried
out. In the case of single-wall tanks with a volume of 1000 l with
thicknesses up to 10 mm, this also applies for long-term weld
Strength analysis strength reduction factors fs ≥ 0.4.
–6
p B,k – p 1 – ρ ⋅ g ⋅ s B ⋅ 10 4.1.6 Conical roof
h RF,σ = ------------------------------------------------------------------- mm (24)
–6
ρ F ⋅ g ⋅ 10 The inclination angle of the roof must not be less than αD = 15°
(κ = 75°). If the inclination of the conical roof is between 15 and
p 1 ⋅ d G E – G B
1.5 ⋅  -------------
20 degrees, the following minimum thickness sD must be
- – ----------------------
 4 π⋅d  observed:
with p B,k = ------------------------------------------------------------- N/mm2 (24a)
lB δD
s D ≥ --------------- ⋅ d (26a)
2
K *K + K *M 1,000
sB 1
with l B = --------------------- ⋅ --------------------------- ⋅ ----------------------------- mm (24b) where:
δ σ ⋅ n Z,d 2 A1 ⋅ A2 ⋅ γM
A1 with effective wall temperature TMK Material δD
p1 ⋅ d GE – GB PE 5.5
with n Z,d = γ F2 ⋅ -------------- – γ F3 ⋅ ---------------------- N/mm (24c) PP-H 4.7
4 π⋅d
PP-B 5.1
and δ σ = 1.5 für Innenaufstellung
δ σ = 2.12 für Außenaufstellung PP-R 5.5
PVC 3.3
Limiting the lifting distance
PVDF 4.1
–6
p B – p 1 – 0.9 ⋅ ρ ⋅ g ⋅ s B ⋅ 10
h RF,w = ---------------------------------------------------------------------------- mm (25) Note: δD was determined for 1 kN/m² at 20 °C, in the short-term.
–6
0.9 ⋅ ρ F ⋅ g ⋅ 10
4.1.6.1 Inward loads
1.5 ⋅ n
with p B = ------------------Z- N/mm2 (25a) The definitive combination of intrinsic weight gD, negative
lB
pressures pu, puK, snow load ps and the negative pressure from
ToC wind pus must be investigated, whereby pu, puK and pus must not
wgr ⋅ 0.75 ⋅ EK be combined with one another and, when wind is used, the snow
with l B = s B ⋅ 3 ----------------------------------------------- mm (25b)
δ w ⋅ A 2l ⋅ n Z load may be reduced to 70%.
The ring tensile load at the edge of the roof is analysed.
p1 ⋅ d GE – GB
with n Z = -------------- – 0.9 ⋅ ---------------------- N/mm (25c) The double analysis must be carried out according to Section
4 π⋅d
4.1.2 with
and δ w = 0.56 für Innenaufstellung
 A ( α ) ⋅ ln  s--- + B ( α )
δ w = 1.12 für Außenaufstellung exist exist   r  A1 ⋅ A2
K L,d = pD L,d ⋅ e ⋅ ------------------ N/mm2 (27)
f sD
The definitive remaining fill height is determined from
h RF = max ( h RF,σ , h RF,w ) mm (26)  A ( α ) ⋅ ln  s--- + B ( α )
exist exist   r  A1 ⋅ A2
K M,d = pD M,d ⋅ e ⋅ ------------------ N/mm2 (28)
Note: f sD
and
In the strength analysis, ( K *K + K *M ) /2 is used for the
 A ( α ) ⋅ ln  s--- + B ( α )
calculation, whereby a loading period of approximately 12 hours exist exist   r  A1 ⋅ A2
is taken into consideration. K K,d = pD K,d ⋅ e ⋅ ------------------ N/mm2 (29)
f zD
ToC
When analysing the limitation of the lifting distance, 0.75 ⋅ EK where: A ( α ) = – 0.000103 ⋅ α D + 0.007825 ⋅ α D – 1.7771
2
ToC 2
is used for the calculation rather than E K (see Section 5.3), B ( α ) = – 0.000433 ⋅ α D + 0.008115 ⋅ α D – 0.1870
as a higher level of stress and therefore a lower modulus must be
The combinations from Table 4 should be examined. A1 must be
taken into account for this deformation calculation than for
determined on the basis of the temperatures shown in Table 4.
stability problems.
For the summer load case, an effective average wall temperature
determined according to Miner
4.1.4.3 Analysis for internal negative pressure
An analysis of the base for internal negative pressure may be T D + T Design KD
TD* = -------------------------------- oC (30)
dispensed with if a residual fill remains in the tank, whereby the 2
remaining fill height must be specified so that the total of γF3x the
fill pressure and γF3x the dead load of the base is greater than is used, which takes TDesign
KD into account over 3 months (TD in
γF2x the negative pressure. line with Fig. 6).
–6
ρ ⋅ g ⋅ s D ⋅ 10
4.1.5 Base/casing welded joint g D = --------------------------------------- + g A N/mm2 (31)
sin κ
There is no need for an explicit analysis of the weld stresses if
the following conditions are met gA Equivalent-surface load for connecting pieces, etc.
– Weld thickness a ≥ 0.7 ⋅ sB The weld strength reduction factor is based on the quality of the
– Long-term-weld strength reduction factor fs ≥ 0.6 (according to longitudinal weld of the conical roof.
DVS 2203-4)
215
4.1.6.2 Outward loads where dA outer diameter of the connecting piece

d cylinder diameter
The double analysis must be carried out according to Section sD required thickness of the roof
4.1.2 with
 C ( α ) ⋅ ln  s--- + D ( α )
For the analysis of the connecting pieces in the roof, only the
exist exist   r  largest connecting point located close to the edge of the roof
K L,d = pD L,d ⋅ e ⋅ A 1 ⋅ A 2 N/mm2 (32) should be analysed. Here, the rated values for the existing
stresses-
and
exist
 C ( α ) ⋅ ln  s--- + D ( α ) K L,M,K,d for inward and also outward
exist   r 
K K,d = pDexist
K,d ⋅ e ⋅ A1 ⋅ A2 N/mm2 (33) loads may be determined from the following equation.
2
where: C ( α ) = 0.000013 ⋅ α D – 0.00097 ⋅ α D – 1.4054 exist
pD
d A1 ⋅ A2
L,M,K,d
- ⋅ ------ ⋅ ------------------
K L,M,K,d = --------------------- (35)
2
2 ⋅ cos κ s D vA
D ( α ) = 0.000265 ⋅ αD – 0.04574 ⋅ α D + 1.5622
As the weld seam in the roof runs parallel to the stress, there is with p D effects according to Section 4.1.6.1 / 4.1.6.2
L,M,K,d
no need to consider a weld strength reduction factor.
Connecting pieces in the roof should be designed as full-width
The combinations from Table 5 should be examined. connecting pieces.
A1 must be determined on the basis of the temperatures shown in
Table 5. 4.1.7.2 Connecting pieces in the cylinder
4.1.7 Connecting pieces For connecting pieces in the cylinder, the analysis of the ring
In general, the connecting pieces must be fitted in the roof. The tensile load must be carried out taking into account the height of
outerdiameter of a connecting piece must not be greater than 0.4 ⋅ d. the connecting piece, similarly to Section 4.1.3.1.
The distance between the centres of the connecting pieces and the
edges, section limits or weld seams in the basic component must be The weakness value can be calculated with one of the following
at least dA/2 + 100 mm. However, the distance from the centres of two equations:
the connecting pieces to the base, and to a neighbouring sections
with a lesser thicknesses, must be at least dA. 0.75
vA1 = ----------------------------------------------------- (35a)
dA
It must be verified that the increased stresses on the basic 1 + -------------------------------------------
component next to the opening due to the stress concentration 2 ⋅ ( d + sZ ) ⋅ sZ
can be absorbed.
The stress in the undisturbed basic component is increased by Support pipe must comply with SDR11 or be thicker
dividing it by weakness factor vA.
or
The flange and blank flange cover must be dimensioned with a
view to stability and tightness, according to Guideline DVS 2205-4. sR
0.75 ⋅ ------
sZ
4.1.7.1 Connecting pieces in the conical roof vA2 = --------------------------------------------------------
- (35b)
sR dA
------ + -------------------------------------------
The weakness value is calculated as follows: sZ 2 ⋅ ( d + s ) ⋅ s
Z Z
0.75
vA = ------------------------------------------------------ (34) the thickness of the support pipe may be selected as required,
dA sR
1 + -------------------------------------------- whereby the condition ------ ≥ 0.6 must be observed
2 ⋅ ( d + sD ) ⋅ sD sZ
Table 4. Load case combinations for calculation of the roof for inward loads.
Installation Combination Analysis according to (13) Analysis according to (15)

location Temp.
exist exist exist
pD Temp. pD Temp. pD
L,d M,d K,d
internal γF1 · gD + γF2 · pu TD 0 – max (γF1 · gD + γF2 · puK, γF1 · gD + γF2 · pus) TDK
external Winter γF1 · gD + γF2 · pu TD γF2 · pS 0°C max (γF1 · gD + γF2 · (ps + puK), γF1 · gD + γF2 · (0.7 · 0°C
pS +pus))
external Summer γF1 · gD + γF2 · pu *
TD 0 – max (γF1 · gD + γF2 · puK, γF1 · gD + γF2 · pus) TDesign
KD
For the higher snow load on the North German Plain, the exceptional load combination γF4 ⋅ (gD + 2.3 ⋅ pS + puK) must also be verified in
the analysis according to (15) and γF4 ⋅ 2.3 ⋅ pS in the analysis according to (13), with a wall temperature of 0°C for the loading period
of at least one week.
Table 5. Load case combinations for the strength calculation of the roof for outward loads.
Installation Combination Analysis according to (13) Analysis according to (15)

location
exist exist exist Temp.
pD Temp. pD Temp. pD
L,d M,d K,d
internal γF2 · pü – γF3 · gD TD 0 – γF2 · püK – γF3 · gD TDK

external Summer γF2 · pü – γF3 · gD *
TD 0 – γF2 · püK – γF3 · gD Design
T KD
216
where dA outer diameter of the connecting piece The required thickness (sÖ) of the lifting lugs results from the
d cylinder diameter bearing stress analysis
sZ required thickness of the cylinder GE
sR thickness of support pipe 1.5 ⋅ γ F1 ⋅ -------- ⋅ A 1
2
The analysis of the ring tensile load for the cylinder must be s Ö = --------------------------------------------- mm (41)
d Sch ⋅ 2 ⋅ K* K,d
carried out at the lower edge of the connecting piece, according
to Section 4.1.3.1. Here, the weld factor may also be omitted The maximum of the two following analyses is decisive for the
from equations 16 and 17 for tanks manufactured from plates, as width of the lifting lugs (bÖ).
connecting pieces may not be located in the disturbance area of
bÖ = max (bÖ,1, bÖ,2)
the longitudinal weld in such cases; a minimum distance of dA
between the centre of the connecting piece and the longitudinal Shear stress analysis of the horizontal butt weld when raising the
weld must be observed. horizontal tank
The structural design must be executed in line with Figure 8, GE A1
Section 5.4 (full-width connecting pieces). 1.5 ⋅ γ F1 ⋅ -------- ⋅ ------
4 fz
b Ö,1 = ---------------------------------------------- mm (42)
4.1.8 Anchors K *K,d
0.7 ⋅ s Z,1 ⋅ -------------- -
If anchors are required, at least 4 anchors should be provided 2
(z ≥ 4). Eye bar
When carrying out anchoring analysis, a distinction must be GE
made between 3 cases: 1.5 ⋅ γ F1 ⋅ -------- ⋅ A 1
2 7
b Ö,2 = --------------------------------------------- + --- ⋅ d L mm (43)
Case 1: short-term positive pressure with liquid temperature TMK s ⋅ K* Ö K,d 3
2
γ F2 ⋅ p üK ⋅ π ⋅ d 1 4.2 Stability analyses
----------------------------------------- – γ F3 ⋅ ( G E – G B ) ⋅ ---
4 z
-≤1
---------------------------------------------------------------------------------------------------- (36) 4.2.1 Superposition of the effects
K *K,d
( b Pr + s B ) ⋅ s B ⋅ --------------- Definitive Young's moduli are required for the stability calculations.
2 ⋅ A1 The buckling of shells is a sudden process, which is essentially
Case 2: long-term positive pressure with liquid temperature TM dependent on the imperfections, i. e. on the extent of the pre-
stretching. The extent of the pre-stretching increases as the
2
γ F2 ⋅ p ü ⋅ π ⋅ d 1 loading period increases due to the creep behaviour of the
-------------------------------------- – γ F3 ⋅ ( G E – G B ) ⋅ --- material. On the other hand, the elastic resistance during warpage
4 z
-≤1
------------------------------------------------------------------------------------------------- (37) is primarily determined by the short-term Young's modulus at the
K *L,d current temperature. The critical buckling stress σk is therefore
( b Pr + s B ) ⋅ s B ⋅ -------------- calculated using the temperature-dependent modulus E TK C.
o
2 ⋅ A1
The temperature/time-dependent Young's moduli for the key
max ( TMK , TAK ) + ( TAK – 5 ) thermoplastics are given in Tables 2 and 3 of Guideline DVS
Case 3: Wind load with --------------------------------------------------------------------------- – 10 in °C
2 2205-1.
2 The most unfavourable load combination must be examined
4 ⋅ γ F2 ⋅ M w 3 γ F2 ⋅ p ü ⋅ π ⋅ d 1 taking the temperature behaviour of the thermoplastics into account.
----------------------------- ⋅ 10 + -------------------------------------- – γ F3 ⋅ ( G E – G B ) ⋅ ---
d 4 z
---------------------------------------------------------------------------------------------------------------------------------------------------- ≤ 1 (38) 4.2.2 Casing
K *K,d
( b Pr + s B ) ⋅ s B ⋅ --------------- For the tank casing, sufficient protection in terms of axial and
2 ⋅ A1 casing compressive stability and in terms of the interaction
The numerator is the lug force to be borne and the denominator between the two must be analysed.
is the acceptable lug force resulting from the shear stress in the The prerequisite is that the ovality of the cylinder is limited in the
seam. Here, half the creep rupture strength is set as the shear following way:
stress.
2 ⋅ ( d max – d min )
The required anchor force (e.g. for the anchor fitting) must be u = -------------------------------------------- ⋅ 100 ≤ 0.5 % (44)
d max + d min
calculated from the maximum lug force (maximum of the three
numerators) taking the lever arms into account.
4.2.2.1 Axial stability
Figure 9 in Section 5.5 shows the design of an anchor.
For each section i, the axial compressive stress from the intrinsic
weight, negative pressures pu, puK, pus snow and wind load
4.1.9 Lifting lugs
present on the lower edge is determined, in the most
One of the possible lifting lug forms is shown in Figure 10 unfavourable combination in each case, and verified with the
(Section 5.4). The prerequisite for the use of these lifting lugs is buckling stress σk,i,d.
that only two lifting lugs are used per tank and that a parallel If the force from GA is not introduced uniformly, but rather
hanger is used. separately via nla points in the cylinder, the equivalent
An analysis of the load introduction in the top section is not compressive force taken as a constant across the area in the
needed as long as the lifting lug is not thicker than 3x the wall cylinder, determined from the equivalent weight GA
thickness of the top section. The hole diameter (dL) must match GA
the diameter of the shackle (dSch). σG = ---------------------------- ⋅ k f N/mm²
A 2 ⋅ π ⋅ r ⋅ sZ
The following applies
(45),
sZ,1 ≤ erf sÖ ≤ 3 ⋅ sZ,1 (39)
must be increased by the concentration factor according to [4].
dSch ≤ dL ≤ 1.1 ⋅ dsch (40)
1.82 r
It must be proven that 1.5x the load (impact factor) can be borne k f = max ----------- ⋅ ------ ,1
n la sZ
at 20° C in the short-term. Here γI = 1.2 must be used, as the
transport of the tank constitutes a risk to persons, irrespective of The width of the load introduction point bla must be selected so that
the later use. the strength is verified (compressive strength = tensile strength).
217
Scaffolding must be loaded with a traffic load of at least pV = with C * = 0.6 for the open tank.
0.001 N/mm² uniformly distributed surface load, but also with a The critical casing pressure of the graduated tank may be
concentrated load of at least PV = 1,500 N at an unfavourable calculated according to DIN EN 1993-1-6 on a three-section
point. The equivalent compressive force from traffic load taken as equivalent cylinder:
a constant in the cylinder is determined from
ToC
max [ A Bü ⋅ p V ,n la ⋅ P V ] EK r s o 2.5
σ V = ------------------------------------------------------------ ⋅ k f p kM,d = 0.67 ⋅ β ⋅ C * ⋅ ----------------- ⋅ ---- ⋅  ----- N/mm2 (52)
2 ⋅ π ⋅ r ⋅ sZ
N/mm² (46) γM lo  r 
The ß values can be found in figures 20a to c of DIN EN 1993-1-
The combinations from Table 6 should be examined to verify the
6.
axial stability.
The stress from the wind moment σW may be divided by 1.2, as 4.2.2.3 Interaction
the buckling stress may be increased by 20% in the case of The interaction of axial and casing compressive stability must be
overall buckling. analysed for each section
The buckling stress may be determined in a simplified manner 1.25 1.25
using the following formula η A,i + η M ≤1 (53)
T C
s Z,i
o When calculating ηA,i for the interaction, the longitudinal stresses
EK
σ k,i,d = α i ⋅ 0.62 ⋅ f α,i ⋅ ----------------
- ⋅ -------- ≤ KK,d
* N/mm2 (47) due to negative pressure must not be taken into consideration, as
γM r their effect is already contained in ηM.
0.70
with α i = ------------------------------------------------------------------
- (48a) 4.2.3 Axial stability next to the cylinder connecting pieces
20 o C
EK exist
-------------------- ⋅ 1 + ----------------------
r
-  The stress σ j,d next to the opening j is calculated using an
20 o C  100 ⋅ s Z,i  equivalent beam with the cross-section values of an open ring,
EL
taking the offset of the line of gravity into consideration. Where an
ei additional roof weight GA is placed on the cylinder, it is not
and f α,i = 1.5 – -------- ≤ 1.0 (48b) necessary to consider the load introduction factor kf, if it is
s Z,i
ensured that the load introduction points are not located above
whereby ei is the eccentricity to the thicker of the two cylinder openings.
neighbouring sections of a graduated cylinder, when this itself is
thicker than the section i under consideration. The critical stress is determined based on equation (47)
The following conditions must be observed for each section i E T°C
K s Z,j
σ k,j,d = α j ⋅ 0.62 ⋅ ------------ ⋅ -------- ≤ K*K,d N/mm² (53a)
A 2l ⋅ σ exist i,d γ r M
η A,i = ------------------------- ≤ 1 (49)
σ k,i,d dA
0.65
with α j = ------------------------------------------------------------------
- for ------------------- ≤ 3.5 (53b)
4.2.2.2 Casing compressive stability 20 o C r ⋅ s Z,j
EK
 r
- ⋅ 1 + -----------------------
------------------- 
The significant negative pressure pexist d from the most 20 o C  100 ⋅ s Z,j 
unfavourable combination of negative pressures is verified with EL
the critical casing pressure p kM,d .
0.45 dA
The following applies: pexist
d = max(pu + peu, pus + peu, puK). α j = ------------------------------------------------------------------
- for ------------------- > 3.5 (53c)
20 o C r ⋅ s Z,j
The following condition must be observed. EK
 r
- ⋅ 1 + -----------------------
------------------- 
A 2l ⋅ p dexist 20 o C  100 ⋅ s Z,j 
EL
η M = ------------------------- ≤ 1 (50)
p kM,d
The following condition must be observed for each opening j
The critical casing pressure of the non-graduated cylinder is
calculated from A 2l ⋅ σ j,d exist
η A,j = ------------------------- ≤ 1 (53d)
ToC σ k,j,d
s Z 2.5 EK
p kM,d = 0.67 ⋅ C * ⋅ ----------------- ⋅ ------ ⋅  ------
r
N/mm2 (51) Note: No analysis of the interaction is required.
γM hZ  r 
with C * = 1.0 for tanks with solid roofs 4.2.4 Conical roof
Table 6. Load combinations for calculating the axial stability of the cylinder.
internal Assembly
without receptacle with receptacle

Season
σ exist
i,d
Wall temperature σ exist
i,d
Wall temperature
Combination 3 ⋅ T
γ F1 ⋅ σ G + γ F2 ⋅ max ( σ pus ,σ puk + σV )
T MK + TAK
as without MK + TAK
--------------------------- -----------------------------------
–
2 receptacle 4
γ F1 ⋅ σ G + γ F2
Combination 3 ⋅ T MK
Summer Winter
T MK
σw ----------- as without -------------------
⋅ max max ( σ pu ,σ pus ) + 0.7 ⋅ σ S + -------- ,σ puk + σS ,σ puk + σV 2 receptacle, 4
external
1,2
but consider
σw wall
max ( T MK , TAK ) + ( TAK – 5 ) shielding for 3 ⋅ max ( T MK , TAK ) + ( TAK – 5 )
γ F1 ⋅ σ G + γ F2 ⋅ max max ( σ pu ,σ pus ) + -------- ,σ puk + σ V ----------------------------------------------------------------------- s -------------------------------------------------------------------------------
1.2 2 w 4
For the higher snow load on the North German Plain, the following exceptional load combination must also be analysed
γF4 ⋅ (σG + σpuK + 2.3 ⋅ σpS + σV) with a wall temperature of TMK/2.
Note: σG also includes the compressive stress from GA, increased by the concentration factor kf.
218
The most unfavourable combination of compressive stresses in a DIN EN National Annex - Nationally determined
circumferential direction at the centre of the conical roof casing 1991-1-6/NA parameters – Eurocode 1: Actions on structures -
line (d/4) Part 1-6: General actions, Actions during
execution
exist p dexist d
σd = -------------------- ⋅ ------ N/mm2 (54) Moulding compounds
4 ⋅ cosκ s D
DIN EN ISO Plastics – Polyethylene (PE) moulding and
is secured with the critical stresses 1872-1 extrusion materials – Part 1: Designation system
and basis for specifications
ToC s D 1.5
EK
- ⋅ sin κ ⋅ cos κ ⋅  ------
DIN EN ISO Plastics – Polyethylene (PE) moulding and
σ k,d = 2.68 ⋅ ---------------- N/mm2 (55)
γM  d 1872-2 extrusion materials – Part 2: Preparation of test
specimens and determination of properties
where: DIN EN ISO Plastics – Polypropylene (PP) moulding and
1873-1 extrusion materials – Part 1: Designation system
A 2l ⋅ σexist d and basis for specifications
η = --------------------------- ≤ 1 (56)
σ k,d DIN EN ISO Plastics – Polypropylene (PP) moulding and
1873-2 extrusion materials – Part 2: Preparation of test
specimens and determination of properties
The combinations from Table 7 should be examined. DIN EN ISO Plastics – Unplasticized poly(vinyl chloride) (PVC-
1163-1 U) moulding and extrusion materials – Part 1:
Designation system and basis for specifications
5 Appendix
DIN EN ISO Plastics – Unplasticized poly(vinyl chloride) (PVC-
5.1 Explanations 1163-2 U) moulding and extrusion materials – Part 2:
Preparation of test specimens and determination
This Guideline was drawn up by the DVS-AG W4.3b (structural of properties
design/apparatus construction) together with the "Plastic tanks
DIN EN ISO Plastics - Fluoropolymer dispersions and
and pipes" ("Calculation" project group) committee of experts.
12086-1 moulding and extrusion materials – Part 1:
In the revision, a distinction was made as to whether tanks are Designation system and basis for specifications
exclusively to be dimensioned according to the loads from the
internal pressure caused by filling material and filling height (this Panels and filler metals
corresponds to the point of view in the 1974 edition) or whether DIN EN Filler materials for thermoplastics – Scope,
additional load cases (e.g. wind load, snow load) must be taken 12943 designation, requirements, tests
into account for dimensioning. The latter approach was selected
for the new edition of this Guideline. DIN EN ISO Extruded sheets of polyethylene (PE-HD) –
14632 Requirements and test methods
The application "Set-up and operation of tanks inside buildings"
DIN EN ISO Plastics – Compression-moulded sheets of
is dealt with in Supplement 1.
15527 polyethylene (PE-UHMW, PE-HD) –
Supplement 2 covers the dimensioning of tray collectors Requirements and test methods
(collecting vessels). DIN EN ISO Plastics – Extruded sheets of polypropylene
Supplement 3 covers dimensioning for flat roofs. 15013 (PP) – Requirements and test methods
DIN EN ISO Plastics – Unplasticized poly(vinyl chloride)
5.2 References 11833-1 sheets – Types, dimensions and characteristics
– Part 1: Sheets of thickness not less than 1 mm
Regulations ISO 15014 Extruded sheets of poly(vinylidene fluoride)
Design fundamentals (PVDF) – Requirements and test methods
DIN EN 1778 Characteristic values for welded thermoplastic Pipes and fittings
constructions; Determination of allowable
stresses and moduli for design of thermoplastic DIN 8061 Unplasticized polyvinyl chloride (PVC-U) pipes –
equipment General quality requirements and testing
DIN EN National Annex – Nationally determined DIN 8062 Unplasticized polyvinyl chloride (PVC-U) pipes –
1991-1-3/NA parameters – Eurocode 1: Actions on structures – Dimensions
Part 1-3: General actions – Snow loads DIN 8074 Polyethylene (PE) - Pipes PE 80, PE 100 -
DIN EN National Annex - Nationally determined Dimensions
1991-1-4/NA parameters – Eurocode 1: Actions on structures - DIN 8075 Polyethylene (PE) pipes - PE 80, PE 100 -
Part 1-4: General actions – Wind actions General quality requirements, testing
Table 7. Load combinations for calculating the stability of the roof
Assembly Combination p dexist Temp.
internal – max [ γ F1 ⋅ g D + γ F2 ⋅ p uK, γ F1 ⋅ g D + γ F2 ⋅ p us ] TDK

external Winter max [ γ F1 ⋅ g D + γ F2 ⋅ ( p S + p uK ), γ F1 ⋅ g D + γ F2 ⋅ ( 0,7 ⋅ p S + p us ) ] 0°C
external Summer γ F1 ⋅ g D + γ F2 ⋅ p uK TDesign

KD
external Wind max [ γ F1 ⋅ g D + γ F2 ⋅ p uK, γ F1 ⋅ g D + γ F2 ⋅ p us ] ( T MK + T AK – 5 )/2
For the higher snow load on the North German Plain, the following exceptional load combination must also be analysedmust be analysed
γF4 ⋅ (gD + 2.3 ⋅ pS + puK) with a wall temperature of 0°C.
219
DIN 8077 Polypropylene (PP) pipes – PP-H, PP-B, PP-R, Guideline Calculation of thermoplastic tanks and apparatus
PP-RCT – Dimensions DVS 2205-3 – Welded joints
DIN 8078 Polypropylene (PP) pipes – PP-H, PP-B, PP-R, Guideline Calculation of thermoplastic tanks and apparatus
PP-RCT – General quality requirements, testing DVS 2205-4 – Flange connections
DIN 8079 Chlorinated polyvinyl chloride (PVC-C) pipes – DIBt List of liquids for plastic tanks, tray collectors and
Dimensions pipes
DIN 8080 Chlorinated polyvinyl chloride (PVC-C) pipes –
General quality requirements, testing Bibliography
DIN 4740-1 Ventilation plants; unplasticized polyvinylchloride [1] Timoshenko, S.: Theory of Plates and Shells. McGraw Hill
(PVC-U) pipes; calculation of the minimum Book Comp, New York/London 1959.
thickness [2] Kempe, B.: Verformungsmessungen an einem Behälter aus
DIN 16961-1 Thermoplastic pipes and fittings with profiled wall Polyethylen hoher Dichte bei Temperaturwechsel
and smooth pipe inside – Part 1: Dimensions [Deformation measurements on a tank made of high-
DIN 16961-2 Thermoplastic pipes and fittings with profiled wall density polyethylene in the event of a temperature change].
and smooth pipe inside – Part 2: Technical Schw. Schn. 42 (1990), H. 4, p. 173.
delivery specifications [3] Tuercke, H.: Zur Stabilität von Behältern aus Thermoplas-
DIN EN ISO Plastics piping systems for industrial applications. ten [On the stability of thermoplastic tanks]. DIBt-
15494 Polybutene (PB), polyethylene (PE) and Mitteilungen, Heft 5/1995.
polypropylene (PP). Specifications for [4] Tuercke, H.: Zur Einleitung axialer Einzellasten am oberen
components and the system. Metric series Rand von Thermoplastbehältern [On the introduction of
DIN EN ISO Plastics piping systems for industrial applications - axial concentrated loads at the upper edge of thermoplastic
15493 Acrylonitrile-butadiene-styrene (ABS), unplasticized tanks] DIBt-Mitteilungen, Volume 4/2002.
poly(vinyl chloride) (PVC-U) and chlorinated
poly(vinyl chloride) (PVC-C) - Specifications for 5.3 Temperature and time-dependent Young's modulus for
components and the system. Metric series stability and deformation calculations
See Guideline DVS 2205-1, Tables 2 and 3.
DVS leaflets and guidelines
5.4 Structural details
Guideline Testing of semi-finished products made of
DVS 2201-1 thermoplastics – Basics – Indications This section presents structural examples for
Guideline Testing of semi-finished products made of – Connecting pieces in the cylinder casing, Figure 8
DVS 2201-2 thermoplastics – Weldability – Test methods – – Base anchoring, Figure 9
Requirements – Lifting lugs, Figure 10
Guideline Calculation of tanks and apparatus made of – Casing/base connection, Figure 11
DVS 2205-1 thermoplastics - Characteristic values – Casing/roof connection, Figure 12
– Edge of open tanks, Figure 13
Guideline Calculation of tanks and apparatus made of
DVS 2205-2 thermoplastics – Vertical round, non-pressurised
tanks
h A ≥ max [ d A ,d A /2 + 100 ]
d A /d ≤ 0.4
a = 0.7 ⋅ min [ s Z ,s R ]
I1 is the external length of the connecting piece, measured at 12

or 6 o'clock
I2 is the internal length of the connecting piece, measured at 3 or
9 o'clock
I3 is the external length of the connecting piece, measured at 3
or 9 o'clock
max [ 1.5 ⋅ ( d A + s R ) ⋅ s R ,100 ] ≥ I 1 ≥ ( d A + s R ) ⋅ s R

I2 ≥ sR + a
d + 2 ⋅ sZ d + 2 ⋅ sZ 2 d A 2
I 3 = I 1 + ----------------------- –  ----------------------- –  ------
2  2   2
Figure 8. Connecting pieces in the cylinder casing.
220
Figure 9. Base anchoring.
Figure 10. Lifting lug.
Figure 11. Casing/base connection.
221
Figure 12.Casing/roof connection.
Figure 13. Edge of open tanks.
222
January 2011

FÜR SCHWEISSEN UND made of thermoplastics Technical Code
VERWANDTE VERFAHREN E.V. Vertical round, non-pressurised tanks DVS 2205-2
Contents: Consideration must be given not only to the hydrostatic loading but
also to pressures effective for short and long times. The following
1 Scope of application minimum values are stipulated:
2 Calculation variables Overpressure: 0.0005 N/mm2 (0.005 bar)
3 Loading
Partial vacuum: 0.0003 N/mm2 (0.003 bar)
3.1 Continuously effective loads
3.1.1 Total dead load The pressures effective for a long time may only be applied if
3.1.2 Load of the filling material they can also take effect.
3.1.3 Internal and external pressures Restriction on the main dimensions:
3.2 Loads effective for a medium-long time
3.2.1 Snow load Tank diameter: d4m
3.2.2 Summer temperature Ratio: h/d  6
3.3 Loads effective for a short time Minimum wall thicknesses: s = 4 mm
3.3.1 Internal and external pressures Attention must be paid to the responsibilities of certain legal fields
3.3.2 Moving loads on the roof (e.g. building law, water law, occupational health and safety law
3.3.3 Wind loads etc.).
3.3.4 Radially symmetrical equivalent loading caused by wind

pressure
3.3.5 Partial vacuum due to wind suction 2 Calculation variables
3.4 Temperature a mm Weld thickness
4 Proof of the steadiness A1 – Reduction factor for the influence of the specific
4.1 Proof of the strength toughness (corresponds to A4 according to the
4.1.1 Effects DVS 2205-1 technical code)
4.1.2 Superimposition of the effects A2 – Reduction factor for the medium in the case of
4.1.3 Shell the proof of the strength
4.1.4 Bottom A2I – Reduction factor for the medium in the case of
4.1.5 Welded joint between the bottom and the shell the proof of the stability and the deformation
4.1.6 Conical roof AB m2 Area of the bottom
4.1.7 Nozzles
AD m2 Area of the roof
4.1.8 Anchoring
4.1.9 Lifting lugs Aj m2 Area exposed to the wind (partial area)
4.2 Proof of the stability AZ m2 Shell area of the cylinder
4.2.1 Superimposition of the effects bPr mm Width of the claw
4.2.2 Shell bÖ mm Width of the lifting lug
4.2.3 Conical roof
c – Force coefficient according to DIN 1055-4
5 Appendix
5.1 Explanations C – C1  C 2
5.2 Standards and technical codes C1 – Stress-increasing factor
5.3 Literature C2 – Material-specific design factor
5.4 Temperature-dependent and time-dependent elastic mod- C* – Coefficient for the circular cylinder subjected to
uli for stability and deformation calculations external pressure loads
5.5 Design-related details
d mm Nominal inside diameter
dA mm Outside diameter of the nozzle
1 Scope of application dL mm Hole diameter in the lifting lug
dmax mm Maximum cylinder diameter
The following design and calculation rules apply to vertical, cylin- dmin mm Minimum cylinder diameter
drical flat-bottom tanks which are fabricated from thermoplastics
in the factory, in particular: dSch mm Diameter of the shackle
ETC
K N/mm2 Elastic modulus in the case of short-time
– polyvinyl chloride (PVC)
loading for T°C
– polypropylene (PP)
– polyethylene (PE) E K20C N/mm2 Elastic modulus in the case of short-time
– polyvinylidene fluoride (PVDF) loading for 20°C
E20C
L N/mm2 Elastic modulus in the case of long-time loading
The cylindrical shell with an identical wall thickness throughout or
for 20°C
with a graduated wall thickness can be welded together from
panels or may consist of a wound pipe or an extruded pipe. fs – Long-time welding factor
223
fsD – Long-time welding factor for the roof qmax kN/m2 Maximum impact pressure effective at the tank
fz – Short-time welding factor r mm Radius of the cylinder
fzD – Short-time welding factor for the roof Rd N/mm2 Dimensioning value of the stressability
g m/s2 Acceleration due to gravity (9.81 m/s2) s mm Minimum wall thickness
gA N/mm2 Equivalent area load for the nozzles and similar sa mm Executed wall thickness of the basic component
items on the roof sB mm Wall thickness of the bottom
gD 2
N/mm Area-related weight of the roof sD mm Wall thickness of the roof
GB N Dead load of the bottom Sd N/mm2 Dimensioning value of the stresses
GD N Dead load of the roof sÖ mm Wall thickness of the lifting lug
GE N Total dead load sZ mm Wall thickness of the cylinder
GF kN Load of the filling material sZF mm Wall thickness of the lowest course
GS N Snow load s*ZF mm Statically required wall thickness of the lowest
GZ N Dead load of the cylinder course
h mm Height of the tank sZm mm Mean wall thickness of the cylinder
hF mm Filling height sZ,1 mm Wall thickness of the highest course
hF,i mm Filling height of the course i sZ,i mm Wall thickness of the course i
hRF mm Residual filling height so mm Wall thickness of the upper course of the
hZ,i mm Height of the course i equivalent cylinder
hZ mm Cylindrical height TA °C Mean ambient temperature (according to Miner,
see DVS 2205-1)
hZF mm Height of the lowest course
vorh TAK °C Highest ambient temperature
KK N/mm2 Stresses effective for a short time
vorh
TD °C Mean roof temperature
KK,d N/mm2 Dimensioning value of stresses effective for a TDK °C Highest roof temperature in the case of indoor
short time installation
vorh
KL,d N/mm2 Dimensioning value of stresses effective for a T*D °C Mean roof temperature for the summer load case
long time
vorh 2 TM °C Mean media temperature (according to Miner,
K M,d N/mm Dimensioning value of stresses with a medium
effective duration see DVS 2205-1)
K *K N/mm2 Creep strength for 10-1 hours TMK °C Highest media temperature
K* K,d N/mm2 Dimensioning value of the creep strength for TZ °C Mean temperature of the cylinder wall
10-1 hours TZK °C Highest temperature of the cylinder wall
K *L,d N/mm2 Dimensioning value of the creep strength for the u % Permissible out-of-roundness
computational working life at the mean effective V m3 Filling volume
temperature vA – Weakening coefficient
K *M,d N/mm2 Dimensioning value of the creep strength for the
wgr mm Tolerable lifting path
medium effective duration (e.g. in the case of
snow for three months at 0°C) Wj kN Wind load
lo mm Length of the upper course of the equivalent z – Number of anchors
cylinder  – Auxiliary variable
MW Nm Bending moment in the case of a wind load D ° Pitch of the roof
nZ,d N/mm Dimensioning value of the tensile force on the  – Coefficient
diaphragm at the lower edge of the cylinder  – Coefficient
 pvorh
D K, d
N/mm2 Short-time dimensioning value of the effects on
the roof according to Table 5 or 6
B – Coefficient for the calculation of the bottom
vorh w – Coefficient
pD N/mm2 Dimensioning value of the effects on the roof
L,M,d
according to Tables 5 and 6 s – Coefficient
peu N/mm2 Radially symmetrical equivalent loading caused  % Tolerable edge fibre expansion
by wind pressure F Partial safety coefficient of the effect/stresses
pkM,d N/mm2 Dimensioning value of the critical shell buckling I Weighting coefficient depending on the loading
pressure type
pmax N/mm2 Auxiliary variable M Partial safety coefficient of the resistance/
pS 2
N/mm Snow load on the roof stressability
pstat N/mm2 Overpressure at the tank bottom due to the A,i – Utilisation of the axial stability in the course i
filling medium M – Utilisation of the shell pressure stability
pstat,i N/mm2 Overpressure per lower edge of the graduation  ° Angle of the roof in relation to the perpendicular
due to the filling medium
 g/cm3 Density of the material ( =   g)
pu N/mm2 Continuously effective external pressure
(or internal partial vacuum) F g/cm3 Density of the filling medium
vorh
puK N/mm2 External pressure (or internal partial vacuum) d N/mm2 Dimensioning value of the crucial compressive
effective for a short time stress in the conical roof
pü N/mm2 Continuously effective internal pressure k,d N/mm2 Dimensioning value of the critical buckling
stress in the conical roof
püK N/mm2 Internal pressure effective for a short time
vorh N/mm2 Dimensioning value of the crucial axial
pus N/mm2 Partial vacuum due to wind suction i,d
compressive stress in the course i
pw,d N/mm2 Auxiliary variable
k,i,d N/mm2 Dimensioning value of the critical axial buckling
p1 N/mm2 Auxiliary variable stress in the course i
p,d N/mm2 Auxiliary variable W N/mm2 Compressive stress on the diaphragm resulting
qj kN/m2 Impact pressure on the partial area Aj from the wind load
224
S ZF = SZ
S ZF = SZ
Figure 3. Flat-bottom tank with a conical roof and a non-graduated wall

thickness.
Figure 1. Open flat-bottom tank with a non-graduated wall thickness.
Figure 4. Flat-bottom tank with a conical roof and a graduated wall thick-
Figure 2. Open flat-bottom tank with a graduated wall thickness. ness.
3 Loading 3.1.1 Total dead load GE

GE = G D + GZ + GB N (1)
3.1 Continuously effective loads Dead load of the roof GD:
Depending on the application, tanks are designed for a computa- GD= AD  sD    g N (2)
tional operating time of up to 25 years (2  105 hours). The com-
Dead load of the cylinder GZ:
putational filling height hF is determined by the existing operating
conditions. G Z = AZ  s Z    g N (3)
225
Dead load of the bottom GB: 3.3.2 Moving loads on the roof
GB = AB  sB    g N (4) It is not allowed to walk on the roofs without taking any load-
distributing measures. Corresponding precautions must be taken
Ladders, platforms, pedestals and similar items must be set up during assembly and inspection work.
and fastened independently of the tank since the free expansion
of the tank (e.g. during filling and emptying and in the case of 3.3.3 Wind loads
temperature changes) would otherwise be hindered. These hin-
drances cause considerable stress peaks which are difficult to re- The wind loads Wj must be estimated as follows:
cord computationally and, if they are taken into account, lead to Wj = cf ∙ q ∙ Aj kN (6)
uneconomic designs. If there is any deviation from this, corre-
sponding proof must be provided. where:
Wj wind load of the partial area Aj.
3.1.2 Load of the filling material GF
cf Force coefficient for the circular cylinder and the roof.
GF = V  F  g kN (5) cf1 = 0.8 may be estimated according to DIN 1055-4, Section
10.2. Installation in a series has already been taken into con-
3.1.3 Internal and external pressures pü and pu sideration in this respect. Extensions cf2 = 1.6.
Higher pressures than indicated in the scope of application must q Kinematic pressure according to DIN 1055-4, Table 2 de-
be taken into account at the level set by the operator. pending on the wind zone and the height above the ground h
(h = hBehälter + hGebäude when the tank is located on a build-
If any safety fittings which cause higher pressures (such as over- ing, otherwise h = hG = hBehälter).
filling protection devices or ventilation and venting facilities) are
connected, only these pressures must be taken into considera- Aj Relevant exposed area in m² (for the tank: diameter times
tion. These pressures must not be effective when the tank has total height hG including the roof)
been emptied completely since the bottom would otherwise be in The stress resulting from the wind moment MW may be calculated
danger or the tank would be lifted. using the following simplified method:
3
3.2 Loads effective for a medium-long time 4  M W,x  10
 W,i = ----------------------------------
- N/mm2 (7)
2
The effective time is three months.   d  s Z,i
3.2.1 Snow load GS Mw,x at the height x above the tank bottom can be calculated on
a clamped equivalent bar.
The snow load according to DIN 1055-5 must be estimated
2
cumulatively over the computational service life at a roof wall  hG – x 
temperature of 0°C. The computational snow load is calculated M W, x = c f1  q  d  ----------------------
2
- + c f2  q 
  Aj  aj  Nm (8)
from the shape coefficient  and the characteristic value of the
snow load sk according to the snow load zone map and the where aj is the lever arm of the area exposed to the wind Aj of the
height above sea level. superstructures and extensions in relation to the height x.
The following value may be estimated for conical and flat roofs: 3.3.4 Radially symmetrical equivalent loading caused by
 = 0.8. wind pressure
The compressive loading due to the inflow of the wind on to the
cylindrical shell is recorded by the equivalent load peu.
The roofs may be heated up considerably in summer. It is neces- peu =   qmax  10-3 N/mm² (9)
sary to take account of a wall temperature of 50°C.
where:
3.3 Loads effective for a short time
 r r 
The effective duration of loads effective for a short time is stipu-  = 0.46   1 + 0.1  C *  ------  ----------  0.6 (10)
 h Z s Zm
lated as 10-1 hours.
C* = 1.0 for the closed tank
Any water hammers which may arise during filling operations
C* = 0.6 for the open tank
must be prevented by taking suitable measures.
3.3.1 Internal and external pressures püK and puK  h Z,i  s Z,i 
s Zm = ---------------------------------- (11)
As far as no higher pressures can occur as a result of the operat- hZ
ing method, the minimum pressures indicated in Section 1 must
be taken into consideration. The definition of püK results in 3.3.5 Partial vacuum due to wind suction
püK  pü (see Fig. 5). The same applies analogously to puK.
In the case of ventilated tanks, an internal partial vacuum results
from a suction effect.
Pressure
pus = 0.6  qmax  10-3 N/mm² (12)

pus = 0.48  10-3 N/mm² is applicable in the case of ventilation
through a pipe leading to the outside.

The tank must be designed for the loading conditions arising
during the transport and the assembly. In this respect, the calcu-
lation is made with 1.5 times the assembly loads (surge factor).
Time
F1 is estimated as the partial safety coefficient. The short-time
Figure 5. Definition of püK. welding factor according to DVS 2205-1 must be taken into con-
226
sideration. In this respect, the characteristic effects or the stresses are multi-
plied by the partial safety coefficients F according to Table 1.
3.4 Temperature
The effective wall temperature is decisive for the dimensioning of Table 1. Partial safety coefficients of the effects.
the components. For parts wetted with the media, proof must be
Effect Partial safety coefficient
provided at the mean media temperature TM in the case of long-
time effects and at the highest media temperature T MK in the Dead weight, filling and assembly F1 = 1.35
case of short-time effects. The mean temperature is the tempera- Pressures, wind and snow F2 = 1.5
ture which, according to Miner, causes the same damage to the
Stress-reducing dead weight F3 = 0.9
material as the changing temperatures in real operation (e.g. ac-
cording to Miner, a 10 % time proportion at 30°C and 90 % at
20°C result in TM = 26.3°C; TMK = 30°C). For non-wetted parts, The dimensioning value of the existing stresses results from F
the mean of the two neighbouring air temperatures may be esti- times the characteristic value of the stresses existing in the com-
mated as the wall temperature using a simplifying method. The ponent.
media temperature is assumed to be the air temperature in the vorh vorh
tank. As far as the ambient temperature is concerned, a differen- K K,d =  F  K K
tiation is made according to the installation location and the effec-
tive duration. The following minimum values are applicable: The dimensioning values of the existing stresses must be multi-
plied by the weighting coefficient I which takes account of the
Minimum values For a short time For a long time loading cases in Table 2.

Table 2. Weighting coefficient.
Outdoor installation TAK = 35°C TA = 20°C
Loading type I
In the case of outdoor installation, the wall temperature of the Loading Case I 1.0
roof must be estimated at min. 50°C as a result of the solar radia-
tion. A decreased ambient temperature TAK - 5°C applies to the Static loading at the room temperature and in constant
proof of the stability in the cylinder in the case of outdoor installa- conditions. Cases of damage cannot lead to any dan-
tion (wind effect). ger to people, things or the environment.
Loading Case II 1.2
Loading in changing conditions (e.g. temperature and
filling height). Cases of damage may lead to danger to
people, things or the environment, e.g. installations or
installation parts which must be monitored and tested.
The characteristic resistances or the stressabilities are divided by

the partial safety coefficient M = 1.1.
For example, the dimensioning value of the short-time strength
K *K,d results from the characteristic short-time strength value K *K
divided by M according to the creep strength diagrams in
DVS 2205-1.
K *K
K=
* ---------
-
K,d M
The dimensioning coefficients of the stressability must be divided
by the reduction coefficients A1 and A2 and, in the case of proof
in the weld, multiplied by the welding factor. In contrast, because
of the shorter representation, the dimensioning values of the
existing stresses are below multiplied by the reduction coeffi-
Without With
cients A1 and A2 and divided by the welding factor. This leads to
collecting device collecting device
the same result.
Without collecting device With collecting device
4.1 Proof of the strength
TD = (TM+TA)/2 TD = (TM+TA)/2
TZ = (TM+TA)/2 TZ = (3 ∙ TM+TA)/4 4.1.1 Effects
Any loads caused by connected nozzles and pipelines are not
Analogously, this is followed by TDK and TZK with TMK and TAK. covered by this calculation and must be taken into consideration
Figure 6. Definition of the effective temperatures. separately by means of design-related measures (e.g. compen-
sators).
It is always necessary to look for the most unfavourable combina-
4 Proof of the steadiness
tion of the overall effects for every component. Two cases must
be investigated for the effects of wind and snow:
The proof of the steadiness is provided according to the concept
of the partial safety coefficients. In general, the following is appli- 1. The full snow load
cable:
2. 0.7 times the snow load + the full wind load
S
------d-  1 Load cases effective for a short time do not have to be combined
Rd with each other.
with Sd dimensioning value of the stresses
Rd dimensioning value of the stressability 4.1.2 Superimposition of the effects
227
Corresponding to the effective duration, a distinction must be 4.1.3.1 Proof in the circumferential direction
made between three loading categories:
For every course i, it must be proven that the ring tensile stresses
– Loading effective for a short time (K) due to the filling and the overpressures can be accommodated at
e.g. puK, püK, pus, peu or wind its lower edge. According to Section 4.1.2, it is necessary to pro-
vide double proof with:
– Effects with a medium effective duration (M)
e.g. snow ps or summer temperatures vorh   F1  p stat,i +  F2  p ü   d A 1  A 2   I
K L,d = ---------------------------------------------------------------  -------------------------- N/mm2 (16)
– Loading effective for a long time (L) 2  s Z,i fs
e.g. dead weight, filling, pu or pü
A1 at the effective wall temperature TM
If the filling is not constant with regard to the filling height and the
temperature during the computational working life of the tank, and
representative equivalent loading can be determined for such   F1  p stat,i +  F2  p üK   d A 1  A 2   I
K K,d
vorh
intermittent loading with Miner's rule. In contrast, the application = ------------------------------------------------------------------  -------------------------- N/mm2 (17)
of Miner's rule is not very practicable for the superimposition of 2  s Z,i fz
the loading in the three loading categories. A1 at the effective wall temperature TMK
Therefore, it is always necessary to provide double proof. with
–6
1. It must be proven that, if the effects with a medium effective p stat,i =  F  g  h F,i  10 N/mm2 (18)
duration are superimposed on the stresses resulting from
loads effective for a long time but without any short-time load- where hF,i means the height of the liquid level above the lower
ing, the stresses do not exceed the creep strength. edge of the course i.
vorh vorh Stresses resulting from effects with a medium effective duration
K L,d K M,d do not arise in the case of this proof:
- + --------------------
------------------- -1 (13)
K*L,d K*M,d
vorh
(K M,d = 0) .
with
The welding factor of the shell weld fs or fz is taken into account
vorh vorh A1  A2  I in the case of cylinders manufactured from plates. According to
K L,M,d =  L,M,d  -------------------------- N/mm2 (14) today's state of the art, preference should be given to heated tool
fs
butt welding. fs = 1 and fz = 1 apply to wound tanks.
and
The residual stresses resulting from the bending of the panels at
vorh
L,M,d = dimensioning value of the existing stresses the room temperature can be neglected if the edge fibre expan-
K*L,d = dimensioning value of the creep strength for the com- sion  = s/d  100 [%] according to Table 3 is not exceeded.
putational working life at the mean effective tempera-
ture Table 3. Tolerable edge fibre expansion.
K*M,d = dimensioning value of the creep strength for the me- Material Edge fibre expansion 
dium effective duration (e.g. in the case of snow for
PE-HD 1.00
three months at 0°C for the roof)
PP-H 0.50
2. It must be proven that, if the other effects are superimposed
on the stresses resulting from short-time loading, the stresses PP-B 0.75
do not exceed the residual strength of the material at the end PP-R 1.00
of the computational working life. In this respect, the creep PVDF 0.50
strength for 10-1 hours is estimated as the residual strength.
PVC-U 0.20
 vorh
K K,d
-----------------------------  1 (15)
PVC-C 0.10
K*K,d
Remark: The value for PE-HD may be used for PE 63, PE 80
A1  A2  I and PE 100.
with K K,d
vorh
=   K, d
vorh
 --------------------------
fz
N/mm2 (15a)
4.1.3.2 Proof in the longitudinal direction
and The greatest tensile stresses must be validated. In this respect,
just 90 % of relieving, continuously effective compressive stress-
*
K K,d = dimensioning value of the creep strength for 10-1 es may be taken into consideration.
hours at the temperature belonging to this loading
combination. Only the lowest course at the interface to the bottom must be
The more unfavourable of both the cases of proof is always investigated for the proof of the stresses in the longitudinal direc-
crucial for the dimensioning of the components. tion. The stresses arising here are caused by the bending fault
moment and the stresses in the longitudinal direction resulting
Remark: from the dead weight, the pressures and the wind must be super-
For the proof of the strength of the roof, it must be checked imposed on them.
whether the consideration of the snow load leads to a more The double proof according to Section 4.1.2 must be provided with:
unfavourable result since, although the loading total is in-
creased, the creep strength also becomes greater because of vorh d d
K L,d = C    F1  p stat +  F2  p ü   --- +  F2  p ü  ---
the effective wall temperature of 0°C. 2 4
 F3   G D + G Z  A 1  A 2   I
4.1.3 Shell -  --------------------------
– -------------------------------------- N/mm2 (19)
d s ZF
The height of the lowest course hZF must be min. 1.4  d  s ZF .
In the case of graduated tanks, neighbouring courses may have A1 at the effective wall temperature TM.
a wall thickness ratio of max. 3 without any further proof. In the –6
case of sudden thickness changes with a wall thickness ratio with p stat =  F  g  h F  10 N/mm (20)
greater than 2, it is necessary to use the shell seam formation ac- vorh
cording to DVS 2205-3, Fig. 2.2 a), 2.2 c) or 2.2 c1). K M,d= 0
228
and  = sB / S ZF
*
vorh d d
K K,d = C    F1  p stat +  F2  p üK   --- +  F2  p üK  ---
2 4 Permissible range for C = 1.2
3
 F2  4  M W  10  F3   G D + G Z  A 1  A 2   I
- – ---------------------------------------  -------------------------- N/mm2
+ ------------------------------------------- (21)
d
2 d s ZF
A1 at the effective wall temperature TMK.

The factor C for the welded interface of the bond between the
bottom and the shell is the product of the stress-increasing factor
C1 = 1.2 and a material-specific design factor C2 according to
Table 4.
*
Table 4. The material-specific design factor C2 and the factor C for
thermoplastics. Figure 7. Diagram for the determination of the thickness of the bottom,
Material C2 C = C 1  C2 derived for PE-HD (for C > 1.2, this diagram is on the safe side).
PE-HD 1.00 1.20
4.1.4.2 Proof for unanchored tanks with overpressure
PP-H (Type 1) 1.17 1.40
If an unanchored tank (e.g. a tank in a collecting device) is load-
PP-B (Type 2) 1.00 1.20 ed with overpressure, the bottom of the tank arches outwards.
PP-R (Type 3) 1.00 1.20 This leads to the lifting of the whole tank and to bending stresses
PVC-NI (normal impact strength) 1.25 1.50 in the bottom. A filling residue to be guaranteed with the filling
PVC-RI (increased impact strength) 1.08 1.30 height hRF must be taken into consideration during the calcula-
tion of this lifting.
PVC-HI (high impact strength) 1.00 1.20
Pressures effective for short and long times are treated in the
PVC-C 1.33 1.60
same way since it may be postulated that the condition with a
PVDF 1.17 1.40 long-time pressure and a residual filling height exists for a limited
time only. The effective pressure is therefore:
Remark: The values for PE-HD may be used for PE 63, PE 80
and PE 100. p1 = max (pü, püK) N/mm2 (23)
It is not necessary to provide any proof of the stresses in the weld Proof must be provided not only of the strength but also of the
if the conditions according to Section 4.1.5 are fulfilled. limitation of the lifting path subjected to nominal loads to
wgr = 10 mm.
One prerequisite for the stress-increasing factor C1 = 1.2 is that
the bottom is not executed with a thickness greater than the wall Proof of the strength
thickness of the lowest course (sB  sZF). –6
p B,k – p 1 –   g  s B  10
h RF, = -----------------------------------------------------------------
- mm (24)
–6
4.1.4 Bottom  F  g  10
p 1  d G D + G Z
4.1.4.1 Proof for the load case of the filling 1,5   ------------- – ----------------------
 4 d 
If the bottom and the cylinder are joined with fillet welds (Fig. 11 with p B,k = ------------------------------------------------------------
- N/mm2 (24a)
lB
in Section 5.5), the required thickness of the bottom may be de-
termined as follows: sB
2
K *K + K *M 1
with l B = ---------------------------
-  --------------------------
-  ---------------------------- mm (24b)
 B  s *ZF  s B  s ZF    n Z,d   l 2 A1  A2  M
with sZF executed wall thickness A1 at the effective wall temperature TMK.
B according to Fig. 7 and p1  d GD + GZ

with n Z,d =  F2  ------------- –  F3  ---------------------- N/mm (24c)
4 d
s *ZF = max  s*ZF,L , s ZF,K
*  mm (22)
and   = 1.5 for indoor installation
d d   = 2.12 for outdoor installation
with s *ZF,L= C    F1  p stat +  F2  p ü   --- +  F2  p ü  ---
2 4
Limitation of the lifting path
 F3   G D + G Z  A 1  A 2   I
– ---------------------------------------  -------------------------- mm (22a) p B – p 1 – 0.9    g  s B  10
–6
d *
K L,d h RF,w = --------------------------------------------------------------------------
- mm (25)
–6
0.9   F  g  10
A1 and K*L,d at the effective wall temperature TM
1.5  nZ
=
with pB ------------------- N/mm2 (25a)
d d lB
and s *ZF,K= C    F1  p stat +  F2  p üK   --- +  F2  p üK  ---
2 4
ToC
wgr  0.75  E K
 F3   G D + G Z  A 1  A 2   I with l B = s B  3 ---------------------------------------------
- mm (25b)
– ---------------------------------------  -------------------------- mm (22b)  w  A 2l  n Z
d K K,d*
p1  d GD + GZ
with n Z = ------------- – 0.9  ---------------------- N/mm (25c)
A1 and K *K,d at the effective wall temperature TM 4 d
and   = 0.56 for indoor installation
In the case of other structural shapes, it is necessary to provide
proof of the bottom due to the cylinder clamping moment.   = 1.12 for outdoor installation
229
The crucial residual filling height results from:  A     ln  --

s
- + B   
vorh   r  A1  A2  I
h RF = max  h RF, , h RF,w  mm (26)
vorh
K L,d = pD L,d e  -------------------------- N/mm2 (27)
f sD
Remarks:  A     ln  s--- + B   
vorh vorh   r  A1  A2  I
 K *K + K *M  /2 is used in the calculation for the proof of the K M,d = pD M,d  e  -------------------------- N/mm2 (28)
f sD
strength. A loading duration of approx. 12 hours is taken into
account in this respect. and
ToC ToC  A     ln  s--- + B   
0.75  E K is used instead of E K (see Section 5.4) in the   r  A1  A2  I
calculation for the proof of the limitation of the lifting path since a
vorh
K K,d = pDK,d
vorh
e  --------------------------
f zD
N/mm2 (29)
higher stress level and thus a lower modulus must be taken into
consideration during this deformation calculation than in the case 2
with A  =
 – 0.000103   D + 0.007825   D – 1.7771
of stability problems. 2
B  =
 – 0.000433   D + 0.008115   D – 0.1870
4.1.4.3 Proof for an internal partial vacuum The combinations in Table 5 must be investigated. A1 must be
It is not necessary to provide any proof of the bottom for an inter- determined on the basis of the temperatures in Table 5. An effec-
nal partial vacuum if a residual filling remains in the tank. In this tive mean wall temperature which is determined according to
respect, the residual filling height must be stipulated in such a Miner
way that the total resulting from F3 times the dead load of the T D + 50
bottom is greater than F3 times the F2 partial vacuum. = TD* -------------------
- oC (30)
2
and takes account of a roof temperature of 50°C over three
4.1.5 Welded joint between the bottom and the shell
months (TD according to Fig. 6) is used for the summer load
It is not necessary to provide any explicit proof of the stresses on case.
the weld if the following conditions are fulfilled: –6
  g  s D  10
– weld thickness a  0.7  sB g D = -------------------------------------
- + gA N/mm2 (31)
sin 
– long-time welding factor fs  0.6 (according to DVS 2203-4)
gA equivalent area load for nozzles and similar items
If one of these conditions is not fulfilled, it is necessary to provide The welding factor is oriented to the quality of the longitudinal
detailed proof of the stresses in the weld (e.g. FE calculation). weld of the conical roof.
In the case of one-shell tanks with capacities up to 1,000 l and
wall thicknesses up to 10 mm, this also applies to long-time weld- 4.1.6.2 Loads directed outwards
ing factors fs  0.4. The double proof according to Section 4.1.2 must be provided
with:
4.1.6 Conical roof  C     ln  --s- + D   
vorh vorh   r 
The pitch of the roof must not be less than D = 15° ( = 75°). K L,d = pDL,d  e  A1  A2  I N/mm2 (32)
and
4.1.6.1 Loads directed inwards
 C     ln  --
s
- + D   
  r 
pDK,d
The crucial combination of the dead weight gD, the partial vacu- vorh vorh
K K,d = e  A1  A2  I N/mm2 (33)
ums pu and puK, the snow load ps and the partial vacuum result-
ing from the wind pus must be investigated. In this respect, pu, 2
with C    = 0.000013   D – 0.00097   D – 1.4054
puK and pus do not have to be combined with each other and, if
2
the wind is estimated, the snow load may be reduced to 70 %. D    = 0.000265   D – 0.04574   D + 1.5622
It is necessary to prove the stresses resulting from the ring ten- A welding factor does not have to be taken into consideration
sion at the edge of the roof. since the weld in the roof runs parallel to the stresses.
The double proof according to Section 4.1.2 must be provided It is necessary to investigate the combinations in Table 6.
with: A1 must be determined on the basis of the temperatures in Table 6.
Table 5. Combinations of load cases for the calculation of the roof for loads directed inwards..
Installation Combi- Proof according to (13) Proof according to (15)

location nation vorh Temp.
 pD
vorh vorh
p DL,d Temp. p DM,d Temp. K,d
Indoors F1 ∙ gD + F2 ∙ pu TD 0 – max (F1 ∙ gD + F2 ∙ puK, F1 ∙ gD + F2 ∙ pus) TDK
Outdoors Winter F1 ∙ gD + F2 ∙ pu TD F2 ∙ pS 0°C max (F1 ∙ gD + F2 ∙ (ps + puK), F1 ∙ gD + F2 ∙ (0.7 ∙ pS +pus)) 0°C
Outdoors Summer F1 ∙ gD + F2 ∙ pu T D
* 0 – max (F1 ∙ gD + F2 ∙ puK, F1 ∙ gD + F2 ∙ pus) 50°C
Table 6. Combinations of load cases for the calculation of the stength of the roof for loads directed outwards.
Installation Combi- Proof according to (13) Proof according to (15)

location nation
 pDvorh
vorh vorh Temp.
pDL,d Temp. pDM,d Temp. K,d
Indoors F2 ∙ pü – F3 ∙ gD TD 0 – F2 ∙ püK – F3 ∙ gD TDK

Outdoors Summer F2 ∙ pü – F3 ∙ gD T D
* 0 – F2 ∙ püK – F3 ∙ gD 50°C
230
4.1.7 Nozzles While paying attention to the lever arms, the required anchor
force (e.g. for the plugs) must be calculated from the maximum
The nozzles must generally be attached to the roof. If nozzles are
claw force (maximum of the three numerators).
attached to the cylinder, the maximum diameter must be limited
to dA = 160 mm. The distance between the centres of the Fig. 9 in Section 5.5 shows the execution of an anchoring
nozzles and the edges, the course boundaries or the welds in the element.
basic component must be min. dA/2 + 100 mm. However, the dis-
tance between the centres of the nozzles and the bottom and a 4.1.9 Lifting lugs
neighbouring course with a lower wall thickness must be min. dA. One of the possible lifting lug shapes is shown on Fig. 10 (Sec-
It must be proven that it is possible to accommodate the stresses tion 5.5). The prerequisites for the use of these lifting lugs are
on the basic component which are increased as a result of the that only two lifting lugs are used per tank and that one parallel
stress concentration close to the opening. hanger is utilised.
The stresses in the undisturbed basic component are increased In order to be able to dispense with any proof of the load intro-
by dividing them by the weakening value vA. duction into the highest course, it must be ensured that the lifting
lug is not thicker than three times the wall thickness of the
The following applies to nozzles in the cylinder and in the conical highest course. The hole diameter (dL) must be adapted to the
roof: diameter of the shackle (dSch).
0.75 The following equations are applicable:
vA = ---------------------------------------------------- (34)
dA sZ,1  erf sÖ  3  sZ,1
1 + ----------------------------------------- - (39)
2   d + sa   sa dSch  dL  1.1  dsch (40)
with dA outside diameter of the opening It must be proven that 1.5 times the loading (surge factor) can be
d cylinder diameter borne for a short time at 20°C. I = 1.2 must be set in this respect
sa executed wall thickness of the basic component since the transport of the tank constitutes a danger to people
For the proof of the nozzles in the roof, it is necessary to provide irrespective of the subsequent utilisation.
proof only for the largest nozzle situated near the edge of the The required wall thickness (sÖ) of the lifting lug results from the
roof. In this respect, the dimensioning values for the existing proof for the face of the hole:
vorh
stresses K L,M,K,d may be determined for loads directed both in-
wards and outwards from the following equation: GE
1.5   F1  -------  A 1   I
2
s Ö = -----------------------------------------------------
d A1  A2  I
pD mm (41)
vorh
K L,M,K,d = ---------------------
L,M,K,d
-  ------  -------------------------
- (35) d Sch  2  K *K,d
2  cos  s D vA
The maximum of both the following cases of proof is crucial for
with p D effects according to Section 4.1.6.1 or 4.1.6.2. the width of the lifting lug (bÖ).
L,M,K,d
In the case of nozzles in the cylinder, it is necessary to provide bÖ = max (bÖ,1, bÖ,2)
proof for ring tensile loads in analogy to Section 4.1.3.1, paying Proof of the shearing stress for the transverse weld during the
attention to the height position of the nozzle. The structural lifting of the lying tank:
designing must be carried out according to Fig. 8, Section 5.5
(push-through nozzle). The wall thickness must correspond to GE A1  I
min. SDR11 (formerly pressure stage PN 10). 1.5   F1  -------  ---------------
4 fz
b Ö,1 = ----------------------------------------------------- mm (42)
K *K,d
4.1.8 Anchoring 0.7  s Z,1  --------------
2
If anchoring becomes necessary, at least four anchors must be
arranged (z  4). Eye bar:
With regard to the proof of the anchoring, a distinction must be GE
made between three cases: 1.5   F1  -------  A 1   I
2 7
b Ö,2 = ----------------------------------------------------- + ---  d L mm (43)
Case 1: Short-time overpressure at the media temperature T MK: s Ö  K *K,d 3
2
 F2  p üK    d 1 4.2 Proof of the stability
---------------------------------------- –  F3   G D + G Z   ---
4 z
---------------------------------------------------------------------------------------------------  1 (36) 4.2.1 Superimposition of the effects
K *K,d
 b Pr + s B   s B  ----------------------- The crucial elastic moduli are needed for the stability calculations.
2  A1  I The buckling of shells is a sudden occurrence which is essentially
Case 2: Long-time overpressure at the media temperature T M: dependent on the imperfections, i.e. on the size of the previous
bulges. The size of the previous bulges increases along with the
2
 F2  p ü    d 1 loading duration because of the creep behaviour of the material.
- –  F3   G D + G Z   ---
------------------------------------ In contrast, the elastic resistance during the beating-out is predom-
4 z
------------------------------------------------------------------------------------------------  1 (37) inantly determined by the short-time elastic modulus at the tem-
K *L,d perature at that moment. The critical buckling stress k is therefore
 b Pr + s B   s B  ----------------------- o
2  A1  I calculated with the temperature-dependent moduli E TK C .
Case 3: Wind load at 20°C (only in the case of outdoor installa- For the essential thermoplastics, the temperature-dependent and
tion): time-dependent elastic moduli are included in Tables 8 and 9
(Section 5.4).
2
4   F2  M w  F2  p ü    d 1
-----------------------------  10 3 + ------------------------------------ - –  F3   G D + G Z   --- It is necessary to investigate the most unfavourable combination
d 4 z of loads taking account of the temperature behaviour of the ther-
--------------------------------------------------------------------------------------------------------------------------------------------------  1 (38)
K *K,d moplastics.
 b Pr + s B   s B  -----------------------
2  A1  I 4.2.2 Shell
The numerator indicates the claw force to be accommodated and Sufficient safety against axial and shell pressure stabilities as
the denominator the claw force which can be accommodated and well as against the interaction of both must be proven for the
results from the shearing stress in the weld. In this respect, half shell of the tank. It is not necessary to prove the stability next to
the creep strength is estimated as the shearing stress. the nozzles because of the limitation of the nozzle diameters.
231
The prerequisite is that the out-of-roundness of the cylinder lated from:
remains limited in the following form:
ToC
EK s Z 2.5
p kM,d = 0.67  C *  ----------------  ------   -----
2   d max – d min  r
N/mm2 (51)
u = ------------------------------------------  100  0.5 % (44) M hZ  r 
d max + d min
with C * = 1.0 for tanks with solid roofs
4.2.2.1 Axial stability with C * = 0.6 for the open tanks
For every course i, the axial compressive stress which exists at The critical shell pressure of the graduated cylinder may be
the lower edge and consists of the dead weight, the partial calculated on a three-course equivalent cylinder according to
vacuums pu, puK and pus as well as the snow and wind loads is DIN 18800-4:
determined in the most unfavourable combination in each case
ToC
and is validated with the buckling stress k,i,d. EK r s o 2.5
p kM,d = 0.67    C *  ----------------  ----   ----- N/mm2 (52)
In the case of outdoor installation: M lo  r 
   The ß values are indicated on Figs. 20a to 20c in DIN 18800-4.

 vorh
i,d = max  F1   G +  F2  max   pu  pus  + 0.7   s + -------
 1.2 
w
- ,
4.2.2.3 Interaction
The interaction between the axial and shell pressure stabilities
-----   F1   G +  F2    puK +  s  N/mm2 (45) must be proven for every course:
1.25 1.25
In the case of indoor installation:  A,i +  M 1 (53)
 The longitudinal stresses caused by a partial vacuum do not

vorh
i,d =  F1   G +  F2  max   puK  pus  N/mm2 (46) have to be taken into consideration during the calculation of A,i
The stress resulting from the wind moment W may be divided by for the interaction since their effect is already included in M.
1.2 because the buckling stress should be increased by 20 % in
the event of global bending. 4.2.3 Conical roof
Using a simplifying method, the buckling stress may be deter- The most unfavourable combination of the compressive stresses
mined according to the following formula: in the circumferential direction in the centre of the shell line of the
ToC
conical roof (d/4):
EK s Z,i
-  -------
 k,i,d =  i  0.62  f ,i  --------------- -  KK,d N/mm2
 vorh
*
(47)
M
 d
r vorh pd d
= ------------------------  ------ N/mm2 (54)
4  cos s D
0.70
with  i = ------------------------------------------------------------------ (48a)
20 o C is validated with the critical stresses:
EK  r 
------------------
o  1 + ---------------------- ToC
20 C  100  s Z,i EK s 1.5
EL -  sin   cos    -----D-
 k,d = 2.68  --------------- N/mm2 (55)
M  d
ei
and=
f ,i 1.5 – --------  1.0 (48b) with
s Z,i

vorh
where ei is the eccentricity in relation to the thicker of the two A 2l   l  d
neighbouring courses in the case of a graduated cylinder if this is  = ---------------------------------------------  1 (56)
 k,d
itself thicker than the course i under consideration.
It is necessary to comply with the following condition for every It is necessary to investigate the combinations in Table 7.
course i:

vorh 5 Appendix
A 2l   I  i,d
 A,i = ------------------------------------------------  1 (49)
 k,i,d 5.1 Explanations
This technical code was elaborated by DVS-AG W4.3b ("Struc-
4.2.2.2 Shell pressure stability tural designing / apparatus engineering") together with the com-
The crucial partial vacuum resulting from the most unfavourable mittee of experts "Plastic tanks and pipes" (project group "Calcu-
combination of the partial vacuums pu, puK, pus and peu is vali- lation").
dated with the critical shell pressure pkM,d. During the revision, a distinction was made as to whether the
The following condition must be fulflled: tanks had to be dimensioned exclusively with regard to the loads
resulting from the internal pressure due to the filling material and

vorh the filling height (this corresponds to the viewpoint of the 1974
A 2l   l  pd
edition) or whether any additional loading cases (e.g. wind or
 M = --------------------------------------------  1 (50) snow loads) had to be taken into consideration during the dimen-
p kM,d
sioning. The latter approach was chosen for the new edition of
The critical shell pressure of the non-graduated cylinder is calcu- this technical code.
Table 7. Load combinations for the stability calculation of the roof.
 pd
Installation Combination vorh Temp.
Indoors max   F1  g D +  F2  p uK  F1  g D +  F2  p us  TDK

Outdoors Winter max   F1  g D +  F2   p S + p uK   F1  g D +  F2   0.7  p S + p us   0°C
Outdoors Summer max   F1  g D +  F2  p uK  F1  g D +  F2  p us  50°C
232
The application relating to the "installation and operation of tanks pr EN ISO 15014 Extruded panels made of polyvinylidene fluo-
within buildings" is dealt with in Supplement 1. ride (PVDF); requirements and test proce-
dures
Supplement 2 includes the dimensioning for collecting devices
(collecting tanks). 5.2.4 Pipes and fittings
Supplement 3 includes the dimensioning for flat roofs. DIN 8061 Pipes made of unplasticised polyvinyl chloride –
General quality requirements
5.2 Standards and technical codes
DIN 8062 Pipes made of unplasticised polyvinyl chloride
(PVC-U and PVC-HI); dimensions
5.2.1 Fundamentals of calculation
DIN 8074 Pipes made of polyethylene (PE) – PE 63, PE 80,
DIN 1055-3 Effects on load-bearing structures – Dead and PE 100 and PE-HD – Dimensions
useful loads for high-rise structures
DIN 8075 Pipes made of polyethylene (PE) – PE 63, PE 80,
DIN 1055-4 Effects on load-bearing structures – Wind loads PE 100 and PE-HD – General quality require-
DIN 1055-5 Effects on load-bearing structures – Snow and ice ments and tests
loads DIN 8077 Pipes made of polypropylene (PP) – PP-H 100,
DIN 4119-1 Above-ground cylindrical flat-bottom tank struc- PP-B 80 and PP-R 80 – Dimensions
tures made of metallic materials; fundamentals, DIN 8078 Pipes made of polypropylene (PP) – PP-H (Type
execution and tests 1), PP-B (Type 2) and PP-R (Type 3) – General
DIN 4119-2 Above-ground cylindrical flat-bottom tank struc- quality requirements and testing
tures made of metallic materials; calculation DIN 8079 Pipes made of chlorinated polyvinyl chloride
DIN 18800-4 Steel structures; stability cases; shell bulges (PVC-C) – PVC-C 250 – Dimensions
DIN EN 1778 Characteristic parameters for welded thermoplas- DIN 8080 Pipes made of chlorinated polyvinyl chloride
tic structures; determination of the permissible (PVC-C) – General quality requirements and test-
stresses and moduli for the calculation of thermo- ing
plastic components DIN 4740-1 Ventilation and air conditioning installations; pipes
made of unplasticised polyvinyl chloride (PVC-U)
5.2.2 Moulding materials – Calculation of the minimum wall thicknesses
DIN EN ISO Polyethylene (PE) moulding materials DIN 16 961-1 Pipes and fittings made of thermoplastics with
1872-1 Part 1: Designation system and basis for specifi- profiled walls and smooth inside pipe surfaces –
cations Part 1: Dimensions
DIN EN ISO Polyethylene (PE) moulding materials DIN 16 961-2 Pipes and fittings made of thermoplastics with
1872-2 Part 2: Manufacture of test specimens and deter- profiled walls and smooth inside pipe surfaces –
mination of properties Part 2: Technical terms of delivery
DIN EN ISO Polypropylene (PP) moulding materials DIN EN ISO Plastic piping systems for industrial applications –
1873-1 Part 1: Designation system and basis for specifi- 15494 Polybutene (PB), polyethylene (PE) and polypro-
cations pylene (PP) – Part 1: Requirements on piping
DIN EN ISO Polypropylene (PP) moulding materials parts and piping systems – Metric series
1873-2 Part 2: Manufacture of test specimens and deter- DIN EN ISO Plastic piping systems for industrial applications –
mination of properties 15493 Acrylonitrile butadiene styrene (ABS), unplasti-
DIN EN ISO Unplasticised polyvinyl chloride (PVC-U) moulding cised polyvinyl chloride (PVC-U) and PVC-C –
1163-1 materials Requirements on piping parts and piping systems
Part 1: Designation system and basis for specifi-
cations 5.2.5 DVS technical bulletins and technical codes
DIN EN ISO Unplasticised polyvinyl chloride (PVC-U) moulding DVS 2205 Calculation of tanks and apparatus made of ther-
1163-2 materials moplastics;
Part 2: Manufacture of test specimens and deter- Part 1 -; characteristic values
mination of properties Part 3 -; welded joints
DIN EN ISO Fluoropolymer dispersions, moulding materials and Part 4 -; flanged joints; as well as supplement
12086-1 extrusion materials DVS 2201 Testing of semi-finished products made of ther-
Part 1: Designation system and basis for specifi- moplastics
cations Part 1: Fundamentals – Remarks
Part 2: Weldability and test procedures – Require-
5.2.3 Panels and welding filler materials ments
DIN EN 12943 Welding filler materials for thermoplastics; DVS 2206 Testing of components and structures made of
scope of application, identification, require- thermoplastics
ments and testing DIBt Media list for tanks, collecting devices and pipes
DIN EN ISO Extruded panels made of polyethylene made of plastic
14632 (PE-HD); requirements and test procedures
E-DIN EN ISO Pressed panels made of polyethylene 5.3 Literature
15527 (PE-UHMW, PE-HMW and PE-HD); require- [1] Timoshenko, S.: Theory of plates and shells. McGraw Hill
ments and test procedures Book Comp, New York / London 1959.
DIN EN ISO Extruded panels made of polypropylene (PP); [2] Kempe, B.: Deformation measurements on a tank made of
15013 requirements and test procedures high-density polyethylene in the case of a temperature
DIN 16927 Panels made of unplasticised polyvinyl chlo- change. Schw. Schn. 42 (1990), No. 4, p. 173.
ride; technical terms of delivery [3] Tuercke, H.: On the stability of tanks made of thermoplas-
E-DIN EN ISO Plastics, panels made of unplasticised polyvinyl tics, DIBt Communications, No. 5/1995.
11833-1 chloride; delivery forms, dimensions and prop-
erties; Part 1: Panels with thicknesses > 1 mm
233
5.4 Temperature-dependent and time-dependent elastic 5.5 Design-related details

moduli for stability and deformation calculations The following design examples are indicated in this section:
T oC – nozzle in the cylinder shell, Fig. 8
Table 8. Temperature-dependent short-time elastic moduli E K in – anchoring of the bottom, Fig. 9
N/mm2. – lifting lug, Fig. 10
– connection between the shell and the bottom, Fig. 11
Material  10°C 20°C 30°C 40°C 50°C 60°C 70°C 80°C
– connection between the shell and the roof, Fig. 12
PE-HD 1,100 800 550 390 270 190 – – – edge of open tanks, Fig. 13
PP-H 1,400 1,200 960 770 620 500 400 320
PP-B 1,200 1,000 790 630 500 400 320 250
PP-R 1,000 800 620 490 380 300 230 180
PVC-NI 3,200 3,000 2,710 2,450 2,210 2,000 – –
 10°C 20°C 40°C 60°C 80°C 100°C – –
PVDF 1,900 1,700 1,330 1,050 820 650 – –
20 oC
Table 9. Time-dependent long-time elastic moduli E L in N/mm2.
Material 1 year 5 years 10 years 15 years 20 years 25 years

PE-HD 308 269 254 245 239 235
PP-H 464 393 365 350 340 330
PP-B 405 334 307 293 283 275
PP-R 322 298 288 283 279 276
PVC-NI 1,800 1,695 1,652 1,627 1,609 1,600
PVDF 810 763 744 733 725 720
Remark: The elastic moduli for PE-HD may also be used for
PE 63, PE 80 and PE 100. The long-time elastic moduli
for PE apply to stresses   0.5 N/mm² and those for
PP to   1 N/mm². The stress dependence of the elas-
tic moduli for PVC-NI and PVDF can be neglected.
Figure 8. Nozzle in the cylinder shell.
Without a gap and without pressing
Anchor bolt
Claw: steel
Spacer plates
PE sheet 2 mm
Minimum number
of claws: 4
Figure 9. Anchoring of the bottom.
234
Use a cross-beam for the lifting

of the tank
Bei
If bÖEinhaltung
is compliedvon bÖ aauch
with, eckiger
square
Anschluss möglich
connection is also possible.
ü  without anchoring Extruder weld

ü  with anchoring
Figure 11. Connection between the shell and the bottom. Figure 12. Connection between the shell and the roof.
235
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Erstellt am:
Zuletzt geändert am:lizensiert für: SLV Nord gGmbH
07.10.2008
02.12.2014
December 2008

Calculation of tanks and apparatus made
FÜR SCHWEISSEN UND of thermoplastics Technical Code
Welded stationary tanks in the case DVS 2205-2
of installation in buildings Supplement 1
Translation of the German edition from November 2003
Contents: Restriction on the main dimensions:

Tank diameter: d4m
Ratio: h/d  6
Minimum wall thicknesses: s = 4 mm
3 Loading
3.1 Continuously effective loads Attention must be paid to the responsibilities of certain legal fields
3.1.1 Total dead load (e. g. building law, water law, occupational health and safety law
3.1.2 Load of the filling material etc.).
3.1.3 Internal and external pressures
3.2.1 Internal and external pressures 2 Calculation variables
3.2.2 Partial vacuum due to wind suction
a mm Weld thickness
3.2.3 Moving loads on the roof
3.2.4 Assembly loads AB m² Area of the bottom
3.3 Temperature AD m² Area of the roof

4 Proof of the steadiness AZ m² Shell area of the cylinder
4.1 Proof of the strength
A1 – Reduction factor for the influence of the specific
4.1.1 Shell
toughness (corresponds to A4 according to the
4.1.2 Bottom DVS 2205-1 technical code)
4.1.3 Nozzles
4.1.4 Lifting lugs A2 – Reduction factor for the medium in the case of
4.2 Proof of the stability the proof of the strength
4.2.1 Shell A2l – Reduction factor for the medium in the case of
4.2.2 Conical roof the proof of the stability
5 Appendix bÖ mm Width of the lifting lug
5.1 Explanations C – C 1  C2
C1 – Stress-increasing factor
5.3 Literature
5.4 Computational elastic moduli for stability calculations C2 – Material-specific design factor
5.5 Design-related details d mm Nominal inside diameter
dA mm Outside diameter of the nozzle
dL mm Hole diameter in the lifting lug
dmax mm Maximum cylinder diameter
The following design and calculation rules apply to vertical, cylin- dmin mm Minimum cylinder diameter
drical flat-bottom tanks which are fabricated from thermoplastics dSch mm Diameter of the shackle
in the factory, in particular: o
T C N/mm² Elastic modulus in the case of short-time load-
– polyethylene (PE) EK ing for T°C
– polypropylene (PP) fs – Long-time welding factor
– polyvinyl chloride (PVC)
fsD – Long-time welding factor for the roof
– polyvinylidene fluoride (PVDF)
This part of the technical code is only applicable to the installation fz – Short-time welding factor
of the tanks in buildings. g m/s² Acceleration due to gravity (9.81 m/s²)
The cylindrical shell with an identical wall thickness throughout or GB N Dead load of the bottom
with a graduated wall thickness can be welded together from GD N Dead load of the roof
panels or may consist of a wound pipe or an extruded pipe. GE N Total dead load
Consideration must be given not only to the hydrostatic loading GF kN Load of the filling material
but also to pressures effective for short and long times. The
following minimum values are stipulated:
h mm Height of the tank
Overpressure: 0.0005 N/mm² (0.005 bar)
hF mm Filling height
Partial vacuum: 0.0003 N/mm² (0.003 bar)
hF,i mm Filling height of the course i
The pressures effective for a long time may only be applied if
they can also take effect. hZ mm Cylindrical height
236
hZ,i mm Height of the course i

hZF mm Height of the lower course
K *K N/mm² Creep strength for 10-1 hours
KL* N/mm² Creep strength for the computational working

life at the mean effective temperature
lo mm Length of the upper course of the equivalent
cylinder
lm mm Length of the central course of the equivalent
cylinder
lu mm Length of the lower course of the equivalent
cylinder
pstat N/mm² Overpressure at the tank bottom due to the fill-
ing medium
pstat,i N/mm² Overpressure per lower edge of the graduation
due to the filling medium
pu N/mm² Continuously effective external pressure (or in-
Figure 1. Open flat-bottom tank with a non-graduated wall thickness.
ternal partial vacuum)
puK N/mm² External pressure (or internal partial vacuum)
effective for a short time
pus N/mm² Partial vacuum due to wind suction
pü N/mm² Continuously effective internal pressure
püK N/mm² Internal pressure effective for a short time
sa mm Executed wall thickness of the basic component
sB mm Wall thickness of the bottom
sD mm Wall thickness of the roof
sM mm Wall thickness of a one-course cylinder
resulting from the partial vacuum stability
sZ mm Wall thickness of the cylinder
sZF mm Wall thickness of the lowest course
sZFC mm Statically required wall thickness resulting from
the longitudinal stress
sZFR – Statically required wall thickness resulting from
the ring tension
sZ,1 – Wall thickness of the highest course
sZ,i mm Wall thickness of the course i Figure 2. Open flat-bottom tank with a graduated wall thickness.
TA – Outdoor air temperature
TD – Temperature of the roof
TM mm Media temperature
TW – Wall temperature of the collecting device
TZ °C Temperature of the tank wall
u % Permissible out-of-roundness
V m³ Filling volume
vA – Weakening coefficient
D ° Pitch of the roof
F – Coefficient for the calculation of the roof
S – Coefficient for the calculation of the roof
B – Coefficient for calculation of the bottom
F mm Coefficient for the calculation of the roof
S mm Coefficient for the calculation of the roof
 % Tolerable edge fibre expansion
F Partial safety coefficient of the effect/stresses
I Weighting factor depending on the loading type
(see DVS 2205-2)
M Partial safety coefficient of the resistance/
stressability
 ° Angle of the roof in relation to the perpendicular
 – Coefficient for the shell pressure stability
 g/cm³ Density of the material ( =   g) Figure 3. Flat-bottom tank with a conical roof and a non-graduated wall
thickness.
F g/cm³ Density of the filling medium
237
3.2.1 Internal and external pressures püK and puK

As far as no higher pressures can occur as a result of the
operating method, the minimum pressures indicated in Section 1
must be taken into consideration. The definition of püK results in
püK  pü (see Figure 5). The same applies analogously to puK.
The following conditions must be complied with for the pressures
effective for a short time:
KK* KK*
p uK  ---------
-  p u and p üK  ---------
-  pü
K *L K *L
Pressure
Time
Figure 4. Flat-bottom tank with a conical roof and a graduated wall thick-
ness. Figure 5. Definition of püK.
3.2.2 Partial vacuum due to wind suction

3 Loading In the case of ventilated tanks, an internal partial vacuum results
from a suction effect (on this subject, see the DVS 2205-2
3.1 Continuously effective loads technical code, Section 3.3.5).
Depending on the application, tanks are designed for a computa- pus = 0.48  10-3 N/mm² is applicable if the ventilation is carried
tional operating time of up to 25 years (2  105 hours). The com- out through a pipe leading to the outside.
putational filling height hF is determined by the existing operating
conditions. 3.2.3 Moving loads on the roof
It is not allowed to walk on the roofs without taking any load-
3.1.1 Total dead load GE distributing measures. Corresponding precautions must be taken
GE = GD + GZ + GB N (1) during assembly and inspection work.
Dead load of the roof GD: 3.2.4 Assembly loads

GD = AD  s D    g N (2) The tank must be designed for the loading conditions arising
during the transport and the assembly. In this respect, the
Dead load of the cylinder GZ: calculation is made with 1.5 times the assembly loads (surge
GZ = AZ  sZ    g N (3) factor). F1 is estimated as the partial safety coefficient. The
short-time welding factor according to DVS 2205-1 must be taken
Dead load of the bottom GB: into consideration.
GB = AB  sB    g N (4) 3.3 Temperature
Ladders, platforms, pedestals and similar items must be set up The effective wall temperature is decisive for the dimensioning of
and fastened independently of the tank since the free expansion the components. Wetted parts must always be designed for the
of the tank (e. g. during filling and emptying and in the case of media temperature TM. For non-wetted parts, the mean of the two
temperature changes) would otherwise be hindered. These neighbouring air temperatures may be estimated as the wall tem-
hindrances cause considerable stress peaks which are difficult to perature using a simplifying method. The media temperature is
record computationally and, if they are taken into account, lead to assumed to be the air temperature in the tank and TA = 20°C the
uneconomic designs. If there is any deviation from this, corre- mean outdoor air temperature over a long time in the case of in-
sponding proof must be provided. door installation. The wall temperatures are indicated on Figure 6.
3.1.2 Load of the filling material GF

G F = V  F  g kN (5)
3.1.3 Internal and external pressures pü and pu

Higher pressures than indicated in the scope of application must
be taken into account at the level set by the operator.
If any safety fittings which cause higher pressures (such as over-
filling protection devices or ventilation and venting facilities) are
connected, these pressures must be taken into consideration.
These pressures must not be effective when the tank has been
emptied since the bottom would otherwise be in danger or the
tank would be lifted.

The effective duration of loads effective for a short time is stipu- With
Without
lated as 10-1 hours (e. g. assembly loads). collecting device collecting device
Any water hammers which may arise during filling operations
must be prevented by taking suitable measures. Figure 6. Definition of the effective temperatures.
238
Outdoor air temperature: TA = 20°C in the case of indoor installa- Table 1. Tolerable edge fibre expansion.
tion
Material Edge fibre expansion 
Without collecting device With collecting device
PE-HD 1.00
TD = (TM + TA)/2 TD = (TM + TA)/2
PP-H 0.50
TZ = (TM + TA)/2 TZ = (3 TM +TA)/4
PP-B 0.75
PP-R 1.00
PVDF 0.50
The proof of the steadiness is provided according to the concept PVC-U 0.20
of the partial safety coefficients. In this respect, the characteristic
PVC-C 0.10
effects or the stresses are multiplied by the partial safety
coefficients F according to the following table:
and PE 100.
Effect Partial safety coefficient
Dead weight, filling and assembly F1 = 1.35 The factor C for the welded interface of the bond between the
bottom and the shell is the product of the stress-increasing factor
Pressures F2 = 1.5 C1 = 1.2 and a material-specific design factor C2 according to
Table 2.
Moreover, the effects are multiplied by the reduction factors A1
and A2 as well as by the weighting coefficent I.
Table 2. The material-specific design factor C2 and the factor C for
The characteristic resistances or the stressabilities are divided by thermoplastics.
the partial safety coefficient M = 1.1.
Material C2 C = C1  C2
4.1 Proof of the strength PE-HD 1.00 1.20
4.1.1 Shell PP-H (Type 1) 1.17 1.40
The height of the lowest course hZF must be min. 1.4  d  s ZF PP-B (Type 2) 1.00 1.20
In the case of graduated tanks, neighbouring courses may have PP-R (Type 3) 1.00 1.20
a wall thickness ratio of max. 3 without any further proof. In the PVC-NI (normal impact strength) 1.25 1.50
case of sudden thickness changes with a wall thickness ratio
greater than 2, it is necessary to use the shell seam formation PVC-RI (increased impact strength) 1.08 1.30
according to DVS 2205-3, Figure 2.2 a, 2.2 c or 2.2 c1. PVC-HI (high impact strength) 1.00 1.20
Lowest course PVC-C 1.33 1.60
The maximum of both the following cases of proof is crucial for PVDF 1.17 1.40
the wall thickness sZF of the lowest course.
s ZF = max  s ZFR, s ZFC 
and PE 100.
  F1  p stat +  F2  p ü   d A 1  A 2   I It is not necessary to provide any proof of the stresses in the weld
s ZFR = --------------------------------------------------------------  -------------------------- mm (6) if a fillet weld is executed with a weld thickness a  0.7  sB and a
K *L fs
2  --------- long-time welding factor fs  0.6.
M
In the case of one-shell tanks with capacities up to 1,000 l and
C    F1  p stat +  F2  p ü   d wall thicknesses up to 10 mm, this also applies to long-time
s ZFC = -----------------------------------------------------------------------  A 1  A 2   I mm (7)
K *L welding factors fs  0.4.
2  ---------
M One prerequisite for the stress-increasing factor C1 = 1.2 is that
with the bottom is not executed with a thickness greater than the wall
thickness of the lowest course (sB  sZF).
–6
p stat =  F  g  h F  10 N/mm2 (8)
4.1.2 Bottom
where hF means the filling height.
B = sB / sZFC
Intermediate courses
The wall thickness sZ,i for every course i results from the ring
tensile stresses due to the filling and the overpressures at its zulässiger Bereich
Permissible range für
for C == 1,2
1.2
lower edge.
  F1  p stat,i +  F2  p ü   d A 1  A 2   I
s Z,i = -----------------------------------------------------------------  -------------------------- mm (9)
K *L fs
2  ---------
M
–6
p stat,i =  F  g  h F,i  10 N/mm2 (10)
The welding factor of the shell weld fs is taken into account in (6)
and (9) in the case of cylinders manufactured from plates.
According to today's state of the art, preference should be given d / sZFC
to heated tool butt welding. fs = 1 applies to wound tanks.
The residual stresses resulting from the bending of the panels at Figure 7. Diagram for the determination of the thickness of the bottom,
the room temperature can be neglected if the edge fibre derived for PE-HD (for C > 1.2, this diagram is on the safe
expansion (Table 1)  = s/d  100 [%] is not exceeded. side).
239
If the bottom and the cylinder are joined with fillet welds (Figure d Sch  d L  1.1  d Sch
11), the required thickness of the bottom may be determined as
follows: It must be proven that 1.5 times the loading (surge factor) can be
borne for a short time at 20°C. I = 1.2 must be set in this respect.
 B  s ZFC  s B  s ZF
The required wall thickness (sÖ) of the lifting lug results from the
with sZF as the executed wall thickness and B according to proof for the face of the hole:
Figure 7 (see Page 4).
GE – GA
In the case of other structural shapes, it is necessary to provide 1.5   F1  ---------------------
2
proof of the bottom due to the cylinder clamping moment. sÖ = -----------------------------------------------  A 1   I mm (13)
K *K
For the proof of the bottom of unanchored tanks with overpres- d Sch   2  ----------
 M 
sure and for the proof of any anchoring which may be required,
see Sections 4.1.4.2 and 4.1.8 in the DVS 2205-2 technical code. The maximum of both the following cases of proof is crucial for
the width of the lifting lug (bÖ).
4.1.3 Nozzles
bÖ = max (bÖ,1, bÖ,2)
The nozzles must generally be attached to the roof.
Proof of the shearing stress for the transverse weld during the
4.1.3.1 Nozzles in the roof lifting of the lying tank:
It is not necessary to provide any proof of the stresses on the roof GE – GA
due to the weakening caused by the nozzle cut-out if the edges 1.5   F1  --------------------- A  
4 - --------------
---------------------------------------------- 1
-I
of the nozzles are min. 100 mm away from the edge of the roof b Ö,1 =  mm (14)
K *K fz
and are not arranged in the region of the longitudinal weld of the 0.7  s Z,1  --------------
roof. 2  M
4.1.3.2 Nozzles in the shell Eye bar:
If nozzles are attached to the cylinder, the maximum outside GE – GA

1.5   F1  ---------------------
diameter of the nozzle is limited to dA = 160 mm. The distance 2 7
between the centres of the nozzles and the edges, the course b Ö,2 = -----------------------------------------------  A 1   I + ---  d L mm (15)
K *K 3
boundaries or the welds in the basic component must be min. s Ö  ----------
M
dA/2 + 100 mm. However, the distance between the centres of
the nozzles and the bottom and a neighbouring course with a
lower wall thickness must be min. dA. 4.2 Proof of the stability
It must be proven that it is possible to accommodate the stresses
4.2.1 Shell
on the basic component which are increased as a result of the
stress concentration close to the opening. The required wall thicknesses resulting from the shell pressure
stability caused by the partial vacuum pu are determined with the
The stresses in the undisturbed basic component are increased
aid of a three-course equivalent cylinder (Figure 8). The
by dividing them by the weakening coefficient vA:
dimensions of the equivalent cylinder are compiled in Table 3.
0.75 The coefficient results from:
vA = ---------------------------------------------------- (11)
dA sM
1 + ----------------------------------------- -  = ------------- (16)
2   d + sa   sa 2  sZ
with dA outside diameter of the opening with
d cylinder diameter
sa executed wall thickness of the basic component   0.4
 h Z   F2   I  p u
s ZFR s Z,i 
s M = 0,77  A 2l  -------------------------------------
- d mm (17)
s a = -----------
- bzw. s a = -------
- mm (12)  T C
o

vA vA  EK 
 ---------------
-d 
M
As far as the above distance between the centre of the nozzle o
T C
and the longitudinal weld is complied with in the case of plate The temperature-dependent and time-dependent E K moduli
tanks, the wall thickness sZFR or sZ,i can be reduced with the are indicated in Table 5 (Section 5.4).
welding factor fs in Equation 12.
The structural designing must be carried out according to Figure
9, Section 5.5 (pushed-through nozzle). The wall thickness of the
nozzle must correspond to min. SDR 11 (formerly PN 10).
4.1.4 Lifting lugs

One of the possible lifting lug shapes is shown on Figure 10
(Section 5.5). The prerequisites for the use of these lifting lugs
are that only two lifting lugs are used per tank and that one
parallel hanger is utilised.
In order to be able to dispense with any proof of the load
introduction into the highest course, it must be ensured that the
lifting lug is not thicker than three times the wall thickness of the
highest course. The hole diameter (dL) must be adapted to the
diameter of the shackle (dSch).
The following equations are applicable:
s Z,i  erf s Ö  3  s Z,i Figure 8. Equivalent cylinder according to DIN 18800-4.
240
Table 3. Dimensions of the equivalent cylinder depending on . PE 100 30 25 204 0.8 337 0.5
Dimensions of Formulae for the calculation 40 30 185 0.9 316 0.6
the equivalent 1/3 <  < 1/2 1/2
 1/3 50 35 171 1.1 297 0.7
cylinder
60 40 156 1.2 279 0.7
lo  ∙ hZ  ∙ hZ –
so sM ∙ (1 + 5 ∙ )/4 2 ∙  ∙ sM sM Table 5. Continuation.
lm lo (hZ – lo)/2 –
Material Mean Effective S S F F
sm sM sM sM media wall
temperature temperature
lu hZ – 2 ∙ lo lm –
su 2 ∙ sm – so 2 ∙ sm – so sM [°C] [°C] [mm] [mm]
PP-H 30 25 256 0.5 296 0.7
The graduations should have approximately identical lengths 40 30 242 0.6 321 0.6
( 500 mm) with thickness changes  1 mm.
50 35 230 0.6 299 0.6
The graduation should be refined in such a way that the condition
sZ,i  h Z,i  so  lo and with sm  lm or su  lu is complied with. A 60 40 218 0.7 278 0.7
uniform graduation should be striven for in this respect. PP-B 30 25 234 0.6 303 0.6
The prerequisite is that the out-of-roundness of the cylinder 40 30 221 0.7 281 0.7
remains limited in the following form: 50 35 209 0.8 260 0.8
2   d max – d min  60 40 198 0.8 239 0.9
u = ------------------------------------------  100  0.5 % (18)
d max + d min PP-R 30 25 209 0.8 332 0.5
4.2.2 Conical roof 40 30 196 0.9 310 0.6
The pitch of the conical roof must not be less than D = 15° 50 35 186 0.9 289 0.7
( = 75°). 60 40 175 1.0 269 0.8
The proof of the stability resulting from the dead weight and the PCV-NI 30 25 381 0.4 446 0.4
partial vacuum is always crucial for the dimensioning of the roof 40 30 372 0.4 413 0.5
with partial vacuums up to 0.003 bar. In the case of tanks which
50 35 363 0.4 384 0.5
do not have any free ventilation and are subjected to partial
vacuums pu > 0.003 bar effective for a long time, the proof of 60 40 354 0.4 353 0.6
the strength may determine the dimensioning. The following PVDF 30 25 274 0.7 480 0.4
approximation applies to 1,000 mm  d  4,000 mm and D = 15°:
40 30 266 0.8 469 0.5
A 2l p u  bar 0.4 50 35 257 0.8 447 0.5
=  ----- –  s   --------  ----------------------
d
sD mm (19a)
   1.4 0.003  60 40 249 0.8 423 0.5
s
with s and S according to Table 4. 70 45 242 0.9 417 0.5
For pu > 0.003 bar, it must be checked whether the roof thick- 80 50 235 0.9 412 0.6
ness determines the dimensioning because of the proof of the
strength according to Equation 19b:
A 2 p u  bar 0.648 5 Appendix
s D =  ------ –  F   --------  ----------------------
d
mm (19b)
   1.4 0.003 
F
5.1 Explanations
with F and F according to Table 4. A long-time welding factor
fsD  0.6 is a prerequisite. If the tanks are installed in buildings, it is not necessary to take
d = 1,000 mm must be used in the calculation for d < 1,000 mm. account of any additional loading resulting, for example, from
wind and snow loads. This permits the less complicated
Table 4. Coefficients for the calculation of the roof for D = 15°. calculation of the tanks compared with the DVS 2205-2 technical
code.
Material Mean Effective S S F F
media wall 5.2 Standards and technical codes
temperature temperature
[°C] [°C] [mm] [mm] See DVS 2205-2, Section 5.2.
PE-HD 30 25 204 0.8 277 0.7
40 30 185 0.9 238 0.9 5.3 Literature
50 35 171 1.1 203 1.2 [1] Timoshenko, S.: Theory of plates and shells. McGraw Hill
60 40 156 1.2 171 1.6 Book Comp, New York / London 1959.
PE 63 30 25 204 0.8 230 1.0
[2] Kempe, B.: Deformation measurements on a tank made of
40 30 185 0.9 214 1.1 high-density polyethylene in the case of a temperature
50 35 171 1.1 200 1.3 change. Schweißen & Schneiden, No. 4/90.
60 40 156 1.2 187 1.4
[3] Tuercke, H.: Simplified proof of the shell pressure stability in
PE 80 30 25 204 0.8 281 0.7 the case of flat-bottom tanks made of thermoplastics, DIBt
40 30 185 0.9 263 0.8 Communications, No. 6/1995.
50 35 171 1.1 246 0.9
[4] Tuercke, H.: On the stability of tanks made of thermoplastics,
60 40 156 1.2 231 1.0 DIBt Communications, No. 5/1995.
241
5.4 Computational elastic moduli for stability calculations
Table 6. Temperature-dependent short-time elastic moduli ET°CK in

N/mm².

PE-HD 1100 800 550 390 270 190 – –
PP-H 1400 1200 960 770 620 500 400 320
PP-B 1200 1000 790 630 500 400 320 250
PP-R 1000 800 620 490 380 300 230 180
PVC-NI 3200 3000 2710 2450 2210 2000 – –
 10°C 20°C 40°C 60°C 80°C 100°C – –
PVDF 1900 1700 1330 1050 820 650 – –

and PE 100.

The following design examples are indicated in this section:
– nozzle in the cylinder shell, Figure 9
– lifting lugs, Figure 10
– connection between the shell and the bottom, Figure 11
– connection between the shell and the roof, Figure 12
– edge of open tanks, Figure 13 Figure 9. Nozzle in the cylinder shell.
Use a cross-beam for the

lifting of the tank
If bÖ is complied with, a square

connection is also possible
242
ü  10 without anchoring
ü  25 with anchoring
Figure 11. Connection between the shell and the bottom.
Extruder weld
Figure 12. Connection between the shell and the roof.
243
Draft January 2015

FÜR SCHWEISSEN UND
of thermoplastics – Vertical round, non- Technical code
VERWANDTE VERFAHREN E.V. pressurised tanks – Tray collectors DVS 2205-2
Supplement 2
Contents: 2 Calculation variables
1 Scope a mm Thickness of the weld seam

2 Calculation variables AB m2 Area of the base
3 Stresses Aj m2 Area exposed to wind (partial area)
3.1 Loads AZ m2 Casing area of the cylinder
3.1.1 Total dead load
3.1.2 Load of the filling material GF A1 – Reduction factor for the influence of the specific
3.2 Wind strength (corresponds to A4 according to
Guideline 2205-1)
3.2.1 Wind loads
3.2.2 Radially symmetrical equivalent load due to wind pressure A2 – Reduction factor for the media influence in
3.3 Assembly loads strength analyses
3.4 Temperature A2K – Reduction factor for the media influence in
4 Stability analyses strength analyses for a 3-month effect
4.1 Strength analyses A2I – Reduction factor for the medium in stability
4.1.1 Effects analysis
4.1.2 Casing bÖ mm Width of the lifting lug
4.1.3 Base bPr mm Width of the lug
4.1.4 Base/casing welded joint
4.1.5 Anchors C – C1 ⋅ C2
4.1.6 Lifting lugs C1 – Stress increase factor
4.2 Stability analysis C2 – Material-specific form factor
4.2.1 Superposition of the effects C* – Factor for the circular cylinder which is
4.2.2 Axial stability subjected to external load
4.2.3 Casing compressive stability cf – Aerodynamic force factor
4.3 Verification of flotation safety
5 Appendix d mm Nominal internal diameter
5.1 Explanations dL mm Hole diameter in the lifting lug
5.2 References dmax mm Largest cylinder diameter
5.3 Temperature and time-dependent Young's moduli for dmin mm Smallest cylinder diameter
stability calculations
dSch mm Diameter of the shackle
5.4 Structural details o
20 C N/mm² Young's modulus for short-term loading at 20°C
EK
1 Scope o
30 C N/mm² Young's modulus for short-term loading at 30°C
EK
The following structure and calculation rules apply to tray o N/mm² Young's modulus for long-term loading at 20°C
20 C
collectors in the form of vertical, cylindrical, factory-fabricated flat EL
base tanks made of thermoplastics, in particular fs – Long-term weld strength reduction factor
– –Polyvinyl chloride (PVC), fz – Short-term weld strength reduction factor
– –Polypropylene (PP),
g m/s² Acceleration due to gravity (9.81 m/s2)
– –Polyethylene (PE),
– –Polyvinylidene fluoride (PVDF). GB N Dead load of the base
GE N Total dead load
The cylindrical casing with continuously equal or graduated wall
thickness can be welded from panels, or consists of a wound GF kN Load of the filling material
pipe or an extruded pipe. The cylinder and base of the tray GZ N Dead load of the cylinder
collectors must not have any openings. hF mm Fill height
The main dimensions depend on those of the tank which they are hF,i mm Fill height of section i
designed to receive, see Section 5. hZ mm Cylindrical height
The minimum wall thickness is 4 mm. hZ,i mm Height of section i
Responsibilities with regard to specific fields of law (for example hZF mm Height of the bottom section
building law, water law, Occupational Health and Safety Law,
etc.) must be taken into account.
244
vorh N/mm² Stress in the case of short-term effect σk,i,d N/mm² Rated value of the critical buckling stress in
KK
section i
vorh N/mm² Rated value of a short-term stress σW N/mm² Membrane compressive stress from the wind
K K,d
load
vorh N/mm² Rated value of a stress in the case of medium
K M,d
effective duration
K *K N/mm² Creep rupture strength for 10-1 hours
K *M,d N/mm² Rated value of the creep rupture strength for

medium effective duration
*
KK,d N/mm² Rated value of the creep rupture strength for
short effective duration
lo mm Length of the upper section of the substitute
cylinder
MW Nm Bending moment in the event of wind load
peu N/mm² Radially symmetrical equivalent load as a result
of wind pressure
pkM,d N/mm² Rated value of the critical casing buckling
pressure
pstat N/mm² Overpressure on the tank base due to the filling
medium
pstat,i N/mm² Overpressure per bottom edge gradation due to
the filling medium
q kN/m² Velocity pressure
qj kN/m² Velocity pressure on partial area Aj Figure 1. Tray collector for flat base tank.
qmax kN/m² Largest velocity pressure affecting the tank
r mm Radius of the cylinder
Rd N/mm² Rated value of the stress capacity 3 Stresses
sB mm Wall thickness of the base
The tray collectors are designed for the same calculated
operating time as the associated tank, whereby the filling from
sZ mm Wall thickness of the cylinder leaks load case is applied for three months.
sZF mm Wall thickness of the bottom section
The following loads must be taken into account in the stability
*
s ZF mm Minimum wall thickness based on calculations
analysis.
sZm mm Average wall thickness of the cylinder
sZ,1 mm Wall thickness of the top section
3.1 Loads
sZ,i mm Wall thickness of section i
so mm Wall thickness of the upper section of the 3.1.1 Total dead load GE
substitute cylinder
Sd N/mm² Rated value of the stress GE = GZ + GB N (1)
TA °C Average ambient temperature (according to Dead load of the cylinder GZ
Miner, see DVS 2205-1)
GZ = AZ ⋅ sZ ⋅ ρ ⋅ g N (2)
TAK °C Maximum ambient temperature
TM °C Average media temperature of the associated Dead load of the base GB
tank
GB = AB ⋅ sB ⋅ ρ ⋅ g N (3)
u % Permissible ovality
V m3 Filling volume Ladders, scaffolding, platforms and similar must be set up and
Wj kN Wind load secured separately from the tray collector, otherwise this
z – Number of anchors prevents the free elongation of the tray collector, in the case of
filling from leaks and temperature changes, for example. These
α – Auxiliary quantity
obstructions cause considerable voltage surges, which are
β – Factor difficult to calculate and taking them into account leads to
δ – Factor uneconomical structures. If this is not followed, an appropriate
δA – Factor for the determination of A2K analysis must be provided.
δB – Factor for the base calculation
ε % Acceptable extreme fibre expansion 3.1.2 Load of the filling material GF
GF = V ⋅ ρF ⋅ g kN (4)
ηM – Utilization of the casing compressive stability
γF – Partial safety factor of the action/stress
γM – Partial safety factor of the resistance/stress 3.2 Wind
capacity
ρ g/cm³ Material density (γ = ρ ⋅ g) 3.2.1 Wind loads
ρF g/cm³ Density of the filling medium The wind loads Wj should be calculated as follows:
σG N/mm² Membrane compressive stress from intrinsic
weight Wj = c f · q · A j kN (5)
vorh N/mm² Rated value of the decisive axial compressive The symbols have the following meanings:
σ i,d
stress in section i
Wj Wind load of the partial area Aj
σk N/mm² Critical buckling stress
cf Aerodynamic force factor
q Velocity pressure
245
Aj Associated exposed area in m² (for the receptacle: Diameter A reduced ambient temperature TAK - 5°C applies to stability
times height hZ) analyses in the cylinder for outdoor installation (wind effect).
The aerodynamic force factor does not need to be calculated
precisely if the following force factors are applied: 4 Stability analyses
Tank cf = 0.8 circular cylinder and roof; this takes all The stability analyses are carried out according to the partial
connecting pieces and row formations into safety factor concept. The following applies:
account
S
Ladder cf = 1.6 Ladders with 20% of the visible area ------d- ≤ 1 (10a)
Rd
Fittings cf = 1.2
with Sd rated value of the stress
The velocity pressure q is dependent on the wind zone, the terrain Rd Rated value of the stress capacity
category, the height of the terrain above sea level and the height of
the tank above the terrain according to DIN EN 1991-1-4/NA, Here, the characteristic forces and/or loads are multiplied by the
Part 1-4. Up to a height of 25 m above ground, the simplified partial safety factors γF as per Table 1.
assumptions of paragraph NA.3.3.2 can be used for calculations.
Table 1. Partial safety factors for forces.
The stress resulting from the wind moment MW may be simplified
and calculated as follows Partial safety
Force
3
factor
4 ⋅ M W,x ⋅ 10
σ W,i = ----------------------------------
- N/mm2 (6) Intrinsic weight, filling, assembly γF1 = 1.35
2
π ⋅ d ⋅ s Z,i Wind γF2 = 1.5
Mw,x at a height x above the tank base can be calculated using Load-reducing intrinsic weight γF3 = 0.9
an equivalent clamped rod.
For example, the rated value of the available stress results from
( hG – x )
2 γF times the characteristic value of the available stress in the
M W, x = c f1 ⋅ q ⋅ d ⋅ ----------------------
2
- + c f2 ⋅ q ⋅
 ( Aj ⋅ aj ) Nm (7) component.
vorh vorh
whereby aj is the lever arm of the area exposed to wind Aj of the KK,d = γ F ⋅ KK (10b)
structures and fittings in relation to the height x.
The measured values of the available stress must still be
multiplied by the reduction factors A1 and A2. When carrying out
3.2.2 Radially symmetrical equivalent load as a result of analyses in the weld seam, the rated value of the available stress must be
wind pressure
divided by the weld strength reduction factor.
The applied pressure load due to the wind blowing on the
The characteristic resistances and/or the stress capacities are
cylindrical casing is determined using an equivalent load peu.
divided by the partial safety factor γM = 1.3.
–3
p eu = δ ⋅ q max ⋅ 10 N/mm2 (8) For example, the rated value of the short-term strength results
from the characteristic short-term strength value K *K divided by
The symbols have the following meanings: γM according to the rupture strength diagrams of DVS 2205-1.
 r  KK*
r
δ = 0.46 ⋅  1 + 0.1 ⋅ C* ⋅ ------ ⋅ ---------- ≤ 0.6 (9)
*
KK,d = --------
- (10c)
γM
 h Z s Zm
C* = 0.6 4.1 Strength analyses
s Zm
 ( h Z,i ⋅ s Z,i )
= ---------------------------------- mm (10)
4.1.1 Effects
hZ
The most unfavourable combination of all the effects must always
be sought for each component.
3.3 Assembly loads
A distinction must be made between three load categories
The tray collector must be designed for load states which arise according to the effective duration.
during transport and assembly. When doing so, 1.5 x mounting
loads (impact factor) are used for calculation. γF1 is applied as a – –Short-term loads (K), such as wind: q, peu
partial safety factor. The short-term weld strength reduction – –Effects of medium effective duration (M), such as filling in the
factor must be taken into account according to DVS 2205-1. case of leakage
– –Long-term effects (L), such as intrinsic weight
3.4 Temperature
Short-term load cases do not need to be combined with each
The effective wall temperature is decisive when dimensioning
other.
components. In the case of a leak, the media-wetted parts must
be analysed using the average media temperature TM. The effective duration of short-term loads is defined as 10-1
A simplified calculation using the average of the two hours and the medium effective duration as 3 months.
neighbouring air temperatures can be performed for non-wetted
parts. In the case of ambient temperature, a distinction is made 4.1.2 Casing
based on the installation location and effective duration. The The height of the bottom section hZF must be at least
following minimum values apply for installation in Germany: 1,4 ⋅ d ⋅ s ZF . In the case of graduated tanks, a maximum wall
thickness ratio for neighbouring sections of 3 is permitted without
Minimum values Short-term Long-term further analysis. If there are thickness inconsistencies with a wall
Indoor installation TAK = 20°C TA = 20°C thickness ratio greater than 2, then the casing seam formation
according to DVS 2205-3 Figure 2.2 a), 2.2 c) or 2.2 c1) must be
Outdoor installation TAK = 35°C TA = 20°C used.
246
4.1.2.1 Analysis in circumferential direction Longitudinal stresses from the intrinsic weight can be ignored.
There is also no need to analyse the short-term tensile load from
For each section i, an analysis must be carried out to check that
wind.
the ring tensile load from filling can be withstood on its lower
edge: The analysis must be carried out according to equation (11)
vorh where:
KM,d
----------------
-≤1 (11)
K *M,d vorh d A 1 ⋅ A 2K
K M,d = C ⋅ γ F1 ⋅ p stat ⋅ --- ⋅ --------------------- N/mm2 (15)
2 s ZF
where:
and
vorh γ F1 ⋅ p stat,i ⋅ d A 1 ⋅ A 2K
K M,d = --------------------------------- ⋅ --------------------- N/mm2 (12) –6
2 ⋅ s Z,i fs p stat = ρ F ⋅ g ⋅ h F ⋅ 10 N/mm2 (16)
where: The factor C for the welded transition of the base-casing
–6 connection is the product of the stress increase factor C1 = 1.2
p stat,i = ρ F ⋅ g ⋅ h F,i ⋅ 10 N/mm2 (13) and a material-specific form factor C2 as per Table 4.
whereby hF,i denotes the height of the liquid level above the Table 4. Material-specific form factor C2 and factor C for
lower edge of section i. thermoplastics.
The reduction factor for the media influence for a 3 month effect
can be calculated for non-swelling media as follows Material C2 C = C1 ⋅ C2
PE-HD 1.00 1.20
A 2K = max ( δ A ⋅ A 2 , 1.0 ) (14)
PP-H (type 1) 1.17 1.40
with δA as per Table 2.
PP-B (type 2) 1.00 1.20
A2K = A2 for swelling media.
PP-R (type 3) 1.00 1.20
Table 2. Factors δA for determining A2K. PVC-NI (normal impact 1.25 1.50
resistance)
TM
°C PE-HD PE 63 PE 80 PE 100 PP-H PP-B PP-R PVC-RI (raised impact 1.08 1.30
3 months resistance)
20 0.52 0.07 0.09 0.17 0.10 0.19 0.07 PVC-HI (high impact resistance) 1.00 1.20
30 0.61 0.12 0.14 0.25 0.16 0.26 0.11 PVC-C 1.33 1.60
40 0.73 0.20 0.24 0.36 0.22 0.34 0.17 PVDF 1.17 1.40
50 0.90 0.34 0.37 0.49 0.31 0.43 0.24 Note: The value for PE-HD may be used for PE 63, PE 80, and
60 1.00 0.54 0.57 0.67 0.41 0.52 0.33 PE 100.
70 – – – – 0.53 0.61 0.45 There is no need for an analysis of the weld stresses in the seam
if the conditions in Section 4.1.4 are met.
80 – – – – 0.65 0.69 0.58
The stress increase factor C1 = 1.2 assumes that the base is not
Note: δA = 1.0 for PVC and PVDF thicker than the wall thickness of the bottom section (sB ≤ sZF)
In the case of cylinders made from plates, the weld strength and no base plate distance ü is greater than those shown in
reduction factor of the casing seam fs or fz must be taken into Figure 6.
account. Heated plate welding is preferred, based on the current
state of the art. fs = 1 and fz = 1 applies for wound tanks. 4.1.3 Base
The residual stresses from the panels bending at room If the base and cylinder are connected with fillet welds (Fig. 6),
temperature can be ignored if the extreme fibre expansions the required base thickness may be determined as follows
(Table 3) ε = s/d ⋅100 [%] are not exceeded.
δ B ⋅ SZF
* ≤ S B ≤ S ZF mm (17)
Table 3. Acceptable extreme fibre expansions. where sZF is the as-built wall thickness and δB as per Figure 2.
Material Extreme fibre expansion ε C ⋅ γ F1 ⋅ p stat ⋅ d
*
SZF = ----------------------------------------- ⋅ A 1 ⋅ A 2K mm (18)
PE-HD 1.00 2 ⋅ K *M,d
PP-H 0.50
The base of the tank must be fully bedded on a level, rigid
PP-B 0.75 supporting plate.
PP-R 1.00
4.1.4 Base/casing welded joint
PVDF 0.50
There is no need for an explicit analysis of the weld stresses if
PVC-U 0.20 the following conditions are met
PVC-C 0.10 – – Weld seam a ≥ 0.7 ⋅ sB
– – Long-term weld strength reduction
Note: The value for PE-HD may be used for PE 63, PE 80, and
factorfs ≥ 0.6
PE 100.
If one of these conditions is not met, then a detailed analysis of
4.1.2.2 Analysis in longitudinal direction the stresses in the seam must be carried out (e.g. FE
calculation).
For analysis of the stress in the longitudinal direction, only the
lowest section at the transition to the base needs to be examined. In the case of single-wall tanks with a volume of 1000 l with wall
Stresses resulting from the bending disturbance moment, thicknesses up to 10 mm, this also applies for long-term weld
intrinsic weight and wind arise here. strength reduction factors fs ≥ 0.4.
247
Figure 2. Diagram for determining the base thickness, derived for PE-HD (for C > 1.2, this diagram is on the safe side).
4.1.5 Anchors γ F1 ⋅ G E
1.5 ⋅ -------------------- A
If anchors are required, at least 4 anchors should be provided 4
- ⋅ -----1-
b Ö,1 = --------------------------------------- mm (23)
(z ≥ 4). The anchor forces (e.g. for the anchor fitting) must be KK,d* fz
calculated from the lug forces, taking the lever arms into account. 0.7 ⋅ s Z,1 ⋅ ------------
2
When analysing the anchoring, the short-term wind load at Eye bar
3 ⋅ max ( T MK ,T AK ) + ( T AK – 5 ) γ F1 ⋅ G E
-----------------------------------------------------------------------------
- – 10 in °C must be examined.
4 1.5 ⋅ --------------------
2 7
b Ö,2 = --------------------------------- ⋅ A 1 + --- ⋅ d L mm (24)
3 γ F2 ⋅ M w 1 s Ö ⋅ KK,d * 3
4 ⋅ 10 ⋅ --------------------- – γ F3 ⋅ G z ⋅ ---
d z
---------------------------------------------------------------------------------- ≤ 1 (19) 4.2 Stability analyses
K *K,d
( b Pr + s B ) ⋅ s B ⋅ ------------- -
2 ⋅ A1 Stability analyses must only be carried out for outdoor
installation. For the tray collector casing, sufficient protection in
The numerator is the lug force to be borne and the denominator is terms of axial and casing compressive stability must be
the acceptable lug force resulting from the shear stress in the seam. demonstrated.
Here, half the creep rupture strength is set as the shear stress.
The prerequisite is that the ovality of the cylinder is limited in the
Figure 4 in Section 5.4 shows the design of an anchor. following way:
4.1.6 Lifting lugs 2 ⋅ ( d max – d min )

u = ------------------------------------------ ⋅ 100 ≤ 0.5 % (25)
One of the possible lifting lug forms is shown in Figure 5 (Section d max + d min
5.4). The prerequisite for the use of these lifting lugs is that only
two lifting lugs are used per tray collector and that a parallel 4.2.1 Superposition of the effects
hanger is used.
Definitive Young's moduli are required for the stability
An analysis of the load introduction in the top section is not calculations. The buckling of shells is a sudden process, which is
needed as long as the lifting lug is not thicker than 3x the wall essentially dependent on the imperfections, i. e. on the extent of
thickness of the top section. The hole diameter (dL) must match the pre-stretching. The extent of the pre-stretching increases as
the diameter of the shackle (dSch). the loading period increases due to the creep behaviour of the
The following applies material. On the other hand, the elastic resistance during
warpage is primarily determined by the short-term Young's
s Z,1 ≤ erf s Ö ≤ 3 ⋅ s Z,1 mm (20) modulus at the current temperature. The critical buckling stress
σk is therefore calculated using the temperature-dependent
o
d Sch ≤ d L ≤ 1.1 ⋅ d Sch mm (21) moduli EKT C .
The temperature/time-dependent Young's moduli for the key
It must be proven that 1.5x the load (impact factor) can be borne
thermoplastics are given in Tables 2 and 3 of Guideline DVS
at 20°C in the short-term.
2205-1.
The required wall thickness sÖ of the lifting lugs results from the
The most unfavourable load combination must be examined
bearing stress analysis
taking the temperature behaviour of the thermoplastics into
γ F1 ⋅ G E account.
1.5 ⋅ --------------------
2
s Ö = ------------------------------------
- ⋅ A1 mm (22) 4.2.2 Axial stability
d Sch ⋅ 2 ⋅ K *K,d
In the case of outdoor installation, the axial compressive stress
The maximum of the two following analyses is decisive for the σ vorh
i,d from intrinsic weight and wind load available on the lower
width of the lifting lugs (bÖ). edge is determined for each section i and verified with the
b Ö = max ( b Ö,1 ,b Ö,2 ) buckling stress σk,i,d. In the case of indoor installation, the axial
stability analysis is not necessary.
Shear stress analysis of the horizontal butt weld when raising the
horizontal tray collector σexist
i,d = γ F1 ⋅ σ G + γ F2 ⋅ σ W N/mm2 (26)
248
The buckling stress may be determined in a simplified manner The β-values can be found in Figures 20a to c of DIN EN 1993-1-
using the following formula 6.
o
EK
T C s An analysis of the interaction of axial and casing compressive
- ⋅ -------
σ k,i,d = α i ⋅ 0.62 ⋅ f α,i ⋅ --------------- - ≤ K *K,d
Z,i
N/mm2 (27) stability is not needed.
γM r
where: 4.3 Verification of flotation safety

0.7
α i = -----------------------------------------------------------------
- (28a) For loss analysis, it must be proven that 0.9x the weight force of
20 o C the tank is greater than the buoyancy force of the submerged
EK
------------------ ⋅  1 + ---------------------
r
- tank part. If this is not the case, then a structural buoyancy guard
20 C 
o
100 ⋅ s Z,i
EL is required.
and The static analysis of the buoyancy guard must be carried out at
media temperature, for a load time of 3 months as an exceptional
ei
f α,i = 1.5 – -------- ≤ 1 aber ≥ 0.4 (28b) load case (γF4 = 1.0). When designing the structure of the
s Z,i buoyancy guard, the horizontal and vertical clearance due to
thermal expansion must be ensured for all operating conditions.
whereby ei is the eccentricity to the thicker of the two
neighbouring sections of a graduated cylinder, when this itself is
thicker than the section i under consideration. 5 Appendix
The following conditions must be observed for each section i
5.1 Explanations
A 2l ⋅ σexist
= ------------------------ ≤ 1
i,d
η A,i (29) This supplement 2 to Guideline DVS 2205-2 was drawn up by the
σ k,i,d DVS-AG W4.3b (structural design/apparatus construction)
together with the "Plastic tanks and pipes" ("Calculation" project
A2I = 1.0 may be applied as the tray collector is only at risk of group) committee of experts.
buckling when it is empty – and thus without any media effect.
5.2 References
4.2.3 Casing compressive stability
The underpressure from peu is verified with the critical casing Regulations
pressure pkM.
See DVS 2205-2
The following condition must be observed
Bibliography
A 2l ⋅ γ F2 ⋅ p eu
η M = ---------------------------------- ≤ 1 (30)
p kM,d [1] Timoshenko, S.: Theory of Plates and Shells. McGraw Hill Book
Comp, New York/London 1959
A2I = 1.0 may be applied as the tray collector is only at risk of
[2] Kempe, B.: Verformungsmessungen an einem Behälter aus
buckling when it is empty – and thus without any media effect.
Polyethylen hoher Dichte bei Temperaturwechsel.
The critical casing pressure of the non-graduated cylinder is [Deformation measurements on a tank made of high-density
calculated from polyethylene in the event of a temperature change] Welding &
cutting, leaflet 4/90
T C o
s 2.5
- ⋅ ------ ⋅  -----Z
EK r [3] Tuercke, H.: Simplified analysis of the casing compressive
p kM,d = 0.67 ⋅ C * ⋅ --------------- N/mm2 (31)
γM hZ  r  stability on flat base tanks made of thermoplastics.
DIBt reports, vol. 6/1995
where C* = 0.6.
[4] Tuercke, H.: Zur Stabilität von Behältern aus Thermoplasten.
The critical casing pressure of the graduated cylinder may be [On the stability of thermoplastic tanks] DIBt reports, vol. 5/1995
calculated according to DIN EN 1993-1-6 on a three-section
equivalent cylinder:
5.3 Temperature and time-dependent Young's moduli for
ToC stability calculations
r s 2.5
- ⋅ ---- ⋅  ----o-
EK
p kM,d = 0.67 ⋅ β ⋅ C * ⋅ --------------- N/mm2 (32)
γM lo  r  See Guideline DVS 2205-1, Tables 2 and 3.
249
5.4 Structural details – –Lifting lug, Figure 5

This section presents structural examples for – –Casing/base connection, Figure 6
– –Edge of tray collectors, Fig 7
– –Tray collector/tank distance, Figure 3
– –Base anchoring, Figure 4
Figure 3. Tray collector/tank distance.
Figure 4. Base anchoring.
250
If bÖ is observed, then a square

connection is also possible.
Figure 6. Casing/base connection.
Figure 7. Edge of tray collectors.
251
January 2011

VERWANDTE VERFAHREN E.V. Vertical round non-pressurised tanks DVS 2205-2
Collecting devices Supplement 2
1 Scope of application a mm Weld thickness

2 Calculation variables AB m2 Area of the bottom
3 Loading Aj m2 Area exposed to the wind (partial area)
3.1 Loads AZ m2 Shell area of the cylinder
3.1.1 Total dead load
3.1.2 Load of the filling material A1 – Reduction factor for the influence of the specific
3.2 Wind toughness (corresponds to A4 according to the
3.2.1 Wind load DVS 2205-1 technical code)
3.2.2 Radially symmetrical equivalent loading caused by wind A2 – Reduction factor for the media influence in the
pressure case of the proof of the strength
3.3 Assembly loads A2K – Reduction factor for the media influence in the
3.4 Temperature case of the proof of the strength with an effect
4 Proof of the steadiness for three months
4.1 Proof of the strength A2I – Reduction factor for the medium in the case of
4.1.1 Effects the proof of the stability

4.1.2 Shell bÖ mm Width of the lifting lug
4.1.3 Bottom
bPr mm Width of the claw
4.1.4 Welded joint between the bottom and the shell
4.1.5 Anchoring c – Force coefficient according to DIN 1055-4
4.1.6 Lifting lugs C – C1 C2
4.2 Proof of the stability C1 – Stress-increasing factor
4.2.1 Superimposition of the effects C2 – Material-specific design factor
4.2.2 Axial stability
C* – Coefficient for the circular cylinder subjected to
4.2.3 Shell pressure stability
external pressure loads
4.3 Proof of the buoyancy safety
5 Appendix d mm Nominal inside diameter
5.1 Explanations dL mm Hole diameter in the lifting lug
5.2 Standards and technical codes dmax mm Maximum cylinder diameter
5.3 Literature dmin mm Minimum cylinder diameter
5.4 Temperature-dependent and time-dependent elastic dSch mm Diameter of the shackle
moduli for stability calculations o
20 C
5.5 Design-related details EK N/mm2 Elastic modulus in the case of short-time loading
o
for 20°C
30 C
EK N/mm2 Elastic modulus in the case of short-time loading
1 Scope of application for 30°C
o
20 C
EL N/mm2 Elastic modulus in the case of long-time loading
The following design and calculation rules apply to collecting for 20°C
devices in the form of vertical, cylindrical flat-bottom tanks which
are fabricated from thermoplastics in the factory, in particular: fs – Long-time welding factor
fz – Short-time welding factor
– polyvinyl chloride (PVC),
g m/s2 Acceleration due to gravity (9.81 m/s2)
– polypropylene (PP),
– polyethylene (PE), GB N Dead load of the bottom
– polyvinylidene fluoride (PVDF). GE N Total dead load
The cylindrical shell with an identical wall thickness throughout or GF kN Load of the filling material
with a graduated wall thickness can be welded together from GZ N Dead load of the cylinder
panels or may consist of a wound pipe or an extruded pipe. The hF mm Filling height
cylinder and bottom of the collecting device must not have any hF,i mm Filling height of the course i
openings whatsoever. hZ mm Cylindrical height
The main dimensions are dependent on those of the tanks which hZ,i mm Height of the course i
they should accommodate (on this subject, see Section 5). hZF mm Height of the lowest course
The minimum wall thickness is 4 mm. vorh
KK N/mm2 Stresses effective for a short time
Attention must be paid to the responsibilities of certain legal fields vorh
K K,d N/mm2 Dimensioning value of stresses effective for a
(e.g. building law, water law, occupational health and safety law
short time
etc.).
252
vorh
K M,d N/mm2 Dimensioning value of stresses with a medium
effective duration
K *K N/mm2 Creep strength for 10-1 hours
K *M,d N/mm2 Dimensioning value of the creep strength for the
medium effective duration
*
KK,d N/mm2 Dimensioning value of the creep strength for the
short effective duration
lo mm Length of the upper course of the equivalent
cylinder
MW Nm Bending moment in the case of a wind load
peu N/mm² Radially symmetrical equivalent loading caused
by wind pressure
pkM,d N/mm² Dimensioning value of the critical shell buckling
pressure
pstat N/mm2 Overpressure at the tank bottom due to the
filling medium
pstat,i N/mm2 Overpressure per lower edge of the graduation
due to the filling medium Open Ventilated
qj kN/m2 Impact pressure on the partial area Aj
qmax 2
kN/m Maximum impact pressure effective at the Figure 1. Collecting device for a flat-bottom tank.
collecting device
r mm Radius of the cylinder
Rd 2
N/mm Dimensioning value of the stressability 3 Loading
sB mm Wall thickness of the bottom
The collecting devices are designed for the same computational
sÖ mm Wall thickness of the lifting lug operating time as that for the relevant tank. The load case of the
sZ mm Wall thickness of the cylinder filling from leakage is estimated for three months.
sZF mm Wall thickness of the lowest course
In the proof of the steadiness, it is necessary to take the following
s *ZF mm Statically required wall thickness loads into consideration.
sZm mm Mean wall thickness of the cylinder
sZ,1 mm Wall thickness of the highest course 3.1 Loads
sZ,i mm Wall thickness of the course i
so mm Wall thickness of the upper course of the 3.1.1 Total deal load GE
equivalent cylinder GE = GZ + GB N (1)
Sd 2
N/mm Dimensioning value of the stresses
TA °C Mean ambient temperature (according to Miner, Dead load of the cylinder GZ
see DVS 2205-1) GZ = AZ  sZ    g N (2)
TAK °C Highest ambient temperature
TM °C Mean media temperature of the relevant tank Dead load of the bottom GB
u % Permissible out-of-roundness GB = AB  sB    g N (3)
V m 3 Filling volume
Ladders, platforms, pedestals and similar items must be set up
Wj kN Wind load
and fastened independently of the collecting device since the free
z – Number of anchors expansion of the collecting device (e.g. during filling resulting
 – Auxiliary variable from leakage and in the case of temperature changes) would
 – Coefficient otherwise be hindered. These hindrances cause considerable
 – Coefficient stress peaks which are difficult to record computationally and, if
A – Coefficient for the determination of A2K they are taken into account, lead to uneconomic designs. If there
is any deviation from this, corresponding proof must be provided.
B – Coefficient for the calculation of the bottom
 % Tolerable edge fibre expansion 3.1.2 Load of the filling material GF
A,i – Utilisation of the axial stability in the course i
M – Utilisation of the shell pressure stability G F = V  F  g kN (4)
F – Partial safety coefficient of the effect/stresses
3.2 Wind
I – Weighting coefficient depending on the loading
case 3.2.1 Wind loads
M – Partial safety coefficient of the resistance/ The wind loads Wj must be estimated as follows:
stressability Wj = cf ∙ q ∙ Aj kN (5)
 g/cm3 Density of the material ( =   g)
F g/cm3 Density of the filling medium where:
G N/mm2 Compressive stress on the diaphragm resulting Wj Wind load of the partial area Aj.
from the dead weight
vorh cf Force coefficient for the circular cylinder and the roof.
 i,d N/mm² Dimensioning value of the crucial axial cf1 = 0.8 may be estimated according to DIN 1055-4, Section
compressive stress in the course i 10.2. Installation in a series has already been taken into con-
k N/mm2 Critical buckling stress sideration in this respect. Extensions cf2 = 1.6.
k,i,d N/mm2 Dimensioning value of the critical buckling stress
q Kinematic pressure according to DIN 1055-4, Table 2 de-
in the course I
pending on the wind zone and the height above the ground h
W N/mm2 Compressive stress on the diaphragm resulting (h = hBehälter + hGebäude when the tank is located on a build-
from the wind load ing, otherwise h = hG = hBehälter).
253
Aj Relevant exposed area in m² (for the tank: diameter times In this respect, the characteristic effects or the stresses are multi-
total height hG including the roof) plied by the partial safety coefficients F according to Table 1.
The stress resulting from the wind moment MW may be calculated
using the following simplified method: Table 1. Partial safety coefficients of the effects.
3 Einwirkung Partial safety coefficient

4  M W,x  10
 W,i = ----------------------------------
- N/mm2 (6) Dead weight, filling and assembly F1 = 1.35
2
  d  s Z,i
Wind F2 = 1.5
Mw,x at the height x above the tank bottom can be calculated on Stress-reducing dead weight F3 = 0.9
a clamped equivalent bar.
2 For example, the dimensioning value of the existing stresses
 hG – x 
M W, x = c f1  q  d  ----------------------
2
- + c f2  q 
  Aj  aj  Nm (7) results from F times the characteristic value of the existing
stresses in the component.
where aj is the lever arm of the area exposed to the wind Aj of the vorh vorh
superstructures and extensions in relation to the height x. KK,d =  F  KK
The dimensioning values of the existing stresses must also be
3.2.2 Radially symmetrical equivalent loading caused by multiplied by the reduction coefficients A1 and A2 as well as by a
wind pressure weighting coefficient I. In this respect, the weighting coefficient
The compressive loading effective on the cylindrical shell due to takes account of the loading type according to Table 2. In the
the inflow of the wind is recorded by the equivalent loading p eu. case of proof in the weld, the dimensioning value of the existing
stresses must be divided by the welding factor.
–3
p eu =   q max  10 N/mm2 (8)
Table 2. Weighting coefficient.
where:
Loading type I
 r r 
 = 0.46   1 + 0.1  C*  ------  ----------  0.6 (9) Loading Case I 1.0
 h Z s Zm
Static loading at the room temperature and in constant
C* = 0.6 for the open tank conditions. Cases of damage cannot lead to any

 h Z,i  s Z,i  danger to people, things or the environment.
s Zm = ---------------------------------- mm (10) Loading Case II 1.2
hZ
Loading in changing conditions (e.g. temperature and
3.3 Assembly loads filling height). Cases of damage may lead to danger to
people, things or the environment, e.g. installations or
The collecting device must be designed for the loading conditions installation parts which must be monitored and tested.
arising during the transport and the assembly. In this respect, the
calculation is made with 1.5 times the assembly loads (surge The characteristic resistances or the stressabilities are divided by
factor). F1 is estimated as the partial safety coefficient. The the partial safety coefficient M = 1.1.
short-time welding factor according to DVS 2205-1 must be taken
into consideration. For example, the dimensioning value of the short-time strength
results from the characteristic short-time strength value K *K divid-
3.4 Temperature ed by M according to the creep strength diagrams in DVS
2205-1.
The effective wall temperature is decisive for the dimensioning of
the components. In the case of leakage, proof must be provided KK*
K=
*
K,d ---------
for the parts wetted with media at the mean media temperature M
TM.
In a simplifying method for non-wetted parts, the mean of both 4.1 Proof of the strength
the neighbouring air temperatures may be estimated as the wall
temperature. At the ambient temperature, a differentiation is 4.1.1 Effects
made according to the installation location and the effective It is always necessary to look for the most unfavourable combina-
duration. The following minimum values are applicable: tion of the overall effects for every component.
Minimum values For a short time For a long time Corresponding to the effective duration, a distinction must be
made between three loading categories:
– Loading effective for a short time (K)
Outdoor installation TAK = 35°C TA = 20°C e.g. wind: q or peu
For the proof of the stability in the cylinder, a reduced ambient – Effects with a medium effective duration (M)
temperature TAK - 5°C applies to outdoor installation (wind effect). e.g. filling in the leakage case
– Loading effective for a long time (L)
e.g. dead weight
Load cases effective for a short time do not have to be combined
The proof of the steadiness is provided according to the concept with each other.
of the partial safety coefficients. In general, the following is appli- The effective duration of loads effective for a short time is stipu-
cable: lated as 10-1 hours and those effective for a medium time as
three months.
S
------d-  1
Rd 4.1.2 Shell
with Sd dimensioning value of the stresses The height of the lowest course hZF must be min. 1.4  d  s ZF .
Rd dimensioning value of the stressability In the case of graduated tanks, neighbouring courses may have
254
a wall thickness ratio of max. 3 without any further proof. In the 4.1.2.2 Proof in the longitudinal direction
case of sudden thickness changes with a wall thickness ratio
Only the lowest course at the interface to the bottom must be
greater than 2, it is necessary to use the shell seam formation
investigated for the proof of the stresses in the longitudinal
according to DVS 2205-3, Fig. 2.2 a), 2.2 c) or 2.2 c1).
direction. The stresses arising here are caused by the bending
fault moment, the dead weight and the wind.
4.1.2.1 Proof in the circumferential direction
The longitudinal stresses resulting from the dead weight can be
For every course i, it must be proven that the ring tensile stresses neglected. The short-time tensile stresses resulting from the wind
due to the filling can be accommodated at its lower edge: do not have to be proven either.
vorh
K M,d The proof must be provided according to Equation (11):
----------------
-1 (11)
K *M,d with
vorh d A 1  A 2K   I
with K M,d = C   F1  p stat  ---  ------------------------------ N/mm2 (15)
2 s ZF
vorh  F1  p stat,i  d A 1  A 2K   I
K M,d = ---------------------------------  ------------------------------ N/mm2 (12) and
2  s Z,i fs
–6
p stat =  F  g  h F  10 N/mm2 (16)
with
The factor C for the welded interface of the bond between the
–6
p stat,i =  F  g  h F,i  10 N/mm2 (13) bottom and the shell is the product of the stress-increasing factor
C1 = 1.2 and a material-specific design factor C2 according to
where hF,i means the height of the liquid level above the lower Table 5.
edge of the course i.
The reduction factor for the media influence in the case of an Table 5. The material-specific design factor C2 and the factor C for
effect for three months is calculated from: thermoplastics.
A 2K = max   A  A 2 , 1.0  (14) Material C2 C = C 1  C2
with A according to Table 3. PE-HD 1.00 1.20

PP-H (Type 1) 1.17 1.40
Table 3. Coefficients A for the determination of A2K. PP-B (Type 2) 1.00 1.20
TM PP-R (Type 3) 1.00 1.20

°C PE-HD PE 63 PE 80 PE 100 PP-H PP-B PP-R PVC-NI (normal impact strength) 1.25 1.50
3 months
PVC-RI (increased impact strength) 1.08 1.30
20 0.52 0.07 0.09 0.17 0.10 0.19 0.07
PVC-HI (high impact strength) 1.00 1.20
30 0.61 0.12 0.14 0.25 0.16 0.26 0.11
PVC-C 1.33 1.60
40 0.73 0.20 0.24 0.36 0.22 0.34 0.17
PVDF 1.17 1.40
50 0.90 0.34 0.37 0.49 0.31 0.43 0.24
60 1.00 0.54 0.57 0.67 0.41 0.52 0.33 Remark:
The value for PE-HD may be used for PE 63, PE 80 and PE 100.
70 – – – – 0.53 0.61 0.45
It is not necessary to provide any proof of the stresses in the weld
80 – – – – 0.65 0.69 0.58 if the conditions according to Section 4.1.4 are fulfilled.
Remark: A = 1.0 applies to PVC and PVDF. One prerequisite for the stress-increasing factor C1 = 1.2 is that
the bottom is not executed with a thickness greater than the wall
The welding factor of the shell weld fs or fz must be taken into thickness of the lowest course (sB  sZF).
account in the case of cylinders manufactured from plates.
According to today's state of the art, preference should be given 4.1.3 Bottom
to heated tool butt welding. fs = 1 and fz = 1 apply to wound
If the bottom and the cylinder are joined with fillet welds (Fig. 6),
tanks.
the required thickness of the bottom may be determined as
The residual stresses from the bending of the panels at the room follows:
temperature can be neglected if the edge fibre expansion (Table
4)  = s/d  100 [%] is not exceeded.  B  SZF
*  S B  S ZF mm (17)
with sZF as the executed wall thickness and B according to
Table 4. Tolerable edge fibre expansion. Fig. 2.
Material Edge fibre expansion  C   F1  p stat  d

*
SZF = -----------------------------------------  A 1  A 2K   I mm (18)
PE-HD 1.00 2  K *M,d
PP-H 0.50 In the case of other structural shapes, it is necessary to provide
proof of the bottom due to the cylinder clamping moment.
PP-B 0.75
PP-R 1.00 4.1.4 Welded joint between the bottom and the shell
PVDF 0.50 It is not necessary to provide any explicit proof of the stresses on
PVC-U 0.20 the weld if the following conditions are fulfilled:
PVC-C 0.10 – weld thickness a  0.7  sB
– long-time welding factor fs  0.6
Remark: If one of these conditions is not fulfilled, it is necessary to provide
The value for PE-HD may be used for PE 63, PE 80 and PE 100. detailed proof of the stresses in the weld (e.g. FE calculation).
255
In the case of one-shell tanks with capacities up to 1,000 l and  F1  G E

wall thicknesses up to 10 mm, this also applies to long-time weld- 1.5  --------------------
2
ing factors fs  0.4. s Ö = ------------------------------------
-  A1  I mm (22)
d Sch  2  K *K,d
4.1.5 Anchoring The maximum of both the following cases of proof is crucial for
If anchoring becomes necessary, at least four anchors must be the width of the lifting lug (bÖ).
arranged (z  4). Taking account of the lever arms, the anchor
forces (e.g. for the plugs) must be calculated from the claw b Ö = max  b Ö,1 ,b Ö,2 
forces.
Proof of the shearing stress for the transverse weld during the
In the case of the proof of the anchoring, it is necessary to lifting of the lying collecting device:
investigate the short-time wind load at 20°C:
 F1  G E
3  F2  M w 1 1.5  -------------------- A  
4  10  --------------------- –  F3  G z  --- b Ö,1
4
= --------------------------------------- -I
-  --------------
1
mm (23)
d z
----------------------------------------------------------------------------------  1 (19) KK,d* fz
0,7  s Z,1  ------------
K *K,d 2
 b Pr + s B   s B  -----------------------
2  A1  I
Eye bar:
The numerator indicates the claw force to be accommodated and
 F1  G E
the denominator the claw force which can be accommodated and 1.5  --------------------
2 7
results from the shearing stress in the weld. In this respect, half b Ö,2 = ---------------------------------  A 1   I + ---  d L mm (24)
the creep strength is estimated as the shearing stress. s Ö  KK,d * 3
Fig. 4 in Section 5.5 shows the execution of an anchoring ele-
ment. 4.2 Proof of the stability
Proof of the stability must only be provided in the case of outdoor
4.1.6 Lifting lugs
installation. Sufficient safety against axial and shell pressure
One of the possible lifting lug shapes is shown on Fig. 5 (Section stabilities must be proven for the shell of the collecting device.
5.5). The prerequisites for the use of these lifting lugs are that
only two lifting lugs are used per collecting device and that one The prerequisite is that the out-of-roundness of the cylinder
parallel hanger is utilised. remains limited in the following form:
In order to be able to dispense with any proof of the load intro- 2   d max – d min 
duction into the highest course, it must be ensured that the lifting u = ------------------------------------------  100  0.5 % (25)
d max + d min
lug is not thicker than three times the wall thickness of the
highest course. The hole diameter (dL) must be adapted to the
diameter of the shackle (dSch). 4.2.1 Superimposition of the effects
The following equations are applicable: The crucial elastic moduli are needed for the stability calcula-
tions. The buckling of shells is a sudden occurrence which is
s Z,1  erf s Ö  3  s Z,1 mm (20) essentially dependent on the imperfections, i.e. on the size of the
previous bulges. The size of the previous bulges increases along
d Sch  d L  1.1  d Sch mm (21) with the loading duration because of the creep behaviour of the
material. In contrast, the elastic resistance during the beating-out
It must be proven that 1.5 times the loading (surge factor) can be
is predominantly determined by the short-time elastic modulus at
borne for a short time at 20°C.
the temperature at that moment. The critical buckling stress k is
The required wall thickness sÖ of the lifting lug results from the therefore calculated with the temperature-dependent moduli
o
proof for the face of the hole: EKT C .
Permissible range for

zulässiger Bereich für C == 1,2
1.2
Figure 2. Diagram for the determination of the thickness of the bottom, derived for PE-HD (for C > 1.2, this diagram is on the safe side).
256
For the essential thermoplastics, the temperature-dependent and The critical shell pressure of the non-graduated cylinder is calcu-
time-dependent elastic moduli are included in Tables 6 and 7 lated from:
(Section 5.4).
T C o
s 2.5
-  ------   -----Z
It is necessary to investigate the most unfavourable combination EK r
p kM,d = 0.67  C *  --------------- N/mm2 (31)
of loads taking account of the temperature behaviour of the ther- M hZ  r 
moplastics.
with C* = 0.6 for the open tank.
4.2.2 Axial stability
The critical shell pressure of the graduated cylinder may be
In the case of outdoor installation, the axial compressive stress calculated on a three-course equivalent cylinder according to
  vorh
i,d which exists at the lower edge and consists of the dead
weight and the wind load is determined for every course i and is
DIN 18800-4:
validated with the buckling stress k,i,d. In the case of indoor ToC
r s 2.5
-  ----   ----o-
EK
installation, it is not necessary to prove the axial stability: p kM,d = 0.67    C *  --------------- N/mm2 (32)
M lo  r 
  vorh
i,d =  F1   G +  F2   W N/mm2 (26)
The  values are indicated on Figs. 20a to 20c in DIN 18800-4.
Using a simplifying method, the buckling stress may be deter-
mined according to the following formula: It is not necessary to provide any proof of the interaction between
the axial and shell pressure stabilities.
ToC s Z,i
EK
 k,i,d =  i  0.62  f ,i  ---------------
-  --------  K *K,d N/mm2 (27)
M r 4.3 Proof of the buoyancy safety
with For cases of damage, it must be proven that 0.9 times the weight
force of the tank is greater than the buoyancy force of the im-
0.7
 i = -----------------------------------------------------------------
- (28a) mersed tank part.
20 o C
EK
------------------   1 +
r
---------------------
- 
20 C 
o
100  s Z,i
EL 5 Appendix
and
ei 5.1 Explanations
=
f ,i 1.5 – --------  1 aber  0.4 (28b)
s Z,i This Supplement 2 to the DVS 2205-2 technical code was elabo-
where ei is the eccentricity in relation to the thicker of the two rated by DVS-AG W4.3b ("Structural designing / apparatus engi-
neighbouring courses in the case of a graduated cylinder if this is neering") together with the committee of experts "Plastic tanks
itself thicker than the course i under consideration. and pipes" (project group "Calculation").
It is necessary to comply with the following condition for every

course i:
See DVS 2205-2, Section 5.2.

vorh
A 2l   I  i,d
 A,i = -----------------------------------------------  1 (29)
 k,i,d 5.3 Literature
A2I = 1.0 may be set because the collecting device is only in [1] Timoshenko, S.: Theory of plates and shells. McGraw Hill
danger of buckling in the empty condition – and thus without any Book Comp, New York / London 1959.
media effect.
[2] Kempe, B.: Deformation measurements on a tank made of
4.2.3 Shell pressure stability high-density polyethylene in the case of a temperature
change, Schweißen & Schneiden, No. 4/90.
The partial vacuum resulting from peu is validated with the critical
shell pressure pkM. [3] Tuercke, H.: Simplified proof of the shell pressure stability in
The following condition must be fulfilled: the case of flat-bottom tank made of thermoplastics, DIBt
Communications, No. 6/1995.
A 2l   I   F2  p eu
 M = -------------------------------------------  1 (30) [4] Tuercke, H.: On the stability of tanks made of thermoplastics,
p kM,d
DIBt Communications, No. 5/1995.
A2I = 1.0 may be set because the collecting device is only in
danger of buckling in the empty condition – and thus without any 5.4 Temperature-dependent and time-dependent elastic
media effect. moduli for stability calculations
T oC
Table 6. Temperature-dependent short-time elastic moduli E K in N/mm2.

PE-HD 1,100 800 550 390 270 190 – –
PP-H 1,400 1,200 960 770 620 500 400 320
PP-B 1,200 1,000 790 630 500 400 320 250
PP-R 1,000 800 620 490 380 300 230 180
PVC-NI 3,200 3,000 2,710 2,450 2,210 2,000 – –
 10°C 20°C 40°C 60°C 80°C 100°C – –
PVDF 1,900 1,700 1,330 1,050 820 650 – –
Remark:
The elastic moduli for PE-HD may also be used for PE 63, PE 80 and PE 100.
257
20 oC
Table 7. Time-dependent long-time elastic moduli E L in N/mm2.
Material 1 year 5 years 10 years 15 years 20 years 25 years Remarks:

The elastic moduli for PE-HD
PE-HD 308 269 254 245 239 235 may also be used for PE 63,
PP-H 464 393 365 350 340 330 PE 80 and PE 100.
PP-B 405 334 307 293 283 275 The long-time elastic moduli for
PE-HD apply to stresses up to
PP-R 322 298 288 283 279 276 0.5 N/mm² and those for PP up to
PVC-NI 1,800 1,695 1,652 1,627 1,609 1,600 1 N/mm². The stress dependence
of the elastic moduli for PVC-NI
PVDF 810 763 744 733 725 720
and PVDF is insignificant.
The following design examples are indicated in this section:
– distance between the collecting device and the tank, Fig. 3

– anchoring of the bottom, Fig. 4
– lifting lug, Fig. 5
– connection between the shell and the bottom, Fig. 6
– edge of collecting devices, Fig. 7
Figure 3. Distance between the collecting device and the tank.
Without a gap and without pressing
Anchor bolt
Claw: steel
PE film: 2 mm Spacer plates
Minimum number
of claws: 4
Figure 4. Anchoring of the bottom.
258
If bÖ is complied with, a square connection

is also possible.
ü  10 without anchoring
ü  25 with anchoring
Figure 6. Connection between the shell and the bottom.
Figure 7. Edge of collecting devices.
259
Draft January 2015

FÜR SCHWEISSEN UND
VERWANDTE VERFAHREN E.V. pressurised tanks – Flat roofs DVS 2205-2
Supplement 3
Intended as a replacement for issue dated January 2010
Contents: g m/s2 Acceleration due to gravity

gD N/mm2 Surface load from the intrinsic weight of the
1 Scope roof panel
2 Calculation variables 2
gStiffene N/mm Uniformly distributed surface load from
3 Structural design
r stiffeners and partitions
4 Loads
5 Temperature hS mm Height of the stiffeners
6 Stability analyses IS mm4 Moment of inertia
6.1 Unstiffened roof k – Buckling value
6.2 Roof with stiffeners
exist
6.2.1 Strength analysis of the roof panel perpendicular to the K K,d N/mm2 Rated value of the short-term load
exist
stiffeners K L,d N/mm2 Rated value of the long-term load
6.2.2 Analyses along the stiffeners *
KK,d N/mm2 Rated value of the creep rupture strength for
7 Accessibility 10-1 hours
8 Appendix *
KL,d N/mm2 Rated value of the creep rupture strength for
8.1 Explanations
the mathematical service life
8.2 References
8.3 Mathematical Young's moduli for stability calculations p N/mm2 Force on the roof
8.4 Structural details pDK,d N/mm2 Rated value of the short-term forces on the roof
pDL,d N/mm2 Rated value of the long-term forces on the roof
1 Scope
pE N/mm2 Equivalent load (short-term)
The following structure and calculation rules apply to flat-roof, puK N/mm2 Short-term external pressure (and/or internal
factory-fabricated flat base tanks made of thermoplastics, in negative pressure)
particular: püK N/mm2 Short-term internal pressure
pu N/mm 2 Long-term external pressure (and/or internal
– –Polyvinyl chloride (PVC),
– –Polypropylene (PP), negative pressure)
– –Polyethylene (PE), pü N/mm 2 Long-term internal pressure
– –Polyvinylidene fluoride (PVDF).
pus N/mm2 Negative pressure due to wind suction
The analyses within this guideline only apply to tanks located PM,d N Rated value of the man load
inside buildings.
m Nmm/mm Bending moment
Flat roofs must not be accessed without implementing load-
n – Number of stiffeners and partitions
distributing measures unless they are designed to hold a
man load of 1.5 kN. sD mm Wall thickness of the roof panel
sS mm Wall thickness of the stiffeners
2 Calculation variables TA °C Average ambient temperature (according to
Miner, see DVS 2205-1)
A1 – Reduction factor for the influence of the
specific strength (corresponds to A4 according TAK °C Maximum ambient temperature
to guideline DVS 2205-1) TM °C Average media temperature (according to
A2 – Reduction factor for the medium during Miner, see DVS 2205-1)
strength analyses TMK °C Maximum media temperature
A2I – Reduction factor for the medium during zS mm Centroidal distance
stability analyses γF – Partial safety factor for the force/load (see
bm mm Supporting width DVS 2205-2)
d o mm Nominal diameter of the tank γM – Partial safety factor for the resistance/load-
T C bearing capacity (see DVS 2205-2)
EK N/mm2 Young's modulus during short-term loading for
T°C μ – Poisson's ratio
fsD – Long-term weld strength reduction factor for ρ g/cm³ Density of the material
the weld seam on the roof panel σk,d N/mm2 Rated value of the critical compressive stress
fzD – Short-term weld strength reduction factor for vorh
σd N/mm2 Rated value of the compressive stress in the
the weld seam on the -roof panel roof panel
260
3 Structural design p DL,d ⋅ d ⋅ 6 ⋅ ( 3 + μ ) A 1 ⋅ A 2

vorh 2
exist
where K L,d = ---------------------------------------------------------------
2
- ⋅ ----------------- (3)
64 ⋅ s D f sD
Flat roofs may be manufactured with or without stiffeners.
In the case of an unstiffened flat roof, the roof can become where
exist
p DL,d = max ( γ F1 ⋅ g D + γ F2 ⋅ p u , γ F2 ⋅ p ü – γ F3 ⋅ g D )
considerably deformed as a result of its intrinsic weight.
(4)
Flat roofs are generally reinforced with two parallel stiffeners. In
the case of larger tanks, more stiffeners may be used. When Analysis according to equation (15) DVS 2205-2:
selecting the number of stiffeners, it is important to remember exist
that an access door will need to be positioned between the K K,d
------------- ≤ 1 (5)
stiffeners and to ensure that there is sufficient space to weld the K*K,d
stiffeners to the roof panel on both sides.
p DK,d ⋅ d ⋅ 6 ⋅ ( 3 + μ ) A 1 ⋅ A 2
vorh 2
exist
Structural measures must be in place to secure the n stiffeners
2
- ⋅ -----------------
where: K K,d = --------------------------------------------------------------- (6)
with n evenly spaced partitions to prevent them from tilting. 64 ⋅ s D f zD
If the roof panel cannot be manufactured from a single part, the exist
weld seam must be perpendicular to the stiffeners. where: p DK,d = max { γ F1 ⋅ g D + γ F2 ⋅ [ max ( p uK ,p us ) + p E ],
K ,p us ) + p E ],γ F2 ⋅ p üK – γ F3 ⋅ g D }
The ratio between the height and thickness of the stiffeners is
(7)
limited to 8:
Weld strength reduction factors fsD and fzD are 1.0 if the roof is
hS manufactured from a single part.
------ ≤ 8
sS
Poisson's ratio can be set to approximately μ = 0.38 for all
thermoplastics.
4 Stresses 6.2 Roof with stiffeners
As well as taking into account the intrinsic weight and minimum
6.2.1 Strength analysis of the roof panel perpendicular to the
pressures, it is also important to ensure a uniform equivalent load
pE: stiffeners
– –Intrinsic weight of the roof incl. stiffeners and partitions If the roof panel is not manufactured from two individual panels,
(gD, gStiffeners) the weld seam must be parallel to the stiffeners.
– –Minimum pressures as per DVS 2205-2 Section 1 (puK, püK, The bending moment in the roof panel between the stiffeners can
pu , pü ) be calculated in a simplified manner as follows:
– –Negative pressure due to wind suction (pus) 2
p⋅d
m = ---------------------------2- (8)
– –pE = 1 kN/m2 = 0.001 N/mm2 for taking into account 8 ⋅ (n + 1)
unplanned individual loads
Analysis according to equation (13) DVS 2205-2, whereby there
The transfer of the equivalent load pE into the cylinder does not
are no loads with a medium effective duration:
need to be examined.
K exist
------------
L,d
≤1 (9)
5 Temperature K *L,d
2
exist p DL,d ⋅ d ⋅ 6 A1 ⋅ A2
The strength analyses for the roof panel should be performed at
2 2
- ⋅ -----------------
where K L,d = ----------------------------------------- (10)
the effective wall temperature (TM + TA)/2 under long-term forces ( n + 1 ) ⋅ 8 ⋅ sD f sD
and (TMK + TAK)/2 under short-term forces. The strength
exist
analyses for the stiffeners should be performed at the average where p DL,d = max ( γ F1 ⋅ g D + γ F2 ⋅ p u , γ F2 ⋅ p ü – γ F3 ⋅ g D ) (11)
media temperature TM. Reduction factor A1 should be
determined based on the applicable temperature. Analysis according to equation (15) DVS 2205-2:
The stability analysis for the roof panel should be performed with K exist
the short-term -Young's modulus for (TMK + TAK)/2. The stability ------------
K,d
≤1 (12)
of the stiffeners should be analysed with the short-term Young's K*K,d
modulus for TMK. In the case of outdoor installations under a exist 2
stationary roof with sun and snow shielding, an ambient exist p DK,d ⋅ d ⋅ 6 A 1 ⋅ A 2
where: K K,d = ------------------------------------------ ⋅ ----------------- (13)
temperature of TAK = 35°C can be assumed for installations in 2 2 f zD
(n + 1 ) ⋅ 8 ⋅ sD
Germany.
exist
where: p DK,d = max { γ F1 ⋅ g D + γ F2 ⋅ [ max ( p uK ,p us ) + p E ],
K ,p us ) + p E ], γ F2 ⋅ p üK – γ F3 ⋅ g D }
6 Stability analyses (14)
6.1 Unstiffened roof Poisson's ratio can be set to approximately μ = 0.38 for all
thermoplastics.
The bending moment in the centre of the panel can be calculated
in a simplified manner as follows: 6.2.2 Analyses along the stiffeners
2
(3 + μ) ⋅ p ⋅ d For the analyses along the stiffeners, a T-beam with a supporting
m = ------------------------------------ (1) width of
64
Analysis according to equation (13) DVS 2205-2, whereby there 0.85 ⋅ d
b m = ------------------- (15)
are no loads with a medium effective duration: n+1
exist is used. The centroidal position zS (measured from the centre of
K L,d
------------------
- ≤1 (2) the roof panel) and the moment of inertia IS are calculated as
K *L,d follows:
261
hS + sD sD
p DL,d ⋅ d ⋅  z S + ------ A ⋅ A
exist 3
h S ⋅ s S ⋅ ------------------- 
2 2
z S = ------------------------------------------
vorh
= ---------------------------------------------------- ⋅ -----------------
1 2
(16) where: KL,d (29a)
hS ⋅ sS + bm ⋅ sD ( n + 1 ) ⋅ 8 ⋅ lS f sD
3 3
hS ⋅ sS bm ⋅ sD hS + sD 2 vorh
where p DL,d = γ F2 ⋅ p ü – γ F3 ⋅ ( g D + g Stiffener )
l S = ----------------- + --------------------- + b m ⋅ S D ⋅ z S + h S ⋅ s S ⋅  ------------------- – z S
2 (29b)
12 12  2 
Analysis according to equation (15) DVS 2205-2:
(17)
Kexist
Poisson's ratio can be set to approximately μ = 0.38 for all ------------
K,d
-≤1 (30)
thermoplastics. K*K,d
sD
p DK,d ⋅ d ⋅  z S + ------  A ⋅ A
6.2.2.1 Inward load exist 3
exist  2 
where: K K,d = ------------------------------------------------------------------ ⋅ -----------------
1 2
Strength analysis on the lower edge of the stiffener (31a)
( n + 1 ) ⋅ 8 ⋅ lS f zD
Analysis according to equation (13) DVS 2205-2, whereby there exist
are no loads with a medium effective duration: where p DK,d = γ F2 ⋅ p üK – γ F3 ⋅ ( g D + g Stiffener ) (31b)
exist
K L,d hS ⋅ sS ⋅ ρ ⋅ g
------------------
- ≤1 (18) where g Stiffener = ( 2 ⋅ n – 1 ) ⋅ -------------------------------- (32)
6
K *L,d d ⋅ 10
sD Stability analysis for the stiffener
p DL,d ⋅ d ⋅  h S + ------ – z S
exist 3
 2 
where
exist
K L,d = ---------------------------------------------------------------------------
- ⋅ A1 ⋅ A2 (19a) The compressive stresses in the stiffener are σvorh designed to
( n + 1 ) ⋅ 8 ⋅ lS withstand the buckling stress σk,d.
d
exist
where p DL,d = γ F1 ⋅ ( g D + g Stiffener ) + γ F2 ⋅ p u (19b) A 2l ⋅ σ d
exist
----------------------------- ≤1 (33)
Analysis according to equation (15) DVS 2205-2: σ k,d
whereby
Kexist
------------
K,d
-≤1 (20) sD
K*K,d p DK,d ⋅ d ⋅  h S + ------ – z S
exist 3
vorh  2 
sD σd = -------------------------------------------------------------------- (34)
p DK,d ⋅ d ⋅  h S + ------ – z S ( n + 1 ) ⋅ 8 ⋅ lS
exist 3
exist  2 
where: K K,d = ------------------------------------------------------------------------------ ⋅ A 1 ⋅ A 2 (21)
( n + 1 ) ⋅ 8 ⋅ lS exist
where p DK,d = γ F2 ⋅ p üK – γ F3 ⋅ ( g D + g Stiffener ) (35)
exist
where p DK,d = γ F1 ⋅ ( g D + g Stiffener ) + γ F2 ⋅ { max ( p uK , p us ) + p E ToC
2 EK 2
(22) k ⋅ π ⋅ ---------------- ⋅ s S
γM
and σ k,d = -----------------------------------------------
- (36)
hS ⋅ sS ⋅ ρ ⋅ g 2
12 ⋅ h S ⋅ ( 1 – μ )
2
and g Stiffener = ( 2 ⋅ n – 1 ) ⋅ --------------------------------
6
(23)
d ⋅ 10
with the buckling value k = 1.1.
Stability analysis for the roof panel
vorh
The compressive stresses in the roof panel σd parallel to the
stiffeners are designed to withstand the buckling stress σk,d. 7 Accessibility
exist
A 2l ⋅ σd Flat roofs may be accessed briefly for maintenance purposes if
----------------------------- ≤1 (24) they are designed to hold a man load of 1.5 kN, i. e. PM,d = γF2 ·
σ k,d
1,500 N.
exist 3
p DK,d ⋅ d ⋅ zS In the case of stiffened flat roofs requiring access, the stiffeners
whereby σdvorh = ---------------------------------- (25) should be welded to the cylinder.
( n + 1 ) ⋅ 8 ⋅ lS
For a combination of
where:
exist pexist
DK,d – γ F2 ⋅ p E und P M,d
p DK,d = γ F1 ⋅ ( g D + g Stiffener ) + γ F2 ⋅ { max ( p uK , p us ) + p E } (26)
in the most unfavourable position, the strength analysis for the
o
T C roof panel may be performed on a 200 mm wide stiffener.
2 2 EK 2
k ⋅ π ⋅ ( n + 1 ) ⋅ ---------------- ⋅ s D
γM The strength analysis for the stiffeners and the stability analysis for
and σ k,d = -------------------------------------------------------------------------
2 2 (27) the panel should be performed as described in Section 6.2.2.1
12 ⋅ d ⋅ ( 1 – μ )
but with
with the buckling value k = 5.5.
pexist
DK,d – γ F2 ⋅ p E und P M,d
6.2.2.2 Outward load in the centre of the stiffener.
Strength analysis for the roof panel The axial stability of the cylinder should be analysed with an
additional, even compressive stress of
Analysis according to equation (13) DVS 2205-2, whereby there
are no loads with a medium effective duration: P M,d r
σ M,d = ---------------------------- ⋅ 1.82 ⋅ ----- (37)
exist 2 ⋅ π ⋅ r ⋅ sZ sZ
K L,d
------------------
-≤1 (28)
K *L,d .
262
8 Appendix
8.1 Explanations
This Supplement 3 to Guideline DVS 2205-2 has been drawn up
by the DVS-AG W4.3b (structural design/apparatus construction)
together with the "Plastic tanks and pipes" ("Calculation" project
group) committee of experts from the German Construction
Institute.
8.2 References
For regulations see Guideline DVS 2205-2 Section 5.2
8.3 Mathematical Young's moduli for stability calculations

See Guideline DVS 2205-1, Table 3.

Figure 3. Detail Y.
*) There should be no cutouts in the shaded area.

sV { ≥ sD
≥ 10 mm
a1 = 0.5 ⋅ min (sD, sZ,1)
a2 = 0.5 ⋅ sZ,1
{ ≥ 5 · sD
Any weld seams inside the roof panel must be perpendicular to the
stiffeners. c
≥ 80 mm
Figure 1. Top view of a flat roof with two stiffeners.
Figure 4. Variant 1 of the flat roof position on the cylinder.
a2 ≥ 0.5 · smin smin = min (sZ,1, sD)
Figure 2. Cross-section of the flat roof with two stiffeners and partitions. Figure 5. Variant 2 of the flat roof position on the cylinder.
263
January 2010

Flat roofs Supplement 3
Replaces November 2003 edition
Contents: gSteife N/mm2 Uniformly distributed area load resulting from

stiffeners and bulkheads
1 Scope of application hS mm Height of the stiffeners
3 Structural designing IS mm4 Moment of inertia
4 Loading k – Buckling value
5 Temperature K N/mm2 Dimensioning value of the stresses effective
6 Proof of the steadiness for a short time
6.1 Unstiffened roof K N/mm2 Dimensioning value of the stresses effective
6.2 Roof with stiffeners for a long time
6.2.1 Proof of the strength of the roof plate transverse to the
stiffeners K N/mm2 Dimensioning value of the creep strength for
6.2.2 Proof longitudinal to the stiffeners 10-1 hours
7 Appendix K N/mm2 Dimensioning value of the creep strength for
7.1 Explanations the computational working life
N/mm2
7.3 Computational elastic moduli for stability calculations p Effect on the roof
7.4 Design-related details pDK,d N/mm2 Dimensioning value of the short-time effects
on the roof
pDL,d N/mm2 Dimensioning value of the long-time effects on
1 Scope of application the roof
pE N/mm2 Equivalent load (for a short time)
The following design and calculation rules apply to flat roofs of
flat-bottom tanks which are fabricated from thermoplastics in the puK N/mm2 External pressure (or internal partial vacuum)
factory, in particular: effective for a short time
püK N/mm2 Internal pressure effective for a short time
– polyvinyl chloride (PVC),
– polypropylene (PP), pu N/mm2 External pressure (or internal partial vacuum)
– polyethylene (PE), effective for a long time
– polyvinylidene fluoride (PVDF). pü N/mm2 Internal pressure effective for a long time
The proof in this technical code only applies to tanks installed pus N/mm2 Partial vacuum due to wind suction
inside buildings. m Nmm/mm Bending moment
It is not allowed to walk on flat roofs without any load- n – Number of stiffeners and bulkheads
distributing aids! sD mm Wall thickness of the roof plate
sS mm Wall thickness of the stiffeners
TA °C Mean ambient temperature
2 Calculation variables (according to Miner, see DVS 2205-1)
A1 – Reduction factor for the influence of the specif- TAK °C Highest ambient temperature
ic toughness (corresponds to A4 according to TM °C Mean media temperature (according to Miner,
the DVS 2205-1 technical code) see DVS 2205-1)
A2 – Reduction factor for the medium in the case of TMK °C Highest media temperature
the proof of the strength zS mm Distance away from the centre of gravity
A2I – Reduction factor for the medium in the case of γF – Partial safety coefficient of the effect/stresses
the proof of the stability (see DVS 2205-2)
bm mm Width also bearing the load γI – Weighting safety coefficient depending on the
d mm Nominal diameter of the tank loading type (see DVS 2205-2)
E N/mm2 Elastic modulus in the case of short-time γM – Partial safety coefficient of the resistance/
loading for T°C stressability (see DVS 2205-2)
fsD – Long-time welding factor for the weld of the µ – Poisson's ratio
roof plate ρ g/cm³ Density of the material
fzD – Short-time welding factor for the weld of the σk,d N/mm2 Dimensioning value of the critical compressive
roof plate stress
g m/s2 Acceleration due to gravity σ N/mm2 Dimensioning value of the compressive stress
gD N/mm2 Area load resulting from the dead weight of the in the roof plate
roof plate
264
3 Structural designing
with p = max ( γ ⋅g +γ ⋅p ,γ ⋅p –γ ⋅g ) (4)
Flat roofs can be manufactured in an unstiffened design or with
Proof according to Equation (15) in DVS 2205-2:
stiffeners.
In the case of an unstiffened flat roof, attention must be paid to K
the great deformation of the roof solely because of the dead
∑
---------------------------- ≤ 1 (5)
weight. K
As a rule, flat roofs are reinforced with two parallel stiffeners. For
larger tanks, it is also possible to arrange more stiffeners. How- p ⋅ d ⋅ 6 ⋅ (3 + µ) A ⋅ A ⋅ γ
with ΣK = ---------------------------------------------------------------- ⋅ -------------------------- (6)
ever, when choosing the number of stiffeners, attention must be 64 ⋅ s f
paid to the arrangement of an entry opening between the stiffen-
ers and to sufficient space in order to weld the stiffeners together with p = max { γ ⋅g +γ ⋅ [ max ( p ,p ) + p ],
with the roof plate on both sides.
As far as the design is concerned, the n stiffeners must be ,p ) + p ],γ ⋅p –γ ⋅g } (7)
prevented from tilting using n bulkheads in each case at regular
The welding factors fsD and fzD are 1.0 if the roof is fabricated
intervals.
from one part.
If the roof plate cannot be fabricated in one part, the weld must
be arranged vertically to the stiffeners. As an approximation, the Poisson's ratio can be set at µ = 0.38
for all thermoplastics.
The ratio of the height to the thickness of the stiffeners is limited
to 8: 6.2 Roof with stiffeners
h
------ ≤ 8 6.2.1 Proof of the strength of the roof plate transverse to the
s
stiffeners
If the roof plate is not fabricated from two partial plates, the weld
4 Loading
must be arranged parallel to the stiffeners.
Not only the dead weight and the minimum pressures but also a Using a simplifying method, the bending moment in the roof plate
uniform equivalent load pE must be taken into consideration: between the stiffeners results from:
– dead weight of the roof including stiffeners and bulkheads (gD
and gSteifen) p⋅d
m = ---------------------------- (8)
– minimum pressures according to DVS 2205-2, Section 1 (puK, 8 ⋅ (n + 1 )
püK, pu and pü)
Proof according to Equation (13) in DVS 2205-2. No loading with
– partial vacuum due to wind suction (pus) a medium effective duration arises in this respect:
– pE = 1 kN/m2
= 0.001 N/mm2 in order to take account of un-
planned individual loads K
------------------ ≤ 1 (9)
It is not necessary to investigate the transmission of the equiva- K
lent load pE in the cylinder.
p ⋅d ⋅6 A ⋅A ⋅γ
with K = ------------------------------------------ ⋅ -------------------------- (10)
5 Temperature (n + 1) ⋅ 8 ⋅ s f
The proof of the strength of the roof plate must be provided at the with p = max ( γ ⋅g +γ ⋅p , γ ⋅p –γ ⋅g ) (11)
effective wall temperature (TM + TA)/2 with long-time effects or
(TMK + TAK)/2 with short-time effects. The mean media tempera- Proof according to Equation (15) in DVS 2205-2:
ture TM must be assumed for the proof of the strength of the stiff-
eners. The reduction factor A1 must be determined according to Σ K
the temperature to be estimated in each case. --------------------- ≤ 1 (12)
K
The proof of the stability of the roof plate must be provided with
the short-time elastic modulus for (TMK + TAK)/2. The stability of p ⋅d ⋅6 A ⋅A ⋅γ
the stiffeners must be proven with the short-time elastic modulus with ΣK = ------------------------------------------ ⋅ -------------------------- (13)
for TMK. In the event of outdoor installation underneath a station- (n + 1) ⋅ 8 ⋅ s f
ary roof as a sun and snow shield, TAK = 35°C may be estimated
as the ambient temperature. with p = max { γ ⋅g +γ ⋅ [ max ( p ,p ) + p ],
,p ) + p ],γ ⋅p –γ ⋅g } (14)
As an approximation, the Poisson's ratio can be set at µ = 0.38
6.1 Unstiffened roof for all thermoplastics
Using a simplifying method, the bending moment in the centre of
the plate results from: 6.2.2 Proof longitudinal to the stiffeners
(3 + µ) ⋅ p ⋅ d A plate beam with the width also bearing the load:
m = ------------------------------------ (1)
64 0.85 ⋅ d
Proof according to Equation (13) in DVS 2205-2. No loading with b = ------------------- (15)
n+1
a medium effective duration arises in this respect:
is calculated for the proof longitudinal to the stiffener. The posi-
K tion of the centre of gravity zS (measured from the central area of
------------------ ≤ 1 (2) the roof plate) and the moment of inertia IS result from:
K
h +s
p ⋅ d ⋅ 6 ⋅ (3 + µ) A ⋅ A ⋅ γ h ⋅ s ⋅ -------------------
with K = ---------------------------------------------------------------- ⋅ -------------------------- (3) 2
f z = ------------------------------------------ (16)
64 ⋅ s h ⋅s +b ⋅s
265
h ⋅s b ⋅s h +s with p = γ ⋅p –γ ⋅ (g + g ) (29b)
l = ----------------- + --------------------- + b ⋅ S ⋅ z + h ⋅ s ⋅  ------------------- – z 
12 12  2 
Proof according to Equation (15) in DVS 2205-2:
(17)
Σ K
As an approximation, the Poisson's ratio can be set at µ = 0.38 --------------------- ≤ 1 (30)
for all thermoplastics K
s
6.2.2.1 Loading directed inwards p ⋅ d ⋅  z + ------  A ⋅ A ⋅ γ
 2 
Proof of the strength at the lower edge of the stiffener with ΣK = ----------------------------------------------------------------- ⋅ -------------------------- (31a)
(n + 1) ⋅ 8 ⋅ l f
Proof according to Equation (13) in DVS 2205-2. No loading with
a medium effective duration arises in this respect: with p = γ ⋅p –γ ⋅ (g + g ) (31b)
K h ⋅s ⋅ρ⋅g
------------------ ≤ 1 (18) with g = ( 2 ⋅ n – 1 ) ⋅ -------------------------------- (32)
K d ⋅ 10
s Proof of the stability of the stiffener
p ⋅ d ⋅  h + ------ – z 
 2 
with K = --------------------------------------------------------------------------- ⋅ A ⋅ A ⋅ γ
(n + 1) ⋅ 8 ⋅ l
(19a) The compressive stresses in the stiffener ∑σ are validated
compared with the buckling stress σk,d:
with p = γ ⋅ (g + g )+γ ⋅p (19b) A ⋅γ ⋅ σ

∑
-------------------------------------------- ≤ 1 (33)
Proof according to Equation (15) in DVS 2205-2: σ
K where
Σ
--------------------- ≤ 1 (20) s
K
∑ p ⋅ d ⋅  h + ------ – z 
 2 
s Σ σ = ------------------------------------------------------------------------------------
(n + 1) ⋅ 8 ⋅ l
(34)
p ⋅ d ⋅  h + ------ – z 
 2 
with ΣK = ----------------------------------------------------------------------------- ⋅ A ⋅ A ⋅ γ
(n + 1) ⋅ 8 ⋅ l
(21)
with p = γ ⋅p –γ ⋅ (g + g ) (35)
with p = γ ⋅ (g + g )+γ ⋅ { max ( p , p ) + p } (22)

E
k ⋅ π ⋅ ---------------- ⋅ s
h ⋅s ⋅ρ⋅g γ
and g = ( 2 ⋅ n – 1 ) ⋅ -------------------------------- (23) and σ = ------------------------------------------------ (36)
d ⋅ 10 12 ⋅ h ⋅ ( 1 – µ )
Proof of the stability of the roof plate with the buckling value k = 1.1.
The compressive stresses in the roof plate σ parallel to the ∑
stiffeners are validated compared with the buckling stress σk,d:
7 Appendix
A ⋅γ ⋅ ∑ σ
7.1 Explanations
-------------------------------------------- ≤ 1 (24)
σ
This Supplement 3 to the DVS 2205-2 technical code was elabo-
rated by DVS-AG W4.3b ("Structural designing / apparatus engi-
∑ p ⋅d ⋅z neering") together with the committee of experts of the German
where Σσ = ----------------------------------------------------- (25) Institute for Construction Engineering: "Plastic tanks and pipes"
(n + 1) ⋅ 8 ⋅ l (project group: "Calculation").
with
Σp = γ ⋅ (g + g )+γ ⋅ { max ( p , p ) + p } (26) See the DVS 2205-2 technical code, Section 5.2.
E 7.3 Computational elastic moduli for stability calculations

k ⋅ π ⋅ ( n + 1 ) ⋅ ---------------- ⋅ s
γ
and σ = ------------------------------------------------------------------------- (27) Table 1. Temperature-dependent short-time elastic moduli E in
12 ⋅ d ⋅ ( 1 – µ ) N/mm .
with the buckling value k = 5.5. Material ≤10°C 20°C 30°C 40°C 50°C 60°C 70°C 80°C
PE-HD 1,100 800 550 390 270 190 – –
6.2.2.2 Loading directed outwards
PP-H 1,400 1,200 960 770 620 500 400 320
Proof of the strength of the roof plate
PP-B 1,200 1,000 790 630 500 400 320 250
Proof according to Equation (13) in DVS 2205-2. No loading with PP-R 1,000 800 620 490 380 300 230 180
a medium effective duration arises in this respect:
PVC-Nl 3,200 3,000 2,710 2,450 2,210 2,000 – –
K ≤10°C 20°C 40°C 60°C 80°C 100°C – –
------------------ ≤ 1 (28)
K PVDF 1,900 1,700 1,330 1,050 820 650 – –
s
p ⋅ d ⋅  z + ------ A ⋅A ⋅γ
Remark:
 2 The elastic moduli for PE-HD may also be used for PE 63, PE 80
with K = --------------------------------------------------------------- ⋅ -------------------------- (29a)
(n + 1) ⋅ 8 ⋅ l f and PE 100.
266
Recess for lifting lug
Bulkhead
Stiffener Executed as a
circumferential ring
f = 10 – 35 mm ≥s a = 0,5 · min (s , s )
s { ≥ 10 mm a = 0,5 · s
Variant 1 Variant 2 ≥5·s
c { ≥ 80 mm
*) No cut-outs should be planned in the hatched area.
Figure 4. Variant 1 of the bearing of the flat roof on the cylinder.
Any weld which may be necessary within the roof plate must be arranged
vertically to the stiffeners.
Figure 1. Top view of a flat roof with two stiffeners.
Section A – A
a ≥ 0.5 · s s = min (s ,s )
Figure 5. Variant 2 of the bearing of the flat roof on the cylinder.
Figure 2. Section through the flat roof with two stiffeners and bulkheads.
Detail Y
Bulkhead for the stabilisation

of the stiffeners
Stiffener, hs ≤ 8 x s;
a = 0.7 x s
Figure 3. Detail Y.
267
Draft January 2015

FÜR SCHWEISSEN UND
VERWANDTE VERFAHREN E.V. pressurised tanks – Flat base tanks in DVS 2205-2
earthquake zones Supplement 4
Intended as a replacement for issue dated February 2013
This Supplement 4 to Guideline DVS 2205-2 has been drawn up by DVS-AG W4.3b (structural design/apparatus construction).
Contents: – The tank is always anchored directly to the foundation,

or indirectly in the case of tanks with receptacles. The structure
1 Scope of the upper and lower supports corresponds to Figures 1 and
2 Structure 2. In the event of structures deviating from this, appropriate
3 Calculation variables analyses must be provided separately.
4 Tank acceleration – Dimensioning of the tank and receptacle is carried out in
4.1 Horizontal tank acceleration parallel according to Guideline DVS 2205-2 with Supplements
4.2 Oscillation duration
2, 3 and 6.
4.2.1 Tank without receptacle
4.2.2 Tank with receptacle – The design of the tank and receptacle corresponds to
4.3 Vertical tank acceleration Guideline DVS 2205-2 with Supplements 2, 3 and 6.
5 Loads
5.1 Tank without receptacle
5.2 Tank in receptacle 2 Structure
5.3 Receptacle
6 Analyses Tanks without receptacles are anchored directly to the
7 Verification foundation, in order to secure them against lateral movement and
7.1 Analysis of axial stability in the double-shell area tilting due to the horizontal earthquake forces.
8 Analyses of the tank without receptacle Tanks in receptacles cannot be anchored directly to the
8.1 Axial stability of the cylinder foundation, however the tank must be secured.
8.2 Axial stability next to the connecting piece The tank in the receptacle is secured against lateral movement
8.3 Anchor using blocks, which – distributed evenly over the area of the tank
9 Analyses of the tank in the receptacle base – are welded to the base of the receptacle on three sides.
9.1 Axial stability
9.2 Lower support The safeguard against tilting can be implemented in two ways:
9.2.1 Blocks 1. Using partitions, which – distributed evenly over the area –
9.2.2 Ring are welded to a reinforcement ring in the upper part of the
9.3 Upper support tank.
9.3.1 Partition Via compressive forces, these partitions transmit the global
9.3.2 Ring plate with collar supporting force from the tank to the receptacle reinforced
10 Analyses of the receptacle with the ring,
10.1 Axial stability 2. Using a ring plate with a collar.
10.2 Anchor The ring plate is welded in the upper part of the tank. The collar
11 References is located inside the receptacle.
Appendix: Structural details
1 Scope
The following structure and calculation rules apply to vertical,
cylindrical, factory-fabricated thermoplastic tanks with a flat base for a mm Thickness of the weld for the blocks
installation in an earthquake zone within Germany. Tanks that are ag m/s² Ground acceleration
installed in an earthquake zone outside Germany must be ah m/s² Horizontal tank acceleration
dimensioned according to the regulations that are applicable there.
By agreement with the operator, the calculations may also be av m/s² Vertical tank acceleration
carried out based on DIN 4149, if the acceleration due to gravity A1 – Reduction factor for the influence of the
and information on the geological substrate and subsoil are known. specific strength
The following prerequisites must be satisfied when using this A2I – Reduction factor for the medium during
supplement: stability analyses
– The tank may be installed indoors or outdoors on. Its foundation AErd N Horizontal force of the lower support
must be in direct contact with the ground. In the case of AoR mm² Cross-sectional area of the open ring cross-
installation on the ceilings of buildings, platforms or similar, section
separate analyses are required that take the oscillation
properties of the whole system into account. aR mm Weld thickness for the ring
268
AR mm² Cross-sectional area of the ring Kexist

K,d N/mm² Rated value of the short-term load
*
AS mm² Shear surface of the equivalent beam K K,d N/mm² Rated value of the creep rupture strength for
ASW,i mm² Shear surface of the section i in the 10-1 hours
receptacle lBlo mm Length of the blocks
b mm Width of the ring plate's plate strip (e. g. 1 lk mm Length of the ring roof strip
mm) lSch mm Length of the partitions
bBlo mm Width of the blocks MErd Nmm Earthquake moment in height x for tank
BErd,A N Horizontal force of the upper support from without receptacle
model A MErd,A Nmm Earthquake moment in height x for tank in
BErd,B N Horizontal force of the upper support from receptacle according to model A
model B MErd,B Nmm Earthquake moment in height x for tank in
BErd,max N Significant horizontal force of the upper receptacle according to model B
support MErd,max,i Nmm Significant earthquake moment of section i
bDp mm Width of the space plate (bPr ≤ bDp ≤ 1.5 ⋅ of the tank in receptacle
bPr) MErd,i Nmm Significant earthquake moment at the lower
bPr mm Width of the anchor lug edge of section i of the tank without
bR mm Width of the ring receptacle
bSch mm Width of the partitions MErd,j Nmm Earthquake moment at the connecting piece
j
d mm Internal diameter of the cylinder
MErd,W Nmm Earthquake moment at height x for
dA,j mm Outer diameter of the connecting piece j receptacle
dR mm Internal diameter of the ring MErd,W,i Nmm Earthquake moment at the lower edge of
dW mm Internal diameter of the receptacle section i of the receptacle
ET°C
K N/mm² Short-term Young's modulus at T°C mK kNs²/m Mass of the roof load
nBlo – Number of blocks
E20°C
K N/mm² Short-term Young's modulus at 20°C
nRD N/mm Greatest membrane force in ring roof
E20°C
L N/mm² Long-term Young's modulus at 20°C
nSch – Number of partitions
ei – Eccentricity of the section thicknesses
Nj N Overall axial force at the connecting piece j
fα,i – Reduction factor for eccentricity
Nk,d N Rated value of the critical compressive force
g m/sec² Acceleration due to gravity of the ring roof strip
GA N Dead load of the additional weight on the N Liquid lo
N Rated value of the global compressive force
R,d
roof from the liquid load in the supporting ring
GB N Dead load of the base pu N/mm² Long-term negative pressure
GD N Dead load of the roof pü N/mm² Long-term positive pressure
GT°C
K N/mm² Shear modulus during short-term loading q – Property coefficient
for T°C r mm Cylinder radius of the tank
GZ N Dead load of the tank's cylinder S – Underground parameters
GZ,W N Dead load of the receptacle's cylinder s1/3 mm Thickness of the cylinder in the lower third
h mm Height of the equivalent beam of the tank
hA,j mm Height of the axis of the cut-out j sB mm Thickness of the tank base
HBlo N Horizontal force in the block sB,W mm Thickness of the receptacle base
hBlo N Height of the blocks sj mm Thickness of the cylinder at the connecting
piece j
HDüb N Rated value of the horizontal anchor force
sKr mm Thickness of the ring plate and the collar
HErd N Total horizontal force from earthquake
s1 mm Wall thickness of the top section
HF N Horizontal inertia from liquid load
sRD mm Thickness of the ring roof
hF mm Fill height
sSch mm Thickness of the partitions
hF,i mm Fill height, measured from the lower edge
of the section i sZ,i mm Thickness of cylinder section i
hg mm Overall height of tank sz,0 mm Thickness of the reinforcement shell
HGA N Horizontal inertia from GA T s Oscillation duration
hR mm Height of the ring TA °C Average ambient temperature (according
to Miner, see Guideline DVS 2205-1)
HSch N Horizontal force in the partition
TAK °C Maximum ambient temperature
hSt mm Height of the lower support above the base
of the receptacle TBieg,mK s Oscillation period for a massless bending
beam, fixed on one side, with head mass
hW,i mm Height of the section i in the receptacle
TF s Oscillation duration of the filled tank
hW,i-1 mm Height of the section i-1 in the receptacle
TM °C Average temperature of liquid (according
I mm4 Moment of inertia of the equivalent beam
to Miner, see Guideline DVS 2205-1)
IW,i mm4 Moment of inertia of the section i in
TMK °C Maximum media temperature
the receptacle
269
TSchub,mK s Oscillation period for a massless shear hF

beam, fixed on one side, with head mass λ = 0.5 ⋅ 1 + ------  (1)
 d
wBieg mm/N Bending deformation of the receptacle at the
support for 1 N
wSchub mm/N Shear deformation of the receptacle at the The earthquake zone of the installation location is established
support for 1 N from Figure 2 of DIN 4149 and/or from lists [4] which indicate the
earthquake zone for municipalities in certain federal states.
WoR mm³ Moment of resistance of the open ring Accordingly, the horizontal ground acceleration, ag, is fixed
cross-section according to Table 2 of DIN 4149.
x mm Height of the section under consideration Similarly, the geological substrate category of the installation
above the tank base location is established from Figure 3 of DIN 4149 and/or from the
z – Number of anchors lists [4].
zS mm Centroidal distance of the open ring from the The subsoil category must be stated by the tank operator. If no
cylinder axis reliable information on the subsoil is available. subsoil category
αi – Auxiliary quantity C must be used.
αj – Auxiliary quantity The horizontal acceleration ah is determined according to DIN
αR – Factor for axial stability, supporting ring 4149, with the spectrum shown in Figure 4, in conjunction with
Table 4, assuming 5% viscous damping, i. e. ß0 = 2.5 and η = 1
αRD Degre Inclination angle of ring roof and the importance factor γIE. For tanks used to store water-
es polluting liquids, at least γIE = 1.6 must be used. The property
β0 – Reinforcement coefficient of the spectrum coefficient must be set at q = 1.5.
acceleration In order to determine the spectrum value, the oscillation period T
η – Damping correction coefficient of the system is required.
4.2 Oscillation duration
ηA,j – Utilisation of the axial stability next to the
connecting piece j 4.2.1 Tank without receptacle
ηH – Utilisation of the analysis of pressure between The tank is shown as a beam, fixed underneath, with height hF
the spacer plate and the base plate and the mass distribution from the liquid load (the intrinsic weight
γF1 – Partial safety factor of the force (dead load, of the tank may be ignored).
liquid load) According to Rammerstorfer [1], formulae (11) and (12) and/or
γF2 – Partial safety factor of the force (pressures, DIN EN 1998-4, formula (A.24), the circuit frequency ω of this
wind) system can be determined from
γF3 – Partial safety factor of the force (diminishing ( 1.5 ⋅ E K ) ⋅ s 1/3
T°C
dead load) ------------------------------------------- ⋅ 10 9
ρF ⋅ hF
γF4 – Partial safety factor of the force ω = 2 ⋅ π ⋅ ------------------------------------------------------------------------------------
- 1/s (2)
hF 2 hF
(earthquake) 2 ⋅ r ⋅  0.157 ⋅  ------ + ------ + 1.49
  r r 
γIE – Importance factor according to DIN 4149
Table 3 (there known as γI) where s1/3 is the cylinder thickness in the lowest third. Due to the
γM – Partial safety factor of the resistance/stress very short effective duration, the dynamic Young's modulus is
capacity increased by 50% compared with the short-term modulus. This
gives the oscillation period through the relationship
λ – Reduction factor for sloshing 2⋅π
T = ----------- to
μ – Poisson's ratio ω
ω 1/s Circuit frequency
ρF ⋅ hF
ρF g/cm³ Density of the filling medium TF = -⋅2⋅r
--------------------------------------------------------
T°C 9
( 1.5 ⋅ E K ) ⋅ s 1/3 ⋅ 10
σG,j N/mm² Load in the cylinder from the dead weight at
the height of the connecting piece j hF 2 hF
σexist ⋅  0.157 ⋅  ------ + ------ + 1.49 s (3)
i,d N/mm² Rated value of the existing load at the lower   r r 
edge of section i
Where scaffolding or a stir tool is positioned on the roof, the
σexist
j,d N/mm² Rated value of the total load in the cylinder at influence of this on the oscillation period must be analysed. The
the connecting piece j oscillation period for a massless bending beam, fixed on one
σ K,i,d N/mm² Rated value of the axial buckling stress in side, with the moment of inertia
section i 3
I = π ⋅ r ⋅ s 1/3 mm4 (4)
σ K,j,d N/mm² Rated value of the axial buckling stress next
to the connecting piece j and the head mass
4 Tank acceleration GA
m K = ---------------------- kNs²/m (5)
1,000 ⋅ g
4.1 Horizontal tank acceleration
is determined from
Determination of the dynamic loads is based on the calculation
recommendations 40-B3 from the German Construction Institute [3]. 3
mK ⋅ h
T Bieg,m = 2 ⋅ π ⋅ ------------------------------------------
- s (6)
The horizontal tank acceleration ah of the tank is determined on T°C
3 ⋅ ( 1.5 ⋅ E K ) ⋅ l
K
the basis of DIN 4149, without considering the slopping of the

liquid in the tank. If the fill height is less than the tank diameter, it is The oscillation period for a massless shear beam, with the shear
recommended to take the slopping into consideration. This may surface
be done approximately by reducing the loads due to the
horizontal tank acceleration by a factor of A S = π ⋅ r ⋅ s 1/3 mm² (7)
270
and the head mass mK is determined from GA
H G = ------- ⋅ a h N (16)
mK ⋅ h A g
T Schub,m = 2 ⋅ π ⋅ -----------------------------------------
- s
K
( 1.5 ⋅ G K ) ⋅ A S
T°C The point of application for this force should be set at the centre
of mass for the road load.
T°C T°C
where G K = 0.36 ⋅ E K N/mm² (8) 5.1 Tank without receptacle
The oscillation period that takes all influences into account is The cylinder is loaded with the linear load HF/hF and the top load
determined from HGA.
The earthquake moment of the cylinder at height x above the
T = 2
T 2F + T Bieg,m + T Schub,m
2 s (9) tank base is determined from
K K
2
The thickness s1/3 of a graduated cylinder is determined from HF ( hF – x )
(numbering of the n+1 sections starting at the top) M Erd = ------- ⋅ ---------------------- + H G ⋅ ( h g – x ) Nmm (17)
hF 2 A
n
 hi ⋅ s i
The use of hg – the total height of the tank – as the position for
the centre of mass of GA is precise enough.
4 ⋅ -------------------
i=1
n
- – s1
 hi 5.2 Tank in receptacle
s 1/3 = ----------------------------------------
i=1
mm (10)
3 A realistic model of the coupled system made up of tank and
receptacle leads to a bend-shear beam that is elastic at the top
4.2.2 Tank with receptacle due to the receptacle and has a fixed support underneath;
The oscillation period of this coupled system can only be underneath said beam is a non-linear torsion spring that absorbs
determined precisely by means of a computer-based calculation. the rise of the cylinder and parts of the container base with
However, based on a fictitious test, the horizontal tank increasing horizontal acceleration. These calculations are very
acceleration ah can be calculated on the safe side with the time-consuming.
plateau value of the spectrum, without determining the oscillation By way of simplification, the overall moments in the cylinder may
period. be calculated using two models. A bendingbeam with horizontal
support at the top is fixed underneath in model A and assumed to
For narrow tanks or in the case of installation in earthquake-
be mounted with articulation underneath in model B.
prone areas with geological subsoil category R, it is more cost
The significant moment for each section MErd,max,i is determined
effective to determine the oscillation period using the formula
from the maximum of the greatest moments in section i of both
below and determine the horizontal acceleration h with the
models. This moment is used to calculate the axial load and
associated spectrum value. The following approximation
therefore the axial stability of each section.
assumes a horizontal coupling between the tank and receptacle at
height hSt. The distance between the supports is hSt.
The supporting forces of the tank in the receptacle may – in so far as
2 3
 π ⋅ r ⋅ ρ ⋅ hF h 
2 they are not calculated using a bending-shear beam with the final
T = 2 ⋅ π ⋅  ----------------------------------9 + m K ⋅ --------  ⋅ [ w Bieg + w Schub ] s (11) wall thickness grade – be determined with the following formula
 2.5 ⋅ h St 2 ⋅ 10 h 2St 
Lower supporting force
h w,i 1 hF hg
A Erd = 1.3 ⋅ H F ⋅ 1 – --- ⋅ -------  – H G ⋅  ------- – 1
n
where w Bieg = i=1
------------------------------------------------
3 ⋅ ( 1.5 ⋅ EK ) ⋅ I w,i
T°C
-  2 h St  A h
St

N (18)
Note: The factor 1.2 was developed in examples with the realistic
2 2 model.
⋅ ( 3 ⋅ h w,i -1 + 3 ⋅ h w,i -1 ⋅ h w,i + h w,i ) mm/N (12)
and upper supporting force
whereby h w,0 = 0 from model A, it follows that
HF hF 2 1 hF HG hg
n h w,i B Erd,A = ------- ⋅  --------- ⋅ 1 – --- ⋅ -------  + ---------A- ⋅  3 ⋅ ------- – 1 (19a)
and w Schub =  (-----------------------------------------------
i=1 1.5 ⋅ G ) ⋅ A SW,i
T°C
- mm/N (13) 2  h St   4 h St  2  h St 
K
from model B, it follows that
4.3 Vertical tank acceleration HF hF hg
B Erd,B = ------- ⋅ --------- + H G ⋅ ------- N (19b)
Consequently, the vertical tank acceleration av is determined on 2 h St A h
St
the safe side with the plateau value of the spectrum and the rated According to model A, the earthquake moment of the cylinder at
value for vertical acceleration 0.7 ⋅ ag. This gives height x above the tank base h is determined from
β0 HF ( hF – x )
2
a v = 0.7 ⋅ a g ⋅ γ IE ⋅ S ⋅ ------ = 1.167 ⋅ a g ⋅ γ IE ⋅ S m/s² (14) M Erd,A = ------- ⋅ ---------------------- + H G ⋅ ( h g – x ) – B Erd,A ⋅ ( h St – x ) Nmm
q hF 2 A
where S is the subsoil parameter according to Table 5 of DIN 4149. (20a)

According to model B, the earthquake moment of the cylinder at
height x above the tank base h is determined from
5 Loads 2
HF ( hF – x )
The significant load results from the horizontal inertia (mass M Erd,B = ------- ⋅ ---------------------- + H G ⋅ ( h g – x ) – B Erd,B ⋅ ( h St – x ) Nmm
hF 2 A
multiplied by acceleration) HF of the liquid load when the tank is (20b)
completely full. if h F – x < 0 , then the first term is zero
2 –6
H F = ρ F ⋅ π ⋅ r ⋅ h F ⋅ a h ⋅ 10 N (15) if h St – x < 0 , then the third term is zero
The point of application for this force should be set at the centre The maximum M Erd,max = max ( M Erd,A ,M Erd,B ) is decisive for
of mass for the liquid. dimensioning.
In the case of roof load GA, the horizontal inertia is determined The maximum B Erd,max = B Erd,B is decisive for dimensioning of
from the upper support.
271
5.3 Receptacle The utilisation is

vorh
A load is applied to the receptacle by the upper supporting force A 2I ⋅ σ0,d
B Erd,max. η = ------------------------
- (24)
σ k,n,d
receptacle base is determined from 8 Analyses of the tank without receptacle
M Erd,W = B Erd,max ⋅ ( h St – x ) Nmm (21) 8.1 Axial stability of the cylinder
For each section i, the axial compressive stress from the dead
weight (can generally be disregarded), long-term negative
6 Analyses pressure pu and earthquake present on the lower edge is
determined, and verified with the buckling stress σk,i,d.
All analyses stipulated in Guideline DVS 2205-2 with
Supplements 2, 3 and 6 must be carried out.  av pu ⋅ r M Erd,i 
= γ F4 ⋅  σ G,i ⋅  1 + ----- + ---------------- + -------------------------------------
exist
σ i,d - N/mm²
In addition, the following analyses for earthquakes must be 
 g  2 ⋅ s Z,i 1.2 ⋅ π ⋅ r 2 ⋅ s 
Z,i
carried out (in so far as the components are available): (25)
– Axial stability of all sections of the tank and receptacle, The buckling stress may be determined using the following
– Axial stability next to the connecting piece in the cylinder, formula:
T°C
– Anchoring of the tank and/or receptacle, ( 1.5 ⋅ E K ) s Z,i
- ⋅ -------- ≤ K K,d
σ k,i,d = α i ⋅ 0.62 ⋅ f α,i ⋅ ---------------------------- * N/mm² (26)
– Shear stress in the parallel weld seams of the blocks, γM r
– Stability of the partitions, 0.70
where α i = ------------------------------------------------------------- (27)
– Stability of the ring plate. 20°C
E K - ⋅ 1 + ---------------------
-------------
r
-
In the case of installation in areas within Germany that are prone to 20°C  100 ⋅ s Z,i 
EL
earthquakes, it is not necessary to carry out any of the strength
analyses that are significant for the analysis of long-term strength, ei
as the analyses of short-term strength with the increased loads and f α,i = 1.5 – -------- ≤ 1 (28)
s Z,i
caused by earthquakes are not significant for measurements.
whereby ei is the eccentricity to the thicker of the two
In the case of installation in an area outside Germany that is neighbouring sections of a graduated cylinder, when this itself is
prone to earthquakes, with high accelerations due to gravity, the thicker than the section i under consideration.
strength of all components must be analysed, taking into account
the dynamic load from the horizontal and vertical acceleration. The calculation temperature should be set as TM.
For the combination of ring tensile load and axial compressive The following condition must be observed for each section i:
load, the strength analyses of the cylinder sections should then
vorh
be carried out with reference stresses according to von Mises. A 2I ⋅ σ i,d
η A,i = ------------------------
-≤1 (29)
Unless required otherwise by the local authorities, TM can be used σ k,i,d
for the wall temperature of the roof for indoor installations and
TAK can be used for outdoor installations. There is no need for an analysis of the casing compressive
stability and the interaction, as the filled tank is under ring tensile
stress.
7 Verification
8.2 Axial stability next to the connecting piece
The analyses are carried out according to the partial safety The compressive stress in the cylinder from the dead weight and
concept. The partial safety factor for the total of the loads in the negative pressure at the height of each connecting piece j is
case of earthquakes is converted into a global axial force and applied at this point on the
weakened cross-section (open ring), together with the earthquake
γ F4 = 1.0 . (22) moment. To do so, the area AoR, the distance of the centre of
mass from the tank axis zS and the moment of resistance WoR of
Loads from wind loads, snow loads and short-term pressures are the ring cross-section must be determined. The axial
not combined with earthquake loads. compressive stress next to the opening must be calculated taking
Analyses for earthquake loads must be carried out for the wall the offset of the line of gravity into consideration, whereby the
temperatures that result when assuming that the temperature of bending stresses may be divided by 1.2.
the liquid is TM and the ambient temperature is TA in the av pu ⋅ r
component under consideration. N j = π ⋅ d ⋅ s j ⋅  σ G,j ⋅  1 + ----- + ------------ N (30)
  g  2 ⋅ s
7.1 Analysis of axial stability in the double-shell area The rated value of the existing load is determined with
The existing axial membrane compressive stress is equal in the  zS M Erd,j 
= γ F4 ⋅  N j ⋅  --------- + ------------------------  + ------------------------  N/mm²
vorh 1
σ j,d (31)
two shells  A oR 1.2 ⋅ W oR 1.2 ⋅ W oR
 
 GD + GZ + kf ⋅ GA av pu ⋅ r M Erd,0 
σ 0,d = γ F4 ⋅  --------------------------------------------- ⋅  1 + ----- + ------------ + ------------------------2-  The following conditions must be observed:
exist
2⋅π⋅r  g 2
 1.2 ⋅ π ⋅ r  vorh
A 2I ⋅ σ j,d
1
⋅ ------------------------- η A,j = ------------------------
-≤1 (32)
s Z,n + s Z,0
N/mm² (23) σ k,j,d
Here, the rated value of the critical buckling stress in the cylinder
The system only fails if the thicker shell becomes unstable, as the at the connecting point j is
thinner shell is supported by the thicker one.
T°C
The buckling stress σk,n,d is calculated according to the formulae 1.5 ⋅ E K s j
σ k,j,d = α j ⋅ 0.62 ⋅ ------------------------ ⋅ ---- ≤ K K,d
* N/mm² (33)
(25) to (27) with sZ,n. γM r
272
0.65 d A,j via these blocks into the base plate of the receptacle and then
where α j = --------------------------------------------------------- for -------------- ≤ 3.5 (34) into the foundation via suitable horizontal anchors. The block
20°C r ⋅ sj
-------------- ⋅ 1 + ------------------ 
EK r under the greatest load must withstand a horizontal force, in a
E
20°C 100 ⋅ s j radial direction, of
L
d A,j 4 ⋅ A Erd
0.45
or α j = --------------------------------------------------------- for -------------- > 3.5 (35) H Blo = ------------------- N (37)
n Blo
20°C
E K ⋅ 1 + ----------------- r ⋅ sj
-
r
-------------- 
EL
20°C 100 ⋅ s j  . The required length of the blocks is determined from the shear
stress analysis for the two parallel weld seams
The dimensioning temperature should be set as TM. H Blo
γ F4 ⋅ ----------- ⋅ A 1
2
8.3 Anchoring I Blo = ----------------------------------- mm (38)
*K
The tank must be anchored. At least 4 anchors are required -------------
K
- ⋅ a Blo
(z ≥ 4). 2 ⋅ γM
A maximum of (TM, TA) is set as the calculation temperature. The calculation temperature should be set as (TM + TA)/2.
The following condition must be observed: The required width of the blocks is based on the analysis of the
2 pressure
 4 ⋅ MErd p ü ⋅ π ⋅ d av  1
γ F4 ⋅  --------------------- + ------------------------- + ------ ⋅ ( G D + G Z + G A ) – γ F3 ⋅ ( G D + G Z + G A ) ⋅ --- b Blo = 0.7 ⋅ I Blo mm (39)
 d 4 g  z
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
*
K K,d The structure of the front horizontal butt weld is executed in the
( b Pr + s B ) ⋅ s B ⋅ -------------- -
2 ⋅ A1 same thickness of a Blo = 0.7 ⋅ s BW mm.
≤1 (36)
9.2.2 Ring
The numerator is the lug force to be borne and the denominator is
the acceptable lug force resulting from the shear stress in the seam. The lower support may also be provided by a ring. This ring is
The total horizontal force HErd = HF + HGA can be transmitted to secured on the outside with an all-round fillet weld ( a R = 0,7 ⋅ s B )
the anchor fittings via steel space plates positioned below the and on the inside with a weld measuring ≥ 3 mm on the base of
anchor lugs. The anchor fittings should be dimensioned for a the receptacle. In order to guarantee secure horizontal support
horizontal force of even if the tank tilts, the height of the ring is determined as
γ F4 ⋅ 4 ⋅ H Erd h R ≥ 2 ⋅ sB mm (40)
H Düb,d = -------------------------------- N (36a)
z
The structural calculations specify the width of the ring as
Moreover, the pressure between the base plate of the tank or b R ≥ max ( s B , 2 ⋅ a R ) mm (41)
receptacle and the spacer plate subject to the greatest load must
be analysed. Here, the compressive strength may be set at The necessary thickness of the weld seam aR is determined from
1.5 times the tensile strength.
γ F4 ⋅ 4 ⋅ 2 ⋅ A Erd
The utilisation follows with a R = ------------------------------------------- mm (42)
K *K
H Düb,d π ⋅ d ⋅ -------
ηH = -------------------------------------------- ≤ 1 (36b) γM
1.5 ⋅ K K *
b Dp ⋅ s B ⋅ -------------------- The welds may be intermittent. At four points, a channel must
γM
ensure that any leakage in the area outside the ring can be
If the mathematical width of the spacer plate is more than detected immediately.
1.5 times the width of the lug, the number of anchors must be
increased. A maximum of (TM, TA) is set as the calculation 9.3 Upper support
temperature.
The structure of the upper support may be executed as
– Loaded partitions between two reinforcement rings
9 Analyses of the tank in the receptacle – A loaded ring plate with collar
The analyses are carried out for the structural elements of the .
upper and lower support shown in Figures 1 and 2. Other
structures of the supports must be analysed accordingly. 9.3.1 Partitions
The centre distance of the partitions must be 500 mm at the tank,
9.1 Axial stability
whereby the number of partitions may not be less than 12 (nSch ≥ 12).
The tank is investigated when it is completely full.
The partition subject to the greatest load must withstand the
The analysis of axial stability for each section takes place compressive force
according to the formulae (25) to (29) with MErd,max,i instead of
MErd,i. 4 ⋅ B Erd,max
H Sch = ---------------------------- N (43)
n Sch
9.2 Lower support
The necessary thickness of the partitions is determined from the
analysis of buckling, assuming restraint on one side (the buckling
9.2.1 Blocks
length is double the length of the partition lSch).
The lower support is provided by h nBlo blocks that are welded to
2
the base of the receptacle in a radial direction. In order to 12 ⋅ γ F4 ⋅ H Sch ⋅ ( 2 ⋅ l Sch )
guarantee secure horizontal support even if the tank tilts, the s Sch = ----------------------------------------------------------------- mm (44)
T°C
height of the blocks is determined as h Blo ≥ 2 ⋅ s B . The weld 2 ( 1.5 ⋅ E K )
3
π ⋅ ---------------------------- - ⋅ b Sch
thickness is a Blo = 0,7 ⋅ s BW mm. The force AErd is transmitted γM
273
TM + TA 10.2 Anchoring
The calculation temperature should be set as -------------------- .
2 The receptacle must be anchored. At least 4 anchors are
required (z ≥ 4).
9.3.2 Ring plate with collar TM + 3 ⋅ TA
---------------------------
- is set as the calculation temperature.
The stability analysis of the ring roof under pressure is carried out 4
on a plate strip of width b (e. g. 1 mm). The following condition must be observed:
The pressure of the horizontal force BErd,max is distributed in 4 ⋅ M Erd,W a v
γ F4 ⋅  ------------------------- + ----- ⋅ G Z,W – γ F3 ⋅ G Z,W ⋅ ---
sinusoidal form across half the circumference. The greatest 1
compressive membrane force in the ring roof below the angle αRD  dW g  z
----------------------------------------------------------------------------------------------------------------------
-≤1 (49)
is determined from K K,d*
( b Pr + s B,W ) ⋅ s B,W ⋅ --------------
4 ⋅ B Erd,max 2 ⋅ A1
n RD = ----------------------------------------- N/mm (45)
π ⋅ d W ⋅ cos α RD The numerator is the lug force to be borne and the denominator
The rated value of the critical compressive force of the roof strip is the acceptable lug force resulting from the shear stress in the
follows with seam.
The analysis of introduction of the total horizontal force is carried
2 ( 1.5 ⋅ E K ) b ⋅ s RD
T°C 3
π ⋅ ------------------------------ 2
- ⋅ ----------------- out according to Section 8, but with the calculation temperature
γM ⋅ ( 1 – μ ) 12
TM + 3 ⋅ TA
N k,d = ---------------------------------------------------------------
- N (46) ---------------------------
-.
I2k 4
dW – d
whereby I = ----------------- can be used for the buckling length on the
k 2
safe side. 11 References
The utilisation follows from
Regulations
γ F4 ⋅ n RD ⋅ b
η = ------------------------------ (47) DIN 4149 Buildings in German earthquake zone – Design
N k,d
TM + TA loads, analysis, and structural design of
In the case of indoor installation, -------------------- should be used as the buildings
2
calculation temperature, while for outdoor installation, a DIN EN 1998-4 Eurocode 8: Design of structures for
maximum of (TM, TAK) should be used. earthquake resistance - Part 4: Silos, tanks
and pipelines
10 Analyses of the receptacle For further standards see Guideline DVS 2205-2 Section 5.2.
The minimum diameter of the receptacle is determined by the Bibliography

required length of the blocks, which in turn is dependent on the [1] Rammerstorfer, F. G., K. Scharf and F. D. Fischer:
number of blocks. Erdbebensichere Bemessung von Zylinderschalen,
The position of the partitions and the height of the receptacle Flüssigkeitsgefüllten Tankbauwerken. Berichte aus dem
results from the requirement that the distance between the lower Institut für Leichbau und Flugzeugbau [Earthquakes: Safe
edge of the roof and the upper edge of the partitions may not be dimensioning of cylinder shells and tank structures filled with
greater than liquid. Reports from the Institute for Light-Weight
1 Construction and Aircraft Construction], Vienna University of
--- ⋅ d ⋅ ( s 1 + s R ) . Technology, Volume ILF – 2 / 90
2
In the case of outdoor installation, the maximum diameter of the [2] Tuercke, H.: Zur Stabilität von Behältern aus Thermoplasten.
receptacle results from the requirement that the slope of the rain [On the stability of thermoplastic tanks] DIBt-Mitteilungen,
deflector must not be less than 10 degrees. Heft 5/1995.
10.1 Axial stability [3] Berechnungsempfehlung für zylindrische Behälter und Silos,
Berücksichtigung des Lastfalls Erdbeben [Calculation
The axial compressive stress from dead weight and earthquake recommendation for cylindrical tanks and silos, considering
available on the lower edge is determined for each section i and earthquakes as a load case]. 40-B3, Deutsches Institut für
verified with the buckling stress σk,i,d. Bautechnik [German Construction Institute]
 av M Erd,W,i  [4] Zuordnung der Erdbebenzonen und Untergrundklassen
= γ F4 ⋅  σ G,i ⋅  1 + ----- + -------------------------------------
vorh
σ i,d -
g  1.2 ⋅ π ⋅ r 2 ⋅ s 
(48)
 [Allocation of the earthquake zones and subsoil categories]
 Z,i www.dibt.de/Data/TB/Zuordnung_der_Erdbebenzonen.xls
The analysis of axial stability for each section takes place [5] Tuercke, H.: Zur Einleitung axialer Einzellasten am oberen
according to the formulae (25) to (26). Rand von Thermoplastbehältern [On the introduction of axial
TM + 3 ⋅ TA concentrated loads at the upper edge of thermoplastic tanks],
---------------------------
- is set as the calculation temperature.
4 DIBt-Mitteilungen, Volume 4/2002
274
Appendix: Structural details
Figure 1. Upper support with partitions.
Figure 2. Upper support with ring roof and collar.
275
Figure 3. Lower support with blocks.
Figure 4. Lower support with ring.
Figure 5. Definition of hSt.
276
February 2013

FÜR SCHWEISSEN UND
Vertical round non-pressurised tanks – DVS 2205-2
Flat-bottomed tanks in earthquake regions Supplement 4
This Supplement 4 to the DVS 2205-2 technical code was elaborated by DVS-AG W4.3b ("Structural designing / apparatus engineering").
Contents: – The tank must always be anchored with the foundation directly
or, for a tank in the collecting vessel, indirectly. The design of
1 Scope of application the upper and lower supports corresponds to Figs. 1 and 2. In
2 Design the case of designs deviating from this, it is necessary to provide
3 Calculation variables corresponding proof separately.
4 Tank acceleration
– The tanks and the collecting vessels are dimensioned in parallel
according to the DVS 2205-2 technical code with Supplements
4.2 Vibration period 2, 3 and 6.
4.2.1 Tank without a collecting vessel
4.2.2 Tank with a collecting vessel – The execution of the tanks and of the collecting vessels complies
4.3 Vertical tank acceleration with the DVS 2205-2 technical code with Supplements 2, 3 and 6.
5 Stresses
5.1 Tank without a collecting vessel

5.2 Tank in the collecting vessel 2 Design
5.3 Collecting vessel
6 Proof Tanks without collecting vessels are anchored to the foundation
7 Provision of proof directly in order to thus secure them against any shifting or tilting
7.1 Proof of the axial stability in the two-shell region as a result of the horizontal earthquake forces.
8 Proof of the tank without a collecting vessel
Tanks in the collecting vessel cannot be anchored to the founda-
8.1 Axial stability of the cylinder tion directly but the tank must be secured.
8.2 Axial stability next to sockets
8.3 Anchoring The collecting vessel is secured against the lateral shifting of the
9 Proof of the tank in the collecting vessel tank with blocks which, uniformly distributed around the circum-
9.1 Axial stability ference of the tank bottom, are welded with the bottom of the col-
9.2 Lower support lecting vessel on three sides.
9.3 Upper support The securing against tilting can be carried out in two ways:
9.3.1 Bulkheads
9.3.2 Ring plate with a collar 1. Using bulkheads which, uniformly distributed around the circum-
10 Proof of the collecting vessel ference, are welded with a reinforcing ring in the upper region
10.1 Axial stability of the tank.
10.2 Anchoring These bulkheads bear the global supporting force from the tank
11 Bibliography to the ring-stiffened collecting vessel via compressive forces.
Appendix: Design-related details 2. Using a ring plate with a collar.
The ring plate is welded on in the upper region of the tank.
The collar grips over the upper edge of the collecting vessel.
The following design and calculation rules apply to vertical, cylin- 3 Calculation variables
drical tanks which are fabricated from thermoplastics in the factory,
have flat bottoms and are intended for installation in a German a mm Thickness of the weld of the blocks
earthquake region. Tanks which are installed in an earthquake
ag m/s² Soil acceleration
region outside Germany must be dimensioned according to the
set of rules applicable there. In agreement with the operator, the ah m/s² Horizontal acceleration of the tank
calculation can also be carried out with reference to DIN 4149 if av m/s² Vertical acceleration of the tank
the soil acceleration and statements about the geological subsoil A1K – Reduction factor for the influence of the
and about the foundation soil are known. specific toughness for a wall temperature
For the application of this supplement, it is necessary to satisfy effective for a short time
the following prerequisites: A2I – Reduction factor for the medium in the case
of the proof of the stability
– The tank may be installed inside or outside buildings. Its foun-
dation must be in direct contact with the earth. In the event of AErd N Horizontal force of the lower support
installation on building ceilings, platforms or similar structures, AR mm² Cross-sectional area of the open ring cross-
separate proof is required and must take account of the vibration section
behaviour of the entire system. AS mm² Shear area of the substitute beam
277
ASW,i mm² Shear area of the course i in the collecting MErd,W Nmm Earthquake moment at the height x for the
vessel collecting vessel
bBlo mm Width of the blocks MErd,W,i Nmm Earthquake moment at the lower edge of the
BErd N Horizontal force of the upper support course i of the collecting vessel
bPr mm Width of the anchor claw mK kNs²/m Mass of the roof load
bSch mm Width of the bulkheads nBlo – Number of blocks
d mm Inside diameter of the cylinder nSch – Number of bulkheads
dA,j mm Outside diameter of the socket j Nj,d N Dimensioning value of the global normal
dW mm Inside diameter of the collecting vessel force at the height of the socket j
NFüllung N Dimensioning value of the global compres-
ET°C
K N/mm² Short-time elastic modulus at T°C R,d
sive force resulting from the filling in the
E20°C
K N/mm² Short-time elastic modulus at 20°C supporting ring
E20°C N/mm² Long-time elastic modulus at 20°C pu N/mm² Partial vacuum effective for a long time
L
ei – Eccentricity of the wall thicknesses of the pü N/mm² Overpressure effective for a long time
courses q – Behaviour coefficient
f,i – Reduction factor for the eccentricity r mm Cylinder radius of the tank
g m/sec² Acceleration due to gravity S – Subsoil parameter
GA N Dead load of the additional weight on the s1/3 mm Wall thickness of the cylinder at the lower
roof third point of the tank
GB N Dead load of the bottom sB mm Wall thickness of the tank bottom
GD N Dead load of the roof sB,W mm Wall thickness of the collecting vessel bottom
sj mm Wall thickness of the cylinder at the height of
GT°C
K N/mm² Shear modulus in the case of short-time the socket j
stresses for T°C
sKr mm Wall thickness of the ring plate and of the
GZ N Dead load of the cylinder of the tank
collar
GZ,W N Dead load of the cylinder of the collecting
s1 mm Wall thickness of the highest course
vessel
sSch mm Thickness of the bulkheads
h mm Height of the substitute beam
sZ,i mm Wall thickness of the cylinder course i
hA,j mm Height of the axis of the cut-out j
sz,0 mm Wall thickness of the reinforcing shell
HBlo N Horizontal force in the block
T s Vibration period
HErd N Total horizontal force resulting from the
earthquake TA °C Mean ambient temperature (according to
Miner, see the DVS 2205-1 technical code)
HF N Horizontal mass force resulting from the filling
TAK °C Highest ambient temperature
hF mm Filling height
TBieg,mK s Vibration period of a bending beam which
hF,i mm Filling height, measured from the lower edge does not have any mass, is clamped on one
of the course i side and has a head mass
hg mm Overall height of the tank
TF s Vibration period of the filled tank
HGA N Horizontal mass force resulting from GA
TM °C Mean media temperature (according to
HSch N Horizontal force in the bulkhead Miner, see the DVS 2205-1 technical code)
hSt mm Height of the upper support above the tank TMK °C Highest media temperature
bottom
TSchub,mK s Vibration period of a shear beam which
hW,i mm Height of the course i in the collecting vessel does not have any mass, is clamped on one
hW,i-1 mm Height of the course i-1 in the collecting side and has a head mass
vessel wBieg mm/N Bending deformation of the collecting vessel
I mm 4 Moment of inertia of the substitute beam at the height of the support for 1 N
IW,i mm4 Moment of inertia of the course i in the wSchub mm/N Shear deformation of the collecting vessel at
collecting vessel the height of the support for 1 N
kf – Concentration factor according to Supple- WR mm³ Resistance moment of the open ring cross-
ment 7 section
Kvorh
K,d N/mm² Dimensioning value of the stresses effective x mm Height of the section under consideration
for a short time above the tank bottom
*
K K,d N/mm² Dimensioning value of the creep strength in z – Number of anchors
the case of 10-1 hours zS mm Distance between the centres of gravity of
lBlo mm Length of the blocks the open ring and of the cylinder axis
lSch mm Length of the bulkheads i – Auxiliary variable
MErd Nmm Earthquake moment at the height x for the j – Auxiliary variable
tank without a collecting vessel R – Factor for the axial stability of the supporting
MErd,B Nmm Earthquake moment at the height x for the ring
tank in the collecting vessel 0 – Reinforcing coefficient of the spectrum
MErd,B,i Nmm Earthquake moment at the lower edge of the acceleration
course i of the tank in the collecting vessel  – Damping correction coefficient
MErd,i Nmm Earthquake moment at the lower edge of the A,i – Utilisation of the axial stability in the course i
course i of the tank without a collecting
A,j – Utilisation of the axial stability next to the
vessel
socket j
MErd,j Nmm Earthquake moment at the height of the F1 – Partial safety coefficient of the effect
socket j (dead load and filling)
278
F2 – Partial safety coefficient of the effect T°C

(pressures and wind)  1.5  E K   s 1/3
-------------------------------------------  10 9
F3 – Partial safety coefficient of the effect F  hF
 = 2    ------------------------------------------------------------------------------------
- 1/s (2)
(reducing dead load) hF 2 h
F4 2  r   0.157   ------ + -----F- + 1.49
– Partial safety coefficient of the effect   r r 
(earthquake)
with s1/3 as the cylinder wall thickness at the lower third point.
I – Weighting coefficient according to the Because of the very short effective duration, the dynamic elastic
DVS 2205-2 technical code modulus is raised by 50 % compared with the short-time modu-
IE – Significance coefficient according to lus. This results in the vibration period via the relationship:
DIN 4149, Table 3 (called I there) 2
=T ----------- to
M – Partial safety coefficient of the resistance/ 
stressability
F  hF
 – Reduction factor for splashing TF = --------------------------------------------------------
-2r
T°C 9
 1/s Angular frequency  1.5  E K   s 1/3  10
F g/cm³ Density of the filling medium
hF 2 h
G,j N/mm² Stresses in the cylinder resulting from the   0.157   ------ + -----F- + 1.49 s (3)
  r r 
dead weight at the height of the socket j
 vorh
i,d N/mm² Stresses existing at the lower edge of the In so far as a platform or a stirrer is arranged on the roof, it is nec-
essary to provide proof of its influence on the vibration period.
course i
The vibration period of a massless bending beam with the moment
vorh
j,d N/mm² Dimensioning value of the total stresses in
of inertia:
the cylinder at the height of the socket j
 K,i,d N/mm² Dimensioning value of the axial buckling I =   r  s 1/3
3
mm4 (4)
stress in the course i
 K,j,d N/mm² Dimensioning value of the axial buckling and the head mass:
stress next to the socket j GA
m K = ---------------------- kNs²/m (5)
1,000  g
4 Tank acceleration
follows from:
4.1 Horizontal tank acceleration 3
mK  h
The horizontal tank acceleration ah of the tank is established on T Bieg,m = 2    ------------------------------------------
- s (6)
T°C
3   1.5  E K   l
K
the basis of DIN 4149 while disregarding the splashing of the me-
dium in the tank. If the filling height is less than the tank diameter, The vibration period of a massless shear beam with the shear area:
it is advisable to take account of the splashing. This can be done
approximately by reducing the stresses caused by the horizontal A S =   r  s 1/3 mm² (7)
tank acceleration with the factor:
and the head mass mK follows from:
h
 = 0.5  1 + -----F-  (1) mK  h
 d T Schub,m = 2    -----------------------------------------
- s
T°C
 1.5  G K   A S
K
The earthquake zone of the installation location is indicated on
Fig. 2 in DIN 4149 and in lists [3] in which the earthquake zone is
T°C T°C
specified for the local authorities in a few federal states. The hori- with G K = 0.36  E K N/mm² (8)
zontal soil acceleration ag is thus defined according to Table 2 in
DIN 4149. The vibration period which takes account of all the influences follows
from:
The geological subsoil class of the installation location is also
indicated on Fig. 3 in DIN 4149 and in the lists [3]. T = 2
T F2 + T Bieg,m + T Schub,m
2 s (9)
K K
The foundation soil class must be specified by the operator of the
tanks. If no assured information about the foundation soil is avail- The thickness s1/3 of a graduated cylinder follows from (numbering
able, the foundation soil class C must be applied. of the n courses beginning at the top):
n
According to DIN 4149, the horizontal acceleration ah results with
the spectrum according to Fig. 4 in conjunction with Table 4 on hi si
4  ------------------- - – s1
i=1
the assumption of 5 % viscous damping, i.e. ß0 = 2.5 and  = 1, n
and the significance coefficient IE. At least IE = 1.2 must be set for  hi
tanks for the storage of water-endangering fluids. The behaviour s 1/3 = ----------------------------------------
i=1
mm (10)
3
coefficient must be applied with q = 1.5.
4.2.2 Tank with a collecting vessel
The vibration period T of the system is needed for the determination
of the spectrum value. The vibration period of this coupled system can only be established
exactly with an EDP-assisted calculation but, as a substitute, the
4.2 Vibration period horizontal tank acceleration ah can be calculated on the safe side
with the plateau value of the spectrum without establishing the
4.2.1 Tank without a collecting vessel vibration period.
The tank is represented as a beam which is clamped at the bottom, For slender tanks or in the case of installation in the earthquake
is located at the height hF and has the mass per unit area result- region with the geological subsoil class R, it is more economically
ing from the filling (the dead mass of the tank may be disregarded). viable to establish the vibration period with the following equation
and to determine the horizontal acceleration ah with the relevant
According to Rammerstorfer [1], Equations (11) and (12) as well spectrum value. The prerequisite for the following approximation
as Equation (A.24) in DIN EN 1998-4, the angular frequency  of is horizontal coupling between the tank and the collecting vessel
this systems can be established from: at the height hSt.
279
2 3 The earthquake moment of the cylinder at the height x above the

   r    hF h 
2
tank bottom results from:
T = 2     ----------------------------------
9
+ m K  --------    w Bieg + w Schub  s (11)
 2.5  h St  10 2 h St 
2
2
HF  hF – x 
MErd,B = -------  ---------------------- + H G   h g – x  – B Erd   h St – x  Nmm (20)
n h w,i hF 2

A
with w Bieg = ------------------------------------------------
-
T°C
i=1 3   1.5  EK   I w,i If hF – x < 0, then the first term is zero.
If hSt – x < 0, then the third term is zero.
2 2
  3  h w,i -1 + 3  h w,i -1  h w,i + h w,i  mm/N (12)
5.3 Collecting vessel
where h w,0 = 0 The collecting vessel is subjected to loads by the upper supporting
force BErd.
n h w,i
and w Schub = 
i=1
-----------------------------------------------
T°C
 1.5  GK   A SW,i
- mm/N (13) The earthquake moment of the cylinder at the height x above the
bottom of the collecting vessel results from:
4.3 Vertical tank acceleration M Erd,W = B Erd   h St – x  Nmm (21)
The vertical tank acceleration av is established on the safe side

with the plateau value of the spectrum and the dimensioning value 6 Proof
of the vertical acceleration 0.7 x ag. This results in:
0 It is necessary to provide all the proof in the DVS 2205-2 technical
a v = 0.7  a g   IE  S  ------ = 1.167  a g   IE  S m/s² (14) code with Supplements 2, 3 and 6.
q
In addition, the following proof must be provided for earthquakes
where S is the subsoil parameter according to Table 5 in DIN 4149.
(in so far as the components are present):
– Proof of the axial stability at the lower edge of all the courses of
5 Stresses the tank and of the collecting vessel
The crucial stresses result from the horizontal mass force (mass – Proof of the axial stability next to sockets in the cylinder
times acceleration) HF of the filling in the completely filled condition. – Proof of the anchoring of the tank and of the collecting vessel
2 6
H F =  F    r  h F  a h  10 N (15) – Proof of the shear stress in the parallel welds of the blocks
The point of attack of this force must be applied at the centre of – Proof of the stability of the bulkheads
gravity of the filling. – Proof of the weld between the ring plate and the collar
In the case of the roof load GA, the horizontal mass force results
In the case of installation in German earthquake regions, it is not
from:
necessary to provide any further proof for the increased stresses
GA caused by the vertical acceleration; this only applies to flat-bottomed
H G = -------  a h N (16) tanks.
A g
The point of attack of this force must be applied at the centre of
gravity of the roof load. 7 Provision of proof
5.1 Tank without a collecting vessel The proof is provided according to the partial safety concept. The
The cylinder is subjected to the line load HF/hF and the head load partial safety coefficient for the stresses induced by earthquakes is:
HGA.  F4 = 1.0 . (22)
The earthquake moment of the cylinder at the height x above the
tank bottom results from: Stresses resulting from wind loads, from snow loads and from
pressures effective for a short time are not combined with earth-
2
HF  hF – x  quake stresses.
M Erd = -------  ---------------------- + H G   h g – x  Nmm (17)
hF 2 A
Proof for earthquake stresses must be provided for the wall tem-
The approach with hg (the overall height of the tank) as the position peratures resulting in the component under consideration on the
of the centre of gravity of GA is accurate enough. assumption of the highest media temperature TMK and the highest
ambient temperature TAK.
5.2 Tank in the collecting vessel
The tank is held at the bottom and at the top; the distance between 7.1 Proof of the axial stability in the two-shell region
these supports is hSt. In both shells, the existing axial compressive membrane stress
The supporting forces of the tank in the collecting vessel are: equals:
at the bottom:  GD + GZ + kf  GA  F4 a v pu  r
 0,d =   F1  ---------------------------------------------   1 + -------
vorh
-  ----- +  F2  ------------
2r   F1 g  2
h 
H F   h St – -----F- – H G   h g – h St 
 2 A
A Erd = ------------------------------------------------------------------------------------ N (18) M Erd,0  1
h St +  F4  ------------------------2-   ------------------------- (23)
1.2    r  s Z,n + s Z,0
and at the top:
The system only fails if the thicker shell becomes unstable since
hF the thinner shell is supported by the thicker shell.
H F  ------ + H G  h g
B Erd
2 A
= ---------------------------------------------- N (19) The buckling stress k,n,d is calculated with sZ,n according to
h St Equations (25) to (27).
280
The utilisation is: In this respect, the dimensioning value of the critical buckling
stress in the cylinder at the socket j is:

vorh
A 2I   I   T°C
0,d sj
 = ----------------------------------------- (24) EK
 k,n,d  k,j,d =  j  0.62  ------------  ---- N/mm² (33)
M r
0.65 d A,j
8 Proof of the tank without a collecting vessel with  j = --------------------------------------------------------- for --------------  3.5 (34)
20°C r  sj
--------------  1 + ------------------ 
EK r
8.1 Axial stability of the cylinder EL
20°C 100  s j
For every course i, the axial compressive stress existing at the
lower edge is established from the dead weight (can also be dis- 0.45 d A,j
or  j = --------------------------------------------------------- for --------------  3.5 (35)
regarded in general), the long-time partial vacuum pu and the 20°C r  sj
earthquake and is validated with the buckling stress k,i,d. E K  1 + ----------------- r
-
-------------- 
EL
20°C 100  s j 
 F4 a v pu  r
 i,d =  F1   G,i   1 + -------
vorh
-  ----- +  F2  ---------------
- +  F4
  F1 g  2  s Z,i TMK must be applied as the dimensioning temperature.
M Erd,i 8.3 Anchoring

 -------------------------------------
2
- N/mm² (25)
1.2    r  s Z,i The tank must be anchored. At least four anchors are required
The buckling stress may be established according to the following (z  4).
equation: TMK is applied as the calculation temperature.
T°C The following condition must be complied with:
EK s Z,i
 k,i,d =  i  0.62  f ,i  --------------  --------  K K,d
* N/mm² (26)
M r 2
4   F4  M Erd  F2  p ü    d a
+ ------------------------------------- –  F3   1 – -----v   G D + G Z   ---
1
--------------------------------
0.70 d 4  g z
with  i = ------------------------------------------------------------- (27) -----------------------------------------------------------------------------------------------------------------------------------------------------------------  1
20°C K K,d*
E 
K -  1 + ---------------------
-------------
r
-  b Pr + s B   s B  --------------------------
20°C  100  s Z,i  2  A 1K   I
EL
(36)
e
and f ,i = 1.5 – -------i-  1 (28) The claw force to be absorbed is located in the numerator and
s Z,i
the absorbable claw force resulting from the shear stress in the
where ei is the eccentricity to the thicker of the two neighbouring weld in the denominator.
courses in the case of a graduated cylinder if this itself is thicker
than the course under consideration. In addition, it must be ensured that the entire horizontal force
HErd = AErd + BErd is reliably guided into the foundation.
The calculation temperature must be applied with TMK.
The following condition must be complied with for every course i:
9 Proof of the tank in the collecting vessel

vorh
A 2I   I  
= ------------------------------------------  1
i,d (29)
 A,i The proof is provided for those design elements of the upper and
 k,i,d lower supports which are portrayed on Figs. 1 and 2. Proof of
other designs of the supports must be provided accordingly.
It is not necessary to provide any proof of the jacket pressure
stability or the interaction since the filled tank is subjected to tensile
hoop stresses. 9.1 Axial stability
Due to the mass forces of the filling, the tank which is held at the
8.2 Axial stability next to sockets bottom and at the top is subjected to stresses like those on a
The compressive stresses in the cylinder resulting from the dead beam flexible on both sides. The greatest moment MErd,B,i must
weight and the partial vacuum at the height of every socket j are be determined for every course i. The moment at the upper edge
converted into a global normal force and are applied together is crucial for courses whose upper edge is located below half the
with the earthquake moment at this position on the weakened span hSt. The moment at the lower edge is crucial for the courses
cross-section (open ring). For this purpose, it is necessary to de- whose lower edge is located above half the span hSt. The moment
termine the area AR, the distance away from the centre of gravity at x = hSt/2 determines the central course.
of the tank axis zS and the resistance moment WR of the ring cross- In analogy to Equations (25) to (29), the axial stability of every
section. Paying attention to the misalignment of the centroidal axis, course is proven with MErd,B,i instead of MErd,i.
it is necessary to calculate the axial compressive stresses next to
the opening. In this respect, the bending stresses may be divided
9.2 Lower support
by 1.2.
The lower support is carried out using nBlo blocks which are
 F4 a v pu  r
N j,d =   d  s j    F1   G,j   1 + -------
-  ----- +  F2  ------------  N (30) welded on to the bottom of the collecting vessel in the radial
   F1 g  2s direction. The thickness of the weld is a = 0.7  s B mm, with sB
as the thickness of the tank bottom. The force AErd is guided into
The dimensioning value of the existing stresses follows with: the baseplate of the collecting vessel via these blocks and into
z S   F4  M Erd,j the foundation via suitable horizontal anchors. The block subjected
= N j,d   ------- + ---------------------
vorh 1
 j,d - + --------------------------- N/mm² (31) to the highest load must bear a radially directed horizontal force of:
A 
R 1.2  W R 1.2  W R
The following condition must be complied with: 4  A Erd
=
H Blo ------------------- N (37)
vorh
n Blo
A 2I   I   j,d
 A,j = ---------------------------------  1 (32) The required length of the blocks results from the proof of the
 k,j,d shear stress of the two parallel welds:
281
H Blo T MK + 3  T AK
 F4  -----------   I  A 1K ----------------------------------
- is applied as the calculation temperature but min.
2 4
I Blo = ---------------------------------------------- mm (38) 50°C in the case of direct solar radiation.
K K*
--------------  0.7  s B
2  M 10.2 Anchoring
The calculation temperature must be applied with TMK. The collecting vessel must be anchored. At least four anchors
are required (z  4).
The required width of the blocks follows from the proof of the
pressing: T MK + 3  T AK
----------------------------------
- is applied as the calculation temperature but min.
b Blo = 0.7  I Blo mm (39) 4
50°C in the case of direct solar radiation.
As far as the design is concerned, the front transverse weld is The following condition must be complied with:
executed in the same thickness a = 0.7  s B mm.
4   F4  M Erd,W a
-------------------------------------- –  F3   1 – -----v  G Z,W  ---
1
dW  g z
9.3 Upper support ------------------------------------------------------------------------------------------------------------
- 1 (45)
*
K K,d
As far as the design is concerned, the upper support can be exe-  b Pr + s B,W   s B,W  --------------------------
cuted as: 2  A 1K   I
– Bulkheads which are located between two reinforcing rings The claw force to be absorbed is located in the numerator and
and are subjected to compressive stresses the absorbable claw force resulting from the shear stress in the
weld in the denominator.
– A ring plate which has a collar and is subjected to tensile stresses
In addition, it must be ensured that the entire horizontal force
9.3.1 Bulkheads HErd = AErd + BErd is reliably guided into the foundation.
The bulkhead subjected to the highest load amongst the nSch
bulkheads must bear the compressive force: 11 Bibliography
4  B Erd
=
H Sch ------------------- N (40) Set of rules
n Sch
DIN 4149 Structures in German earthquake regions –
The required thickness of the bulkheads results from the proof of Load assumptions, dimensioning and execution
the buckling on the assumption of clamping on one side (the of customary superstructures
buckling length is twice the bulkhead length lSch).
DIN EN 1998-4 Eurocode 8: Designing of structures against
2 earthquakes – Part 4: Silos, tank structures and
12   F4  H Sch   2  l Sch    l
s Sch = ------------------------------------------------------------------------- mm (41) pipelines
T°C
2 EK
3
  ----------- -  b Sch
M For further standards, see the DVS 2205-2 technical code, Section
5.2.
T MK + T AK
The calculation temperature must be applied with --------------------------- . Literature
2
[1] Rammerstorfer, F. G., K. Scharf and F. D. Fischer: Earthquake-
9.3.2 Ring plate with a collar proof dimensioning of cylinder shells and fluid-filled tank struc-
As far as the design is concerned, the thickness of the ring plate tures.
and of the collar must be chosen as follows: [2] Tuercke, H.: On the stability of tanks made of thermoplastics.
DIBt Communications, No. 5/1995.
dW
s Kr  ---------- (42) [3] Assignment of the earthquake zones and subsoil classes
300
www.dibt.de/Data/TB/Zuordnung_der_Erdbebenzonen.xls
The utilisation in the weld between the ring plate and the collar
results from: Reports from the Institute of Lightweight Construction and Aircraft
Construction, TU Vienna, No. ILFB - 2 / 9.
 F4  B Erd   l  A 1K
 = -------------------------------------------------------
- (43)
dW K K*
  -------  s Kr  ------------- -  fZ
2 2  M
T MK + 3  T AK
----------------------------------- is applied as the calculation temperature but min.
4
50°C in the case of direct solar radiation.
10 Proof of the collecting vessel
10.1 Axial stability

For every course i, the axial compressive stress existing at the
lower edge is established from the dead weight and the earth-
quake and is validated with the buckling stress k,i,d.
 F4 a v M Erd,W,i
 i,d =  F1   G,i   1 + -------
vorh
-  ----- +  F4  -------------------------------------
- (44)
  F1 g  2
1.2    r  s Z,i
The proof of the axial stability of every course is provided in analogy
to Equations (25) and (26).
282
Appendix: Design-related details
Closed ring
Bulkheads distributed
Closed ring
around the circumference,
thickness sSch and height
hSch according to the
structural analysis
Gap
Blocks, three sides welded,

length lB and width bB
according to the structural
analysis
Assembly aid
Block
Gap
Figure 1. Variant with bulkheads.
283
Gap
Blocks, three sides welded,

length lB and width bB
according to the structural
analysis
Assembly aid
Block
Gap
Figure 2. Variant with a ring plate and a collar.
284
Draft January 2015

FÜR SCHWEISSEN UND
of thermoplastics – Vertical, round non- Technical code
VERWANDTE VERFAHREN E.V. pressurised tanks – Tanks with DVS 2205-2
supporting frames in earthquake zones Supplement 5
Intended as a replacement for issue dated February 2013
This Supplement 5 to Guideline DVS 2205-2 has been drawn up by DVS-AG W4.3b (structural design/apparatus construction).
Contents: 2 Structure
1 Scope Tanks with supporting frames are always installed without

2 Structure receptacles.
3 Calculation variables The tanks with supporting frames dealt with in this Supplement
4 Tank acceleration are anchored directly to the foundation, in order to secure them
4.1 Horizontal tank acceleration against lateral movement and tilting due to the horizontal
4.2 Oscillation period for horizontal oscillation earthquake forces.
4.3 Vertical tank acceleration
4.4 Oscillation period for vertical oscillation
5 Loads 3 Calculation variables
5.1 From horizontal tank acceleration
5.2 From vertical tank acceleration a mm Smallest clearance under the sloping base
6 Analyses ag m/s² Ground acceleration
7 Verification ah m/s² Horizontal tank acceleration
8 Dimensioning of the tank with supporting frame av m/s² Vertical tank acceleration
8.1 Axial stability of the cylinder
8.2 Axial stability of the frame A1 – Reduction factor for the influence of the
specific strength
8.3 Axial stability next to the connecting piece in the cylinder
8.4 Axial stability next to the connecting piece in the frame A2I – Reduction factor for the medium during
8.5 Axial stability of the supporting rings stability analyses
8.6 Buckling stability of the stiffeners AR mm² Cross-sectional area of the open ring cross-
8.7 Anchoring section
9 References AS mm² Shear surface of the equivalent beam
bDp mm Width of the space plate (bPr ≤ bDp ≤ 1.5 ⋅ bPr)
1 Scope bPr mm Width of the anchor lug
d mm Internal diameter of the cylinder
The following structure and calculation rules apply to vertical, dA,j mm Outer diameter of the connecting piece j
cylindrical, factory-fabricated thermoplastic tanks with supporting
dA,ZarS mm Outer diameter of the connecting piece in
frame and conical or sloping base for installation in an
the frame
earthquake zone within Germany.
ET°C
K N/mm² Short-term Young's modulus at T°C
The following prerequisites must be satisfied when using this
supplement: E20°C
K N/mm² Short-term Young's modulus at 20°C
– The tank may be installed indoors or outdoors. Its foundation E20°C
L N/mm² Long-term Young's modulus at 20°C
must be in direct contact with the ground. In the case of
ei – Eccentricity of the section thicknesses
installation on the ceilings of buildings, platforms or similar,
separate analyses are required that take the oscillation fα,i – Reduction factor for eccentricity
properties of the whole system into account. g m/sec² Acceleration due to gravity
– Dimensioning of the tank is carried out in parallel according to GA N Dead load of the additional weight on the
Guideline DVS 2205-2 with Supplements 3 and 7 / 9. roof
– The design of the tank corresponds to Guideline DVS 2205-2 GB N Dead load of the base
with Supplements 3 and 7 / 9. Gges N Dead load of the tank with supporting frame
GT°C
K N/mm² Shear modulus during short-term loading for
T°C
GZ N Dead load of the tank's cylinder
285
h mm Height of the equivalent beam for TM °C Average temperature of liquid (according to

consideration of roof loads Miner, see Guideline DVS 2205-1)
HDüb N Rated value of the horizontal anchor force TMK °C Maximum media temperature
HErd N Total horizontal force from earthquake TSchub,mK s Oscillation period for a massless shear
HF N Horizontal inertia from liquid load beam, fixed on one side, with head mass
hF mm Fill height Tv s Oscillation period for vertical oscillation
hF* mm Height of the equivalent beam W mm³ Moment of resistance of the frame fitted with
stiffeners, in order to determine the
hg mm Overall height of tank compressive stress of the highest buckling
H GA N Horizontal inertia from GA panel of the stiffeners
hR mm Height of the largest supporting ring WR mm³ Moment of resistance of the open ring
hS mm Height of the buckling panel cross-section
hZar mm Height of the frame x mm Height of the section under consideration
max above the foundation
h Zar mm Greatest height of the frame
z – Number of anchors
I mm4 Moment of inertia of the equivalent beam
zS mm Centroidal distance of the open ring from the
Kexist
K,d N/mm² Rated value of the short-term load cylinder axis
*
K K,d N/mm² Rated value of the creep rupture strength for αB Degre Inclination angle of base
10-1 hours es
K RLiquid lo N/mm² Compressive stress in the supporting ring αi – Factor for axial stability, section i
from the liquid load
Liquid lo αj – Factor for axial stability, connecting piece j
K Zar N/mm² Compressive stress in the frame from the in the cylinder
liquid load
αR – Factor for axial stability, supporting ring
kσ – Auxiliary quantity
αZar – Factor for axial stability, frame
MErd(x) Nmm Earthquake moment in height x for tank with
supporting frame αZarS – Factor for axial stability, connecting piece in
the frame
MErd,i Nmm Earthquake moment at the lower edge of
section i of the tank with supporting frame β – Aspect ratio of the buckling panel
MErd,j Nmm Earthquake moment at the connecting piece β0 – Reinforcement coefficient of the spectrum
j acceleration
m – Number of stiffeners η – Damping correction coefficient
mK kNs²/m Mass of the roof load ηA,i – Utilisation of the axial stability in section i
N Erd,j,d N Rated value of the global axial force at the ηA,j – Utilisation of the axial stability next to the
height of connecting piece j from vertical connecting piece j
acceleration ηA,R – Utilisation of the axial stability in the ring
Nj,d N Rated value of the global axial force at the ηA,S – Utilisation of the buckling stability in the
height of connecting piece j stiffeners
pu N/mm² Long-term negative pressure ηA,Zar – Utilisation of the axial stability in the frame
pü N/mm² Long-term positive pressure ηH – Utilisation of the analysis of pressure between
püK N/mm² Short-term positive pressure the spacer plate and the base plate
q – Property coefficient γF1 – Partial safety factor of the force (dead load,
liquid load)
r mm Cylinder radius of the tank
γF2 – Partial safety factor of the force (pressures,
rR mm Radius of the largest supporting ring wind)
S – Underground parameters γF3 – Partial safety factor of the force (diminishing
s mm Thickness of the base, the lowest cylinder dead load)
section, the rings and the frame γF4 – Partial safety factor of the force
s1 mm Wall thickness of the top section (earthquake)
s1/3 mm Thickness of the cylinder in the lower third of γIE – Importance factor according to DIN 4149
the equivalent beam Table 3 (there known as γI)
sB mm Thickness of the tank base γM – Partial safety factor of the resistance/stress
sj mm Thickness of the cylinder at the connecting capacity
piece j λ – Reduction factor for sloshing
suB mm Thickness of the sub-base ω 1/s Circuit frequency
sZ,i mm Thickness of cylinder section i ρF g/cm³ Density of the filling medium
TA °C Average ambient temperature (according to σe N/mm² Buckling stress in the stiffener
Miner, see Guideline DVS 2205-1) σG,i N/mm² Load in the cylinder from the dead weight at
TAK °C Maximum ambient temperature the lower edge of section i; also
T Bieg,mK s Oscillation period for a massless bending encompasses roof loads, including the
beam, fixed on one side, with head mass stress concentration [4]
TF s Oscillation duration of the filled tank σG,j N/mm² Load in the cylinder from the dead weight at
the height of the connecting piece j
Th s Oscillation period for horizontal oscillation
σG,Zar N/mm² Compressive stress in the frame from the
dead weight
286
σexist N/mm² Rated value of the existing load at the lower T°C
i,d
( 1.5 ⋅ E K ) ⋅ s 1/3
edge of section i ------------------------------------------- ⋅ 10 9
σexist ρ F ⋅ h F*
j,d N/mm² Rated value of the total load in the cylinder at ω = 2 ⋅ π ⋅ ------------------------------------------------------------------------------------
- 1/s (1)
the connecting piece j h F* 2 h F*
2 ⋅ r ⋅  0.157 ⋅  ------ + ------ + 1.49
σk,d N/mm² Rated value of the buckling stress of the   r r 
stiffener where s1/3 is the cylinder thickness in the lowest third of h F* . Due
σk,i,d N/mm² Rated value of the axial buckling stress in to the very short effective duration, the dynamic Young's modulus
section i is increased by 50% compared with the short-term modulus. This
gives the oscillation period through the relationship T = 2 ⋅ π- to
----------
σk,j,d N/mm² Rated value of the axial buckling stress next ω
to the connecting piece j
ρ F ⋅ h F* h*F 2 h *F
σk,R,d N/mm² Rated value of the axial buckling stress of TF = - ⋅ 2 ⋅ r ⋅  0.157 ⋅  ------ + ------ + 1.49 s
--------------------------------------------------------
T°C 9   r r 
the supporting ring ( 1.5 ⋅ E K ) ⋅ s 1/3 ⋅ 10
σk,Zar,d N/mm² Rated value of the axial buckling stress of (2)
the frame Where scaffolding or a stir tool is positioned on the roof, the
σk,ZarS,d N/mm² Rated value of the axial buckling stress of influence of this on the oscillation period must be analysed. The
the frame next to the connecting piece oscillation period for a massless bending beam, fixed on one
σexist N/mm² Rated value of the total load in the side, with the moment of inertia
R,d
supporting ring 3
I = π ⋅ r ⋅ s 1/3 mm4 (3)
σ S,d
F
N/mm² Rated value of the stress from liquid load in
the stiffener and the head mass
pü
σ S,d N/mm² Rated value of the stress from long-term GA
positive pressure in the stiffener m K = ---------------------- kNs²/m (4)
1,000 ⋅ g
σ Zar,d
exist
N/mm² Rated value of the total load in the frame
is determined from
σ ZarS,d
exist
N/mm² Rated value of the total load in the frame
next to the connecting piece 3
mK ⋅ h
TBieg,m = 2 ⋅ π ⋅ ------------------------------------------
- s
T°C
3 ⋅ ( 1.5 ⋅ EK ) ⋅ I
K
4 Tank acceleration
(to simplify, h = hg) (5)
4.1 Horizontal tank acceleration The oscillation period for a massless shear beam, with the shear
surface
Determination of the dynamic loads is based on the calculation
recommendations 40-B3 from the German Construction Institute [3]. A S = π ⋅ r ⋅ s 1/3 mm² (6)
The horizontal tank acceleration ah of the tank is determined on and the head mass mK is determined from
the basis of DIN 4149, without considering the slopping of the
liquid in the tank. mK ⋅ h
T Schub,m = 2 ⋅ π ⋅ -----------------------------------------
- s
T°C
( 1.5 ⋅ G K ) ⋅ A S
K
The earthquake zone of the installation location is established
from Figure 2 of DIN 4149 and/or from lists [4] which indicate the T°C T°C
earthquake zone for municipalities in certain federal states. where GK = 0.36 ⋅ E K N/mm² (7)
Accordingly, the horizontal ground acceleration, a g, is fixed The oscillation period for the horizontal oscillation, taking all
according to Table 2 of DIN 4149. influences into account, follows from
Similarly, the geological substrate category of the installation 2 2 2
Th = TF + T Bieg,m + T Schub,m s (8)
location is established from Figure 3 of DIN 4149 and/or from the K K
lists [4]. The thickness s1/3 of a graduated cylinder follows from
The subsoil category must be stated by the tank operator. If no (numbering of the n + 1 sections starting at the top; the section
reliable information on the subsoil is available. subsoil category n + 1 is the frame)
C must be used. n+1
 hi ⋅ s i
The horizontal acceleration ah is determined according to DIN 4 ⋅ -------------------
i=1
n+1 - – s1
4149, with the spectrum shown in Figure 4, in conjunction with  hi
Table 4, assuming 5% viscous damping, i. e. ß0 = 2.5 and η = 1 s 1/3 = ---------------------------------------
i=1
- mm (9)
and the importance factor γIE. For tanks used to store water- 3
polluting liquids, at least γIE = 1.6 must be used. The property
coefficient must be set at q = 1.5. 4.3 Vertical tank acceleration
The vertical acceleration av of the tank is determined on the basis
In order to determine the spectrum value, the oscillation period of DIN 4149, whereby the rated value for the ground acceleration
Th of the system is required. ag in accordance with Table 2 of DIN 4149 must be reduced by a
factor of 0.7. The spectrum and coefficients correspond to those
4.2 Oscillation period for horizontal oscillation used to determine the horizontal acceleration (Section 4.1).
In order to determine the spectrum value, the oscillation period Tv
The tank is shown as a beam fixed underneath, with the height
of the system's vertical oscillation is required.
hF* = hF – r ⋅ tanαB + hZarand the mass distribution from the liquid
load (the intrinsic weight of the tank may be ignored). By way of 4.4 Oscillation period for vertical oscillation
simplification, this mass distribution is also used in the area of the
frame. The oscillation period of a tank with supporting frame and a
conical or sloping base cannot be described with simple
According to Rammerstorfer's [1] formulae (11) and (12) / the formulae. Consequently, the vertical tank acceleration av is
formula in DIN EN 1998-4 (A.24), the circuit frequency ω of this determined on the safe side with the plateau value of the
system can be determined from spectrum and the rated value for vertical acceleration 0.7 ⋅ ag.
287
This gives Unless required otherwise by the local authorities, TM can be

β0 used for the wall temperature of the roof for indoor installations and
a v = 0.7 ⋅ a g ⋅ γ IE ⋅ S ⋅ ------ = 1.167 ⋅ a g ⋅ γ IE ⋅ S m/s² (10) TAK can be used for outdoor installations.
q
where S is the subsoil parameter according to Table 5 of DIN 4149.
7 Verification
5 Loads The analyses are carried out according to the partial safety
concept. The partial safety factor for the total of the loads in the
5.1 From horizontal tank acceleration case of earthquakes is
The significant load results from the horizontal inertia (mass γ F4 = 1.0 . (14)
multiplied by acceleration) of the liquid load when the tank is
completely full. Loads from wind loads, snow loads and short-term pressures are
r ⋅ tanα B not combined with earthquake loads.
H F = ρ F ⋅ π ⋅ r ⋅  h F* – h Zar + ---------------------- ⋅ a h ⋅ 10
2 –6
N (11)
 3  Analyses for earthquake loads must be carried out for the wall
The point of application for this force should be set at the centre temperatures that result when assuming that the temperature of
of mass for the liquid. the liquid is TM and the ambient temperature is TA in the
component under consideration.
In the case of roof load GA, the horizontal inertia is determined
from Loads from horizontal acceleration are added together directly with
the loads from vertical acceleration, this is on the safe side.
GA
H G = ------- ⋅ a h N (12)
A g
The point of application for this force should be set at the centre 8 Dimensioning of the tank with supporting frame
of mass for the road load.
8.1 Axial stability of the cylinder
In order to determine the earthquake moment at a height x above
the foundation, in a simplified manner, the full length of the For each section i, the axial compressive stress present on the
equivalent beam is loaded with the linear load ρ F ⋅ π ⋅ r 2 ⋅ a h ⋅ 10 – 6 lower edge from the dead weight of the tank (can generally be
and the top load HGA. disregarded), the dead weight of the roof load and from the
horizontal and vertical effect of the earthquake is determined,
and verified with the buckling stress σk,i,d.
tank base is determined from
 av pu ⋅ r M Erd,i 
= γ F4 ⋅  σ G,i ⋅  1 + ----- + ---------------- + -------------------------------------
2
( h*F – x ) exist
σ i,d -
g  2 ⋅ s Z,i 1.2 ⋅ π ⋅ r 2 ⋅ s 
–6
2
M Erd (x) = ρ F ⋅ π ⋅ r ⋅ a h ⋅ 10 ⋅ ---------------------- + H G ⋅ ( h g – x ) Nmm 
2 A  Z,i
(13) N/mm² (15)
The use of hg – the total height of the tank – as the position for
The stress σG,i also encompasses the dead weight of the roof
the centre of mass of GA is precise enough.
loads, including the concentration factor according to [4].
5.2 From vertical tank acceleration The buckling stress may be determined using the following
The cylinder, frame, base and rings/stiffeners are placed under formula:
greater loads in the liquid and roof load cases as the effect from T°C
1.5 ⋅ E K s Z,i
the vertical earthquake acceleration a v is added to the effect σ k,i,d = α i ⋅ 0.62 ⋅ f α,i ⋅ ------------------------ ⋅ -------- ≤ K K,d
* N/mm² (16)
from the acceleration due to gravity g. γM r
0.70
where α i = ------------------------------------------------------------- (17)
6 Analyses 20°C
-------------- ⋅ 1 + ---------------------- 
EK r
All analyses stipulated in Guideline DVS 2205-2 with 20°C  100 ⋅ s Z,i 
EL
Supplements 3 and 7 / 9 must be carried out.
ei
In addition, the following analyses for earthquakes must be and f α,i = 1.5 – -------- ≤ 1 (18)
carried out: s Z,i
– Axial stability at the lower edge of all cylinder sections whereby ei is the eccentricity to the thicker of the two
– Axial stability at the lower edge of the frame neighbouring sections of a graduated cylinder, when this itself is
– Axial stability next to the connecting piece in the cylinder thicker than the section i under consideration.
– Axial stability next to the connecting piece in the frame
– Axial stability of the supporting rings The calculation temperature should be set as TM.
– Buckling stability of the stiffeners The following condition must be observed for each section i:
– Anchoring
exist
In the case of installation in areas within Germany that are prone A 2I ⋅ σ i,d
η A,i = ------------------------- ≤1 (19)
to earthquakes, it is not necessary to carry out any of the strength σ k,i,d
analyses that are significant for the analysis of long-term
strength, as the analyses of short-term strength with the There is no need for an analysis of the casing compressive
increased loads caused by earthquakes are not significant for stability and the interaction, as the filled tank is under ring tensile
measurements. stress.
In the case of installation in an area outside Germany that is 8.2 Axial stability of the frame
prone to earthquakes, with high accelerations due to gravity, the
strength of all components must be analysed, taking into account The axial compressive stress present on the lower edge of the
the dynamic load from the horizontal and vertical acceleration. frame from the liquid load, the dead weight of the tank (can
For the combination of ring tensile load and axial compressive generally be disregarded), the dead weight of the roof load and
load, the strength analyses of the cylinder sections should be from the horizontal and vertical effect of the earthquake is
carried out with reference stresses according to von Mises. determined, and verified with the buckling stress σk,Zar,d.
288
 filling av M Erd (0)  0.65 d A,j

+ σ G,Zar ) ⋅  1 + ----- + ------------------- α j = --------------------------------------------------------- --------------
exist
σ Zar,d = γ F4 ⋅  ( KZar - N/mm² (20) ≤ 3.5 (27)
g  π ⋅ r 2 ⋅ s 
where for
 r ⋅ sj
 20°C
-------------- ⋅ 1 + ------------------ 
EK r
20°C  100 ⋅ s j 
The stress σG,Zar also encompasses the dead weight of the roof E L
loads, including the concentration factor according to [5]; K Füllung
Zar
according to formula (4) from DVS 2205-2, Supplement 7 and/or 0.45 d A,j
or α j = --------------------------------------------------------- for -------------- > 3.5 (28)
formula (8) from DVS 2205-2, Supplement 9. 20°C r ⋅ sj
-------------- ⋅ 1 + ------------------ 
EK r
The buckling stress may be determined using the following 20°C  100 ⋅ s j 
E L
formulae:
for hZar /r > 0.5 8.4 Axial stability next to the connecting piece in the frame
T°C
( 1.5 ⋅ E K ) s The compressive stress in the frame from the liquid load, dead
σ k,Zar,d = α Zar ⋅ 0.62 ⋅ ----------------------------
- ⋅ --- ≤ K K,d
* N/mm² (21a)
γM r weight and vertical effect of the earthquake at the height of the
connecting piece is converted into a global axial force and applied
for hZar/r ≤ 0.5 at this point on the weakened cross-section (open ring), together
T°C
( 1.5 ⋅ E K ) s r 2 s with the earthquake moment. To do so, the area AR, the distance
- ⋅ --- ⋅ 1 + 1.5 ⋅  ----------- ⋅ --- ≤ K K,d
σk,Zar,d = α Zar ⋅ 0.62 ⋅ ---------------------------- *
of the centre of mass from the tank axis zS and the moment of
γM r  h Zar  r
resistance WR of the ring cross-section must be determined. The
N/mm² (21b) axial compressive stress next to the opening must be calculated
taking the offset of the line of gravity into consideration.
0.70
where α Zar = -------------------------------------------------------- (22) The stress σG,Zar also includes the dead weight of the roof loads,
20°C
-------------- ⋅ 1 + ----------------- 
EK r but not the concentration factor, as the connecting pieces in the
20°C  100 ⋅ s  cylinder are not arranged below the introduction points for the
EL
roof loads.
In the case of indoor installation, (TM + TA)/2 should be used as The rated value of the existing load is determined from
the effective temperature of the frame, while for outdoor
 av zS
+ σ G,Zar ) ⋅  1 + ----- ⋅  ------- + ---------
installation, max (TM, TA) should be used. exist filling 1
σ ZarS,d = γ F4 ⋅  π ⋅ d ⋅ s ⋅ ( KZar
 g   A R W R
The following condition must be observed: 
M Erd,ZarS 
exist + -----------------------  N/mm² (29)
σ Zar,d WR 
η A,Zar = ----------------- ≤ 1 (23)
σ k,Zar,d filling
K Zar according to formula (4) from DVS 2205-2, Supplement 7
and/or formula (8) from DVS 2205-2, Supplement 9.
8.3 Axial stability next to the connecting piece in the In the case of indoor installation, (TM + TA)/2 should be used as
cylinder the effective temperature of the frame, while for outdoor
installation, max (TM,TA) should be used.
The compressive stress in the cylinder from the dead weight and
negative pressure at the height of each connecting piece j is The following conditions must be observed:
converted into a global axial force and applied at this point on the
weakened cross-section (open ring), together with the σ ZarS,d
exist
η A,ZarS = -------------------- ≤ 1 (30)
earthquake moment. To do so, the area AR, the distance of the σ k,ZarS,d
centre of mass from the tank axis zS and the moment of
resistance WR of the ring cross-section must be determined. The Here, the rated value of the critical buckling stress in the cylinder
axial compressive stress next to the opening must be calculated at the connecting piece is
taking the offset of the line of gravity into consideration, whereby for hZar/r > 0.5
the bending stresses may be divided by 1.2. T°C
( 1.5 ⋅ E K ) s
The stress σG,j also includes the dead weight of the roof loads, σ k,Zar,d = α ZarS ⋅ 0.62 ⋅ ----------------------------
- ⋅ --- ≤ K K,d
* N/mm² (31a)
γM r
but not the concentration factor, as the connecting pieces in the
cylinder are not arranged below the introduction points for the for hZar/r ≤ 0.5
roof loads. T°C
( 1.5 ⋅ E K ) s r 2 s
- ⋅ --- ⋅ 1 + 1.5 ⋅  ----------- ⋅ ---
σ k,Zar,d = α ZarS ⋅ 0.62 ⋅ ----------------------------
The rated value of the existing load is determined from γM r  h Zar  r
pu ⋅ r ≤ K K,d
* N/mm² (31b)
 av
= γ F4  σ G,j ⋅  1 + ----- + ---------------- ⋅ 2 ⋅ π ⋅ r ⋅ s j
exist
σ j,d
 g  2 ⋅ s Z,j 0.65 d A,ZarS
 where α ZarS = -------------------------------------------------------- for ----------------
- ≤ 3.5
M Erd,j 
20°C r⋅s
-------------- ⋅ 1 + ----------------- 
zS EK r
⋅  --------- + ------------------------ + ------------------------ 
1
 A R,j 1.2 ⋅ W R,j 1.2 ⋅ W R,j
N/mm² (24) 20°C  100 ⋅ s 
 EL
(32)
The dimensioning temperature should be set as TM.
0.45 d A,ZarS
The following conditions must be observed: or α ZarS = -------------------------------------------------------- for ----------------- > 3.5 (33)
20°C r⋅s
-------------- ⋅ 1 + ----------------- 
EK r
exist
A 2I ⋅ σ j,d 20°C  100 ⋅ s 
E
η A,j = ------------------------- ≤ 1 (25) L
σ k,j,d
8.5 Axial stability of the supporting rings
Here, the rated value of the critical buckling stress in the cylinder filling
With the compressive stress according to Section 6.1.1 KR
at the connecting point j is pü
and 6.2.1 KR (pü instead of püK) of Guideline DVS 2205-2,
T°C Supplement 7, only the largest ring is analysed; to be on the safe
( 1.5 ⋅ E K ) s j
- ⋅ ----
σ k,j,d = α j ⋅ 0.62 ⋅ ---------------------------- N/mm² (26) side and to simplify the calculation, there is no exact assignment
γM r of the various compressive stresses to the individual rings.
289
The largest ring has a radius of

k σ = – 0.37 ⋅ β + 2.7 ≥ 2.3 for β ≥ 0.8 (45)
r + --s-  ⋅ n
 2 For the effective temperature of the supporting rings, a maximum
rR = ------------------------- mm (34) of (TM, TA) should be used.
n+1
The following applies to indoor and outdoor installations The utilisation is
av zS  F  av M Erd (0) 
 K Füllung ⋅  1 + ----- + KR  ⋅ 2 ⋅ π ⋅ r R ⋅ s ⋅  ------- + --------- 
1 ⋅ 1 + ----- + σ S,d + -------------------- 
pü
exist
σ R,d = γ F4 ⋅
pü
γ F4 ⋅  σ S,d
 R,d  g   AR WR   g W 

η A,S = --------------------------------------------------------------------------------------------------- ≤ 1 (46)
N/mm² (35) σ k,d
For the effective temperature of the supporting rings, a maximum m–1
3
of (TM, TA) should be used. r ⋅ sS  2
2 ⋅ i 2 1.5 
1 –  --------------

3
π ⋅ r ⋅ s + --------------- ⋅  8 + 16 ⋅ 
The following condition must be observed for the supporting ring: 12  m + 1
 
where W = ------------------------------------------------------------------------------------------------------------------------------
i=1
exist
σ R,d m
-------------- ⋅ r
η A,R = -------------- ≤ 1 m+1
σ k,R,d (47)
Note: A2I not applicable as it is not in contact with the liquid (36)
Note: The frame and stiffeners form a total cross-section, as the
whereby for hR/rR > 0.5 stiffeners are welded to the frame. The numerator from the
T°C
formula (47) represents the moment of inertia for this total cross-
( 1.5 ⋅ E K ) s section; the denominator is the distance from the centre of mass
σ k,R,d = α R ⋅ 0.62 ⋅ ----------------------------
- ⋅ ----- ≤ K K,d
* N/mm² (37a)
γM rR to the centre of the highest buckling panel of the stiffeners.
for hR/rR ≤ 0.5
8.7 Anchoring
T°C
( 1.5 ⋅ E K ) s rR  2 s
- ⋅ ----- ⋅ 1 + 1.5 ⋅  -------
σ k,R,d = α R ⋅ 0.62 ⋅ ---------------------------- - ⋅ ----- ≤ K K,d
* The tank with supporting frame must be anchored. At least 4
γM rR  hR  rR anchors must be used.1)
N/mm² (37b) For the effective temperature of the supporting rings, a maximum
of (TM, TA) should be used.
0.65
where α R = -------------------------------------------------------- (38)
20°C rR  The following condition must be observed:
-------------- ⋅ 1 + ----------------
EK
-
20°C  100 ⋅ s  4 ⋅ M Erd (0) a v
γ F4 ⋅  --------------------------- + ----- ⋅ ( KZar ⋅ π ⋅ d ⋅ s + G ges ) – γ F3
EL filling
 d g 
filling 1
8.6 Buckling stability of the stiffeners ⋅ ( KZar ⋅ π ⋅ d ⋅ s + G ges ) ⋅ ---
z
With the compressive stress according to Section 6.1.1 σ S,d and
F ------------------------------------------------------------------------------------------------------------------------------------------------ ≤ 1 (48)
pü K *K,d
6.2.1 σ S,d (pü instead of püK) from Guideline DVS 2205-2, ( b Pr + s uB ) ⋅ s uB ⋅ --------------
Supplement 9 and the stresses from the horizontal and vertical 2 ⋅ A1
effect of the earthquake, the greatest stiffener span is
determined. The numerator is the lug force to be borne and the denominator
is the acceptable lug force resulting from the shear stress in the
The height of the buckling panel in the centre is seam.
m + 0.5
h S = a + ------------------- ⋅ d ⋅ tan α B mm (39) The total horizontal force HErd = HF + HGA can be transmitted to
m+1 the anchor fittings via steel space plates positioned below the
The aspect ratio is anchor lugs. The anchor fittings should be dimensioned for a
hS ⋅ ( m + 1 ) horizontal force of
β = ------------------------------ (40)
d γ F4 ⋅ 4 ⋅ H Erd
H Düb,d = -------------------------------- N (49)
The rated value of the buckling stress is z
kσ ⋅ σe .
σ k,d = ---------------- ≤ K K,d
* N/mm² (41)
γM Moreover, the pressure between the base plate of the tank or
receptacle and the spacer plate subject to the greatest load must
2
π ⋅ EK
T°C
sS ⋅ ( m + 1 ) 2
be analysed. Here, the compressive strength may be set at 1.5
where - ⋅ -----------------------------
σ e = ------------------------------ - N/mm² (42)
2 d times the tensile strength.
12 ⋅ ( 1 – μ )
The utilisation follows with
and kσ prepared for quick use from the diagrams according to [3]:
In the event that the stiffeners are not welded to the sloping base, H Düb,d
η H = -------------------------------------------- ≤ 1 (50)
the following applies 1.5 ⋅ K K *
b Dp ⋅ s B ⋅ --------------------
k σ = β + 1.1 ≤ 2.3 (43) γM
or, in the event that the stiffeners are welded to the sloping base, If the mathematical width of the spacer plate is more than 1.5
the following applies times the width of the lug, the number of anchors must be
2 increased. A maximum of (TM, TA) is set as the calculation
k σ = – 3.1 ⋅ β + 5.1 ⋅ β + 0.3 for β < 0.8 (44) temperature.
1) Subject to the following conditions, in the case of indoor installation, anchoring to safeguard against tilting may be dispensed with:
– The stiffeners and the partitions, extended to the frame, are welded to the frame
– The stiffeners and partitions are adequately dimensioned for the load if the tank is tilted
– The rise on one side of the cylinder is not greater than 20 mm.
290
9 References
Regulations
DIN EN 1998-4 Eurocode 8: Design of structures for earthquake
resistance - Part 4: Silos, tanks and pipelines
DIN 4149 Buildings in German earthquake zone – Design
loads, analysis, and structural design of
buildings
Further standards: see Guideline DVS 2205-2, Section 5.2
Bibliography
[1] Rammerstorfer, F. G., K. Scharf and F. D. Fischer:
Erdbebensichere Bemessung von Zylinderschalen,
Flüssigkeitsgefüllten Tankbauwerken. Berichte aus dem
Institut für Leichbau und Flugzeugbau [Earthquakes: Safe
dimensioning of cylinder shells and tank structures filled with
liquid. Reports from the Institute for Light-Weight
Construction and Aircraft Construction], Vienna University of
Technology, Volume ILFB – 2 / 90.
[On the stability of thermoplastic tanks] DIBt-Mitteilungen,
Heft 5/1995.
[3] Berechnungsempfehlung für zylindrische Behälter und Silos,
Berücksichtigung des Lastfalls Erdbeben [Calculation
recommendation for cylindrical tanks and silos, considering
earthquakes as a load case]. 40-B3, Deutsches Institut für
Bautechnik [German Construction Institute]
[4] Zuordnung der Erdbebenzonen und Untergrundklassen
[Allocation of the earthquake zones and subsoil categories]
[5] Tuercke, H.: Zur Einleitung axialer Einzellasten am oberen
Rand von Thermoplastbehältern [On the introduction of axial
concentrated loads at the upper edge of thermoplastic tanks].
DIBt-Mitteilungen, Volume 4/2002.
291
February 2013

FÜR SCHWEISSEN UND
Vertical-skirt tanks in earthquake regions Supplement 5
This Supplement 5 to the DVS 2205-2 technical code was elaborated by DVS-AG W4.3b ("Structural designing / apparatus engineering").
Contents: 2 Design
1 Scope of application Vertical-skirt tanks are always installed without collecting vessels.
2 Design
3 Calculation variables The vertical-skirt tanks dealt with in this supplement are anchored
4 Tank acceleration to the foundation directly in order to thus secure them against any
4.1 Horizontal tank acceleration shifting or tilting as a result of the horizontal earthquake forces.
4.2 Vibration period for the horizontal vibration
4.4 Vibration period for the vertical vibration 3 Calculation variables
5 Stresses
5.1 From horizontal tank acceleration a mm Smallest free space underneath the sloping
5.2 From vertical tank acceleration base

6 Proof ag m/s² Soil acceleration
7 Provision of proof ah m/s² Horizontal acceleration of the tank
8 Dimensioning of the vertical-skirt tank
8.1 Axial stability of the cylinder av m/s² Vertical acceleration of the tank
8.2 Axial stability of the skirt A1K – Reduction factor for the influence of the
8.3 Axial stability next to sockets in the cylinder specific toughness for a wall temperature
8.4 Axial stability next to sockets in the skirt effective for a short time
8.5 Axial stability of the supporting rings A2I – Reduction factor for the medium in the case
8.6 Buckling stability of the gussets of the proof of the stability
8.7 Anchoring AR mm² Cross-sectional area of the open ring cross-
9 Bibliography section
AS mm² Shear area of the substitute beam
1 Scope of application bPr mm Width of the anchor claw
d mm Inside diameter of the cylinder
The following design and calculation rules apply to vertical, cylin- dA,j mm Outside diameter of the socket j
drical vertical-skirt tanks which are fabricated from thermoplastics
in the factory, have conical bottoms or sloping bases and are dA,ZarS mm Outside diameter of the socket in the skirt
intended for installation in a German earthquake region. ET°C
K N/mm² Short-time elastic modulus at T°C
For the application of this supplement, it is necessary to satisfy E20°C
K N/mm² Short-time elastic modulus at 20°C
the following prerequisites:
E20°C
L N/mm² Long-time elastic modulus at 20°C
– The tank may be installed inside or outside buildings. Its foun-
ei – Eccentricity of the wall thicknesses of the
dation must be in direct contact with the earth. In the event of
courses
installation on building ceilings, platforms or similar structures,
separate proof is required and must take account of the vibration f,i – Reduction factor for the eccentricity
behaviour of the entire system. g m/sec² Acceleration due to gravity
– The tanks are dimensioned in parallel according to the DVS GA N Dead load of the additional weight on the
2205-2 technical code with Supplements 3 and 7 or 9. roof
– The execution of the tanks complies with the DVS 2205-2 tech- GB N Dead load of the bottom
nical code with Supplements 3 and 7 or 9. Gges N Dead load of the vertical-skirt tank
GT°C
K N/mm² Shear modulus in the case of short-time
stresses for T°C
GZ N Dead load of the cylinder of the tank
292
h mm Height of the substitute beam for the consid- TM °C Mean media temperature (according to
eration of roof loads Miner, see the DVS 2205-1 technical code)
HErd N Total horizontal force resulting from the TMK °C Highest media temperature
earthquake TSchub,mK s Vibration period of a shear beam which
HF N Horizontal mass force resulting from the filling does not have any mass, is clamped on one
hF mm Filling height side and has a head mass
hF* mm Height of the substitute beam Tv s Vibration period of the vertical vibration
hg mm Overall height of the tank W mm³ Resistance moment of the skirt infilled with
gussets in order to establish the compres-
H GA N Horizontal mass force resulting from GA sive stresses on the highest buckling field of
hR mm Height of the largest supporting ring the gussets
hS mm Height of the buckling field WR mm³ Resistance moment of the open ring cross-
hZar mm Height of the skirt section
max x mm Height of the section under consideration
h Zar mm Greatest height of the skirt
I mm4 Moment of inertia of the substitute beam above the foundation
Kvorh N/mm² Dimensioning value of the stresses effective z – Number of anchors
K,d
for a short time zS mm Distance between the centres of gravity of
*
K K,d N/mm² Dimensioning value of the creep strength in the open ring and of the cylinder axis
the case of 10-1 hours B ° Inclination angle of the bottom
K RFüllung N/mm² Compressive stress in the supporting ring i – Factor for the axial stability of the course i
resulting from the filling j – Factor for the axial stability of the socket j in
Füllung the cylinder
K Zar N/mm² Compressive stress in the skirt resulting
from the filling R – Factor for the axial stability of the supporting
k – Auxiliary variable ring
MErd(x) Nmm Earthquake moment at the height x for verti- Zar – Factor for the axial stability of the skirt
cal-skirt tanks ZarS – Factor for the axial stability of the socket in
MErd,B,i Nmm Earthquake moment at the lower edge of the the skirt
course i of the tank in the collecting vessel  – Side ratio of the buckling field
MErd,i Nmm Earthquake moment at the lower edge of the 0 – Reinforcing coefficient of the spectrum
course i of the vertical-skirt tank acceleration
MErd,j Nmm Earthquake moment at the height of the  – Damping correction coefficient
socket j
A,i – Utilisation of the axial stability in the course i
m – Number of gussets
A,j – Utilisation of the axial stability next to the
mK kNs²/m Mass of the roof load socket j
N Erd,j,d N Dimensioning value of the global normal A,R – Utilisation of the axial stability in the ring
force at the height of the socket j resulting
A,S – Utilisation of the buckling stability in the
from vertical acceleration
gussets
Nj,d N Dimensioning value of the global normal
A,Zar – Utilisation of the axial stability in the skirt
force at the height of the socket j
F1 – Partial safety coefficient of the effect
pu N/mm² Partial vacuum effective for a long time (dead load and filling)
pü N/mm² Overpressure effective for a long time
F2 – Partial safety coefficient of the effect
püK N/mm² Short-time overpressure (pressures and wind)
q – Behaviour coefficient F3 – Partial safety coefficient of the effect
r mm Cylinder radius of the tank (reducing dead load)
rR mm Radius of the largest supporting ring F4 – Partial safety coefficient of the effect
S – Subsoil parameter (earthquake)
s mm Wall thickness of the bottom, of the lowest I – Weighting coefficient according to the
cylinder course, of the rings and of the skirt DVS 2205-2 technical code
s1 mm Wall thickness of the highest course IE – Significance coefficient according to
DIN 4149, Table 3 (called I there)
s1/3 mm Wall thickness of the cylinder at the lower
third point of the substitute beam M – Partial safety coefficient of the resistance/
stressability
sB mm Wall thickness of the tank bottom
 – Reduction factor for splashing
sj mm Wall thickness of the cylinder at the height of
the socket j  1/s Angular frequency
suB mm Wall thickness of the bottom F g/cm³ Density of the filling medium
sZ,i mm Wall thickness of the cylinder course i e N/mm² Buckling stress in the gusset
TA °C Mean ambient temperature (according to G,i N/mm² Stresses in the cylinder resulting from the
Miner, see the DVS 2205-1 technical code) dead weight at the lower edge of the coruse
i; also encompasses roof loads including the
TAK °C Highest ambient temperature stress concentration [4]
T Bieg,mK s Vibration period of a bending beam which G,j N/mm² Stresses in the cylinder resulting from the
does not have any mass, is clamped on one dead weight at the height of the socket j
side and has a head mass
G,Zar N/mm² Compressive stress resulting from the dead
TF s Vibration period of the filled tank weight in the skirt
Th s Vibration period of the horizontal vibration
293
vorh
i,d N/mm² Stresses existing at the lower edge of the
 1.5  E K   s 1/3
T°C
course i -------------------------------------------  10 9
vorh N/mm² Dimensioning value of the total stresses in  F  h F*
j,d  = 2    ------------------------------------------------------------------------------------
- 1/s (1)
the cylinder at the height of the socket j h F* 2 h *
2  r  0.157   ------ + -----F- + 1.49

k,d N/mm² Dimensioning value of the buckling stress of   r r 
the gusset with s1/3 as the cylinder wall thickness at the lower third point of
k,i,d N/mm² Dimensioning value of the axial buckling
h F* . Because of the very short effective duration, the dynamic
stress in the course i
elastic modulus is raised by 50 % compared with the short-time
k,j,d N/mm² Dimensioning value of the axial buckling modulus. This results in the vibration period via the relationship
stress next to the socket j
T = 2  - to
----------
k,R,d N/mm² Dimensioning value of the axial buckling 
stress of the supporting ring
 F  h F* h*F 2 h *
k,Zar,d N/mm² Dimensioning value of the axial buckling TF = -  2  r   0.157   ------ + -----F- + 1.49 s
--------------------------------------------------------
T°C 9   r r 
stress of the skirt  1.5  E K   s 1/3  10
k,ZarS,d N/mm² Dimensioning value of the axial buckling (2)
stress of the skirt next to sockets
In so far as a platform or a stirrer is arranged on the roof, it is nec-
vorh
R,d N/mm² Dimensioning value of the total stresses in essary to provide proof of its influence on the vibration period.
the supporting ring The vibration period of a massless bending beam with the moment
F
 S,d N/mm² Dimensioning value of the stresses resulting of inertia:
from the filling in the gusset
3
pü
 S,d N/mm² Dimensioning value of the stresses resulting I =   r  s 1/3 mm4 (3)
from long-time overpressure in the gusset and the head mass:
vorh
 Zar,d N/mm² Dimensioning value of the total stresses in
GA
the skirt m K = ---------------------- kNs²/m (4)
1,000  g
vorh
 ZarS,d N/mm² Dimensioning value of the total stresses in
the skirt next to sockets follows from:
3
mK  h
TBieg,m = 2    ------------------------------------------
- s
4 Tank acceleration K
3   1.5  EK   I
T°C
(h = hg is applicable in a simplifying method) (5)

The vibration period of a massless shear beam with the shear area:
The horizontal tank acceleration ah of the tank is established on A S =   r  s 1/3 mm² (6)
the basis of DIN 4149 while disregarding the splashing of the
medium in the tank. and the head mass mK follows from:
The earthquake zone of the installation location is indicated on mK  h

T Schub,m = 2    -----------------------------------------
- s
Fig. 2 in DIN 4149 and in lists [3] in which the earthquake zone is T°C
 1.5  G K   A S
K
specified for the local authorities in a few federal states. The

horizontal soil acceleration ag is thus defined according to Table 2 with GK
T°C
= 0.36  E K
T°C
N/mm² (7)
in DIN 4149.
That vibration period for the horizontal vibration which takes account
The geological subsoil class of the installation location is also of all the influences follows from:
indicated on Fig. 3 in DIN 4149 and in the lists [3].
2 2 2
Th = TF + T Bieg,m + T Schub,m s (8)
K K
The foundation soil class must be specified by the operator of the
tanks. If no assured information about the foundation soil is avail- The thickness s1/3 of a graduated cylinder follows from (numbering
able, the foundation soil class C must be applied. of the n + 1 courses beginning at the top; the n + 1th course is
the skirt):
n+1
According to DIN 4149, the horizontal acceleration ah results with
the spectrum according to Fig. 4 in conjunction with Table 4 on  hi si
4  ------------------- - – s1
i=1
the assumption of 5 % viscous damping, i.e. ß0 = 2.5 and  = 1, n+1
and the significance coefficient IE. At least IE = 1.2 must be set for  hi
tanks for the storage of water-endangering fluids. The behaviour s 1/3 = ---------------------------------------
i=1
- mm (9)
3
coefficient must be applied with q = 1.5.
The vibration period Th of the system is needed for the determi-
nation of the spectrum value. The vertical tank acceleration av is also established on the basis
of DIN 4149. In this respect, the dimensioning value of the soil
acceleration ag according to Table 2 in DIN 4149 must be de-
4.2 Vibration period for the horizontal vibration creased by the factor 0.7. The spectrum and the coefficients cor-
respond to those which are used for the determination of the hor-
The tank is represented as a
*
beam which is clamped at the bottom, izontal acceleration (Section 4.1).
is located at the height hF = hF – r  tanB + hZar and has the
The vibration period Tv of the vertical vibration of the system is
mass per unit area resulting from the filling (the dead mass of the
needed for the determination of the spectrum value.
tank may be disregarded). In the region of the skirt as well, this
mass per unit area is applied in a simplifying method.
4.4 Vibration period for the vertical vibration
According to Rammerstorfer [1], Equations (11) and (12) as well The vibration period of a vertical-skirt tank with a conical bottom
as Equation (A.24) in DIN EN 1998-4, the angular frequency  of or a sloping base cannot be described with simple formulae. The
this system can be established from: vertical tank acceleration av is therefore established on the safe
294
side with the plateau value of the spectrum and the dimensioning Stresses resulting from wind loads, from snow loads and from
value of the vertical acceleration 0.7 x ag. This results in: pressures effective for a short time are not combined with earth-
quake stresses.
0
a v = 0.7  a g   IE  S  ------ = 1.167  a g   IE  S m/s² (10) Proof for earthquake stresses must be provided for the wall tem-
q
peratures resulting in the component under consideration on the
where S is the subsoil parameter according to Table 5 in DIN 4149. assumption of the highest media temperature TMK and the highest
ambient temperature TAK.
5 Stresses Stresses resulting from horizontal acceleration are directly added to
the stresses resulting from vertical acceleration. This is located on
5.1 From horizontal tank acceleration the safe side.
The crucial stresses result from the horizontal mass force (mass
times acceleration) of the filling in the completely filled condition.
8 Dimensioning of the vertical-skirt tank
r  tan
H F =  F    r   h F* – h Zar + ---------------------B-  a h  10
2 6
N (11)
 3  8.1 Axial stability of the cylinder
The point of attack of this force must be applied at the centre of For every course i, the axial compressive stress existing at the
gravity of the filling. lower edge is established from the dead weight of the tank (can
In the case of the roof load GA, the horizontal mass force results also be disregarded in general), the dead weight of the roof load
from: and the horizontal and vertical effects of the earthquake and is
validated with the buckling stress k,i,d.
GA
H G = -------  a h N (12)  F4 a v pu  r  F4  M Erd,i
=  F1   1 + -------
g
  i,d
A vorh
-  -----   +  F2  ---------------- + -------------------------------------
-
  F1 g  G,i 2  s Z,i 1.2    r 2  s
The point of attack of this force must be applied at the centre of Z,i
gravity of the roof load.
N/mm² (15)
In order to establish the earthquake moment at the height x
above the foundation, the entire length of the substitute beam is The stress G,i also encompasses the dead weight of the roof
subjected to the line load  F    r 2  a h  10 6 and the head load loads including the concentration factor according to [4].
HGA in a simplifying method. The buckling stress may be established according to the following
The earthquake moment of the cylinder at the height x above the formula:
tank bottom results from: T°C
EK s Z,i
 h F* – x 
2 -  -------
 k,i,d =  i  0.62  f ,i  ----------- -  K K,d
*
N/mm² (16)
2 6 M r
M Erd (x) =  F    r  a h  10  ---------------------- + H G   h g – x  Nmm
2 A
(13) 0.70
with  i = ------------------------------------------------------------- (17)
The approach with hg (the overall height of the tank) as the position 20°C
--------------  1 + --------------------- -
EK r
of the centre of gravity of GA is accurate enough. 20°C  100  s Z,i 
EL
5.2 From vertical tank acceleration e
and f ,i = 1.5 – -------i-  1 (18)
The cylinder, the skirt, the bottom and the rings or the gussets s Z,i
are subjected to higher stresses in the load case resulting from
the filling and the roof load since the effect resulting from the ver- where ei is the eccentricity to the thicker of the two neighbouring
tical earthquake acceleration av is also added to the effect resulting courses in the case of a graduated cylinder if this itself is thicker
from the acceleration due to gravity g. than the course under consideration.
The calculation temperature must be applied with TMK.
6 Proof The following condition must be complied with for every course i:

vorh
It is necessary to provide all the proof in the DVS 2205-2 technical A 2I   I  
i,d
code with Supplements 3 and 7 or 9.  A,i = ------------------------------------------  1 (19)
 k,i,d
In addition, the following proof must be provided for earthquakes:
– Axial stability at the lower edge of all the cylinder courses It is not necessary to provide any proof of the jacket pressure sta-
– Axial stability at the lower edge of the skirt bility or the interaction since the filled tank is subjected to tensile
– Axial stability next to sockets in the cylinder hoop stresses.
– Axial stability next to sockets in the skirt
– Axial stability of the supporting rings 8.2 Axial stability of the skirt
– Buckling stability of the gussets
– Anchoring At the lower edge of the skirt, the existing axial compressive stress
is established from the filling, the dead weight of the tank (can
In the case of installation in German earthquake regions, it is not also be disregarded in general), the dead weight of the roof load
necessary to provide any proof of the strength for which the proof and the horizontal and vertical effects of the earthquake and is
of the creep is crucial since the proof of the short-time strength validated with the buckling stress k,Zar,d.
with the stresses increased by earthquakes is not crucial for the
 F4 a v M Erd (0)
dimensioning.
 Zar,d = F1   KZar +  G,Zar    1 + -------
Füllung
-  ----- +  F4  -------------------
-
vorh
  F1 g  2
r s
7 Provision of proof N/mm² (20)
The proof is provided according to the partial safety concept. The The stress G,Zar also encompasses the dead weight of the roof
partial safety coefficient for the stresses induced by earthquakes is: loads including the concentration factor according to [4]; K Füllung
Zar
according to Equation (4) in DVS 2205-2, Supplement 7 or Equa-
 F4 = 1.0 . (14) tion (8) in DVS 2205-2, Supplement 9.
295
The buckling stress may be established according to the follow- 8.4 Axial stability next to sockets in the skirt
ing formula:
The compressive stresses in the skirt resulting from the filling, the
for hZar/r > 0.5: dead weight and the vertical effect of the earthquake at the height
T°C of the socket are converted into a global normal force and are
EK
-  s---  K K,d
 k,Zar,d =  Zar  0.62  ----------- * N/mm² (21a) applied together with the earthquake moment at this position on
M r the weakened cross-section (open ring). For this purpose, it is
for hZar/r  0.5 necessary to determine the area AR, the distance away from the
T°C
centre of gravity of the tank axis zS and the resistance moment
E r 2 s
 k,Zar,d =  Zar  0.62  ------------  ---  1 + 1.5   -----------  ---  K K,d
s * WR of the ring cross-section. Paying attention to the misalign-
M r  h Zar  r ment of the centroidal axis, it is necessary to calculate the axial
N/mm² (21b) compressive stresses next to the opening.
The stress G,Zar also encompasses the dead weight of the roof
0.70
with  Zar = -------------------------------------------------------- (22) loads but without a concentration factor since the sockets in the
20°C
cylinder are not arranged underneath the introduction points of
--------------  1 + ---------------- -
EK r
20°C  100  s  the roof loads.
EL
The dimensioning value of the existing stresses follows from:
(TMK + TAK)/2 must be applied as the effective temperature of
the skirt but min. 50°C in the case of direct solar radiation.  F4 a v
+  G,Zar    1 + -------
Füllung
ZarS,d =   d  s   F1   K Zar
vorh -  -----
The following condition must be complied with:   g
F1
 A,Zar
I   vorh
Zar,d
= ------------------------------  1 (23) A
1 zS 
  ------- + --------

M Erd,ZarS
- +  F4  ----------------------- N/mm² (29)
 k,Zar,d R WR WR
Füllung
K Zar according to Equation (4) in DVS 2205-2, Supplement 7
8.3 Axial stability next to sockets in the cylinder or Equation (8) in DVS 2205-2, Supplement 9.
The compressive stresses in the cylinder resulting from the dead (TMK + TAK)/2 must be applied as the effective temperature of
weight and the partial vacuum at the height of every socket j are the skirt but min. 50°C in the case of direct solar radiation.
converted into a global normal force and are applied together
with the earthquake moment at this position on the weakened cross- The following condition must be complied with:
section (open ring). For this purpose, it is necessary to determine
the area AR, the distance away from the centre of gravity of the  I  vorh
 A,ZarS = -------------------------  1
ZarS,d
(30)
tank axis zS and the resistance moment WR of the ring cross-  k,ZarS,d
section. Paying attention to the misalignment of the centroidal
axis, it is necessary to calculate the axial compressive stresses In this respect, the dimensioning value of the critical buckling
next to the opening. In this respect, the bending stresses may be stress in the cylinder at the socket is:
divided by 1.2.
for hZar/r > 0.5:
The stress G,j also encompasses the dead weight of the roof T°C
EK s
loads but without a concentration factor since the sockets in the  k,Zar,d =  ZarS  0.62  -----------
-  ---  K K,d
* N/mm² (31a)
cylinder are not arranged underneath the introduction points of M r
the roof loads.
for hZar/r  0.5
The dimensioning value of the existing stresses follows from:
T°C
EK r 2 s
-  ---  1 + 1.5   -----------  ---  K K,d
 F4 a v pu  r s
 k,Zar,d =  ZarS  0.62  ----------- *
=  F1   G,j   1 + -------  h Zar  r
vorh
 j,d -  ----- +  F2  ----------------  2    r  s j M r
  g 2  s Z,j
F1
N/mm² (31b)
zS  F4  M Erd,j
  --------- + ------------------------
-  + --------------------------
1
- N/mm² (24)
A  1.2  W
R,j 1,2  W R,j 0.65 d A,ZarS
R,j
with  ZarS = -------------------------------------------------------- for ----------------
-  3.5 (32)
20°C rs
--------------  1 + ---------------- -
TMK must be applied as the dimensioning temperature. EK r
20°C  100  s 
The following condition must be complied with: EL
vorh
A 2I   I   j,d 0.45 d A,ZarS
----------------
-  3.5
 A,j = ---------------------------------  1 (25) or  ZarS = -------------------------------------------------------- for (33)
 k,j,d 20°C rs
--------------  1 + ---------------- -
EK r
20°C  100  s 
In this respect, the dimensioning value of the critical buckling E L
stress in the cylinder at the socket j is:
T°C
s 8.5 Axial stability of the supporting rings
EK
 k,j,d =  j  0.62  -----------
-  ----j N/mm² (26)
M r Proof for the largest ring only is provided with the compressive
pü
stresses according to Sections 6.1.1 KRFüllung and 6.2.1 KR (pü
0.65 d A,j instead of püK) in the DVS 2205-2 technical code, Supplement 7;
with  j = --------------------------------------------------------- for --------------  3.5 (27) in a simplifying method on the safe side, it is not necessary to ex-
20°C r  sj
--------------  1 + ----------------- -
EK r actly assign the various compressive stresses to the individual
20°C  100  s j  rings.
E L
The largest ring has the radius:
0.45 d A,j
or  j = --------------------------------------------------------- for --------------  3.5 (28)
20°C r  sj r + --s-   n
--------------  1 + ----------------- -
EK r  2
20°C  100  s j  r R = ------------------------
- mm (34)
EL n+1
296
The following applies to indoor and outdoor installation: TMK must be applied as the effective temperature of the support-
ing rings but min. (TMK + 35)/2 in the case of outdoor installation.
 F4 a v
R,d =   F1  KR,d
Füllung 
-  ----- +  F2  KR   2    r R  s
vorh pü
 1 + ------- The utilisation is:
   g 
F1
zS   F4 a v M Erd (0)
  ------- + -------- F   1 + -------
1
- N/mm² (35)  S,d -  ----- +  S,d pü
+  F4  --------------------
A W    F1 g  W
R R
 A,S = ---------------------------------------------------------------------------------------------------------  1 (46)
TMK must be applied as the effective temperature of the support-  k,d
ing rings but min. (TMK + 35)/2 in the case of outdoor installation.
m–1
3
r s  2
2  i 2 1.5 
1 –  --------------
The following condition must be complied with for the supporting

3
  r  s + --------------S-   8 + 16  
ring: 12  m + 1
 i=1 
vorh
with W = ------------------------------------------------------------------------------------------------------------------------------ (47)
 I   R,d m
--------------  r
 A,R = --------------------
-1 m+1
 k,R,d
Remark: The skirt and the gussets form one overall cross-section
Remark: A2I is not necessary since there is no wetting with media since the gussets are welded with the skirt. The numerator in
(36) Formula (47) constitutes the moment of inertia of this overall
cross-section; the denominator is the distance between the centre
where:
of gravity and the centre of the highest buckling field of the gussets.
for hR/rR > 0.5:
8.7 Anchoring
T°C
EK s
 k,R,d =  R  0.62  -----------
-  -----  K K,d
* N/mm² (37a) The vertical-skirt tank must be anchored. At least four anchors
M rR must be arranged.
for hR/rR  0.5 (TMK + TAK)/2 must be applied as the effective temperature but
min. 50°C in the case of direct solar radiation.
T°C
EK rR  2 s
-  -----  1 + 1.5   -------
s
 k,R,d =  R  0.62  ----------- -  -----  K K,d
* The following condition must be complied with:
M rR  hR  rR
4  M Erd (0) a
 F4  --------------------------- –  F3   1 – -----v   K Zar    d  s + G ges   ---
N/mm² (37b) Füllung 1
d  g z
0.65 --------------------------------------------------------------------------------------------------------------------------------------------------------------------  1
with  R = -------------------------------------------------------- (38) K K,d*
20°C
rR   b Pr + s uB   s uB  --------------------------
--------------  1 + ----------------
EK
- 2  A 1K   I
20°C  100  s 
EL (48)
The claw force to be absorbed is located in the numerator and
8.6 Buckling stability of the gussets the absorbable claw force resulting from the shear stress in the
Proof for the highest gusset field is provided with the compressive weld in the denominator.
F pü
stresses according to Sections 6.1.1  S,d and 6.2.1  S,d (pü In addition, it must be ensured that the entire horizontal force:
instead of püK) in the DVS 2205-2 technical code, Supplement 9
ah
and the stresses from the horizontal and vertical effects of the =
H Erd H F + G Ges  ------ (49)
earthquake. g
The height of the buckling field at the central point is: is reliably guided into the foundation.
hS = a+m + 0.5-  d  tan 

------------------ mm (39)
m+1 B
9 Bibliography
The side ratio is:
Set of rules
hS   m + 1 
 = -----------------------------
- (40) DIN EN 1998-4 Eurocode 8: Designing of structures against
d earthquakes – Part 4: Silos, tank structures and
The dimensioning value of the buckling stress is processed from pipelines
the diagrams according to [3]: DIN 4149 Structures in German earthquake regions –
k  e Load assumptions, dimensioning and execu-
 k,d = ----------------  K K,d
* N/mm² (41) tion of customary superstructures
M
For further standards, see the DVS 2205-2 technical code, Sec-
2
  EK
T°C
sS   m + 1  2 tion 5.2.
with  e = ------------------------------
2
-  -----------------------------
- N/mm² (42)
12   1 –   d Literature
and k for quick use: [1] Rammerstorfer, F. G., K. Scharf and F. D. Fischer: Earth-
quake-proof dimensioning of cylinder shells and fluid-filled tank
If the gussets are not welded with the sloping base, the following structures. Reports from the Institute of Lightweight Construc-
is applicable: tion and Aircraft Construction, TU Vienna, No. ILFB – 2 / 90.
k  =  + 1.1  2.3 (43) [2] Tuercke, H.: On the stability of tanks made of thermoplastics.
or if the gussets are welded with the sloping base, the following is DIBt Communications, No. 5/1995.
applicable: [3] Assignment of the earthquake zones and subsoil classes
2
k  = – 3.1   + 5.1   + 0.3 for   0.8 (44)
[4] Tuercke, H.: On the introduction of axially directed individual
loads into the upper edge of thermoplastic tanks. DIBt Com-
k  = – 0.37   + 2.7  2.3 for   0.8 (45) munications, No. 4/2002.
297
Draft January 2015

FÜR SCHWEISSEN UND
VERWANDTE VERFAHREN E.V. pressurised tanks – Shell construction DVS 2205-2
Supplement 6
1 Preliminary remark A1 – Reduction factor for the influence of the

specific strength
2 Scope
3 Calculation variables A2 – Reduction factor for the liquid during strength
analyses
4 Strength analyses
5 Stability analyses C – Factor for the welded transition of the base/
casing connection
6 Anchors
d mm Nominal internal diameter
7 Appendix
fs – Long-term weld strength reduction factor
fz – Short-term weld strength reduction factor
1 Preliminary remark
g m/sec² Acceleration due to gravity
Tanks made of plates are limited in size due to the expansion GD N Dead load of the roof
limitation (see DVS 2205-2 Table 3) when the plates undergo
cold bending. If the lower section is made of two shells, however, GZ N Dead load of the cylinder
larger tanks can be produced. The support provided by the hF mm Fill height
second shell shrunk on from the outside is fully effective when
analysing the strength of the loads in the circumferential direction hZ,0 mm Required height of the outer shell
and when axial forces are removed, i. e. both wall thicknesses hZ,n mm Height of the bottom section
may be added together in order to determine an equivalent wall
thickness. When analysing the strength in the axial direction the K *K, d N/mm² Rated value of the creep rupture strength for
outer shell is only partially effective. Electronic calculations have 10-1 hours
shown that the sum of the original thickness plus half the outer K*L, d N/mm² Rated value of the theoretical creep strength at
wall thickness can be used as the equivalent wall thickness when design life at the average effective
determining the load created by bending. temperature
exist
K K, d N/mm² Rated value of the load in the case of a short-
term force in the circumferential direction
2 Scope
K Lexist N/mm² Rated value of the load in the case of a long-
,d
term force in the circumferential direction
cylindrical, factory-fabricated flat base thermoplastic tanks made K N,exist N/mm² Rated value of the load in the axial direction in
K, d
from panels with a reinforced bottom section. the case of a short-term axial force
The following prerequisites must be satisfied when using this K M,exist N/mm² Rated value of the load in the axial direction in
K, d
supplement: the case of a short-term moment
KN,exist N/mm² Rated value of the load in the axial direction in
– Only one outer shell; double-shell effect L, d
the case of a long-term axial force
– The shells must be welded to one another and to the base in a N/mm² Rated value of the load in the axial direction in
way that corresponds to one of the variants shown in Figure 1 KM,exist
L, d
the case of a long-term moment
– The base thickness is identical to the thickness of the bottom MW Nmm Bending moment under wind load on the lower
section without outer shell cylinder edge
– The thickness of the outer shell is 0.5 to 1.0 times the püK N/mm² Short-term positive pressure
thickness of the bottom section
pü N/mm² Long-term positive pressure
– The outer shell with a height of hZ,0 is shrunk on to the bottom
sZ,n mm Wall thickness of the bottom section
section with a height of hZ,n without gaps and without any
impermissible pre-stressing sZ,0 mm Thickness of the reinforcement shell
– The bottom section is at least 100 mm higher than the outer γF1 – Partial safety factor of the force (dead load,
shell liquid load)
hZ,n hZ,0 + 100 mm γF2 – Partial safety factor of the force (pressures,
wind)
– The characteristic material values are identical for both shells
– No openings in the reinforced area
298
γF3 – Partial safety factor of the force (diminishing and

dead load)
K LN,exist + K LM,exist
γI – Weighting factor according to load type ------------------------------------------
,d ,d
≤1 (8)
K *Ld
F g/cm³ Density of the filling medium
where
4 Strength analyses γ F2 ⋅ p ü ⋅ d γ F3 ⋅ ( G D + G Z )
-------------------------- – ---------------------------------------
N,exist 4 π⋅d
K L, d = ------------------------------------------------------------------------- ⋅ A 1 ⋅ A 2 (9)
Strength analysis in the circumferential direction in the s Z, n + s Z, 0
reinforced section
and
The stress ratios for short-term and long-term loads must be
–6
observed. M,exist γ F1 ⋅ ρ ⋅ g ⋅ h F ⋅ 10 + γ F2 ⋅ p ü d
K L, d = C ⋅ ---------------------------------------------------------------------------- ⋅ --- ⋅ A 1 ⋅ A 2 (10)
K Kexist s Z, n + 0.5 ⋅ s Z, 0 2
,d
-≤
----------- 1 (1)
K K* , d
Calculating the required height of the outer shell
where The respective maximum of the following two conditions
–6 d determines the required height of the outer shell hZ,0.
( γ F1 ⋅ ρ F ⋅ g ⋅ h F ⋅ 10 + γ F2 ⋅ p üK ) ⋅ --- ⋅ A 1 ⋅ A 2
exist 2
K K, d = ---------------------------------------------------------------------------------------------------------------------
- (2) h Z, 0 = max [ h Z, 0, 1, h Z, 0, 2 ] (11)
( s Z, n + s Z, 0 ) ⋅ f z
where
and
h Z, 0, 1 ≥ 1.4 ⋅ d ⋅ ( s Z, n + s Z, 0 ) (12)
K Lexist
,d
-≤1
---------- (3) and
K L* , d
2 ⋅ K k,d * ⋅s
Z,n ⋅ f z 2 ⋅ K L,d * ⋅s
Z,n ⋅ f s
where h Z,0,2 = h F – min ---------------------------------------- – γ 2 ⋅ püK , -----------------------------------------
d ⋅ A1 ⋅ A2 d ⋅ A1 ⋅ A2
–6 d
( γ F1 ⋅ ρ F ⋅ g ⋅ h F ⋅ 10 + γ F2 ⋅ p ü ) ⋅ --- ⋅ A 1 ⋅ A 2 1
exist 2
K L, d = ------------------------------------------------------------------------------------------------------------------ (4) ⋅ γ F2 – p ü ------------------------------------------
–6
- (13)
( s Z, n + s Z, 0 ) ⋅ f s γ F1 ⋅ ρ F ⋅ g ⋅ 10
Strength analysis in the axial direction in the reinforced

section 5 Stability analyses
The stress ratios for short-term and long-term loads must be
The axial and casing compressive stability are calculated in a
observed.
simplified manner without taking into account the outer shell.
K N,exist + KK M,exist
-------------------------------------------
K, d
*
,d
≤1 (5)
K Kd 6 Anchors
where
The anchors for the double-shell tank are calculated according to
γ F2 ⋅ p üK ⋅ d γ F3 ⋅ ( G D + G Z ) 4 ⋅ γ F2 ⋅ M W DVS 2205-2 Section 4.1.8, whereby it is important to note that
- – --------------------------------------- + ------------------------------
-----------------------------
N,exist 4 π⋅d π⋅d
2 the external weld seam that is integral to the strength of the
K K, d = ----------------------------------------------------------------------------------------------------------------- ⋅ A 1 ⋅ A 2 (6) anchor only corresponds to 0.7·sZ,0 and not 0.7·sB. The
s Z, n + s Z, 0
denominator in formulae (36), (37) and (38) should always be
and (bPr + sB)·sZ,0 and not (bPr + sB)·sB.
–6
M,exist γ F1 ⋅ ρ ⋅ g ⋅ h F ⋅ 10 + γ F2 ⋅ p üK d
K K, d = C ⋅ ------------------------------------------------------------------------------- ⋅ --- ⋅ A 1 ⋅ A 2 (7)
s Z, n + 0.5 ⋅ s Z, 0 2
299
7 Appendix
a) b)
a) SB = Szn; a = 0.7 · Szn; a' = 0.7 · Szo b) SB = Szn; a = 0.7 · Szn; a' = 0.7 · Szo; f = 0.3 · Szn
c) d)
c) SB = Szn; f ' = Szn; f = 0.5 · Szo d) SB = Szn; a = 0.7 · Szn; a' = 0.7 · Szo
A mathematical analysis must be performed in order to use
this variant.
Figure 1. Welds for tanks with multi-walled cylinders.
300
January 2011

Shell construction method Supplement 6
1 Preliminary remarks A1 – Reduction factor for the influence of the specific

2 Scope of application toughness
3 Calculation variables A2 – Reduction factor for the medium in the case of
4 Proof of the strength the proof of the strength
5 Proof of the stability
C – Factor for the welded interface of the bond be-
6 Anchoring
tween the bottom and the shell
7 Appendix
d mm Nominal inside diameter
fs – Long-time welding factor
1 Preliminary remarks
fz – Short-time welding factor
The size of tanks fabricated from plates is limited because of the g m/sec2 Acceleration due to gravity
edge fibre expansion limitation (see DVS 2205-2, Table 3) during GD N Deal load of the roof
the cold bending of the plates. In contrast, larger tanks can be

fabricated if the lower course is fabricated from two shells. The
supporting effect of the reinforcing shell shrunk on from the out- hF mm Filling height
side is fully effective during the proof of the strength for the hZ,0 mm Required height of the reinforcing shell
stresses in the circumferential direction and during the removal of
hZ,n mm Height of the lowest course
axial forces, i.e. both wall thicknesses may be added for the
determination of an equivalent wall thickness. With regard to the K *K, d N/mm2 Dimensioning value of the creep strength for
proof of the strength in the axial direction, the reinforcing shell 10-1 hours
also take effect in part only. Electronic calculations have shown K*L, d N/mm2 Dimensioning value of the creep strength for the
that the total of the original thickness plus half the reinforcing wall computational working life at the mean effective
thickness can be used as the equivalent wall thickness for the temperature
determination of the stresses resulting from the bending. vorh
K K, d N/mm2 Dimensioning value of the stresses effective for
a short time in the circumferential direction
2 Scope of application K Lvorh
,d N/mm2 Dimensioning value of the stresses effective for
a long time in the circumferential direction
The following design and calculation rules apply to vertical, cylin- K N,vorh N/mm2 Dimensioning value of the stresses effective for
K, d
drical thermoplastic flat-bottom tanks which are equipped with a a short time in the axial direction resulting from
reinforced lowest course and are fabricated from panels in the the normal force
factory.
K M,vorh
K, d N/mm2 Dimensioning value of the stresses effective for
For the application of this supplement, it is necessary to comply a short time in the axial direction resulting from
with the following prerequisites: the moment
– only one reinforcing shell; two-shell design KN,vorh
L, d N/mm2 Dimensioning value of the stresses effective for
– the welding of the shells with each other and with the bottom a long time in the axial direction resulting from
corresponds to one of the variants indicated on Fig. 1 the normal force
– the thickness of the bottom is identical with the thickness of the KM,vorh
L, d N/mm2 Dimensioning value of the stresses effective for
lowest course without the reinforcing shell a long time in the axial direction resulting from
the moment
– the thickness of the reinforcing shell is between 0.5 and 1.0
MW Nmm Bending moment in the case of a wind load at
times the thickness of the lowest course
the lower edge of the cylinder
– the reinforcing shell at the height hZ,0 is shrunk on to the low- püK N/mm2 Overpressure effective for a short time
est course at the height hZ,n without any gaps or any impermis-
sible pretension pü N/mm2 Overpressure effective for a long time
sZ,n mm Wall thickness of the lowest course
– the lowest course is min. 100 mm higher than the reinforcing
shell (hZ,n hZ,0 + 100 mm) sZ,0 mm Wall thickness of the reinforcing shell
– the characteristic material values are identical for both shells F1 – Partial safety coefficient of the effect (dead load
and filling)
– no openings in the reinforced region
301
F2 – Partial safety coefficient of the effect (pressures and

and wind)
F3 – Partial safety coefficient of the effect (reducing K N,vorh + K LM,vorh
----------------------------------------
L, d ,d
-1
dead load) K*Ld
I – Weighting coefficient depending on the loading with
type
F g/cm³ Density of the filling medium  F2  p ü  d  F3   G D + G Z 
-------------------------- – ---------------------------------------
4 d
K LN,vorh = -------------------------------------------------------------------------  A 1  A 2   l
,d s Z, n + s Z, 0
4 Proof of the strength
and
Proof of the strength in the circumferential direction in the –6
 F1    g  h F  10 +  F2  p ü d
reinforced course K LM,vorh = C  ----------------------------------------------------------------------------  ---  A 1  A 2   l
,d s Z, n + 0.5  s Z, 0 2
It is necessary to comply with the utilisation factors for short-time
and long-time loading. Calculation of the required height of the reinforcing shell
K Kvorh,d
The maximum of both the following conditions determines the
-1
----------- required height of the reinforcing shell hZ,0.
K K* , d
h Z, 0 = max  h Z, 0,1, h Z, 0,2 
with
with
–6 d
  F1   F  g  h F  10 +  F2  p üK   ---  A 1  A 2   l
vorh 2
K K, d = -----------------------------------------------------------------------------------------------------------------------------
- h Z, 0,1  1.4  d   s Z, n + s Z, 0 
 s Z, n + s Z, 0   f z
and
and
K Lvorh,d
-1
----------
K L* , d
[
2  K K* , d  s Z, n  f z
d  A1  A2  l
2  K L* , d  s Z, n  f s
d  A1  A2  l ]
h Z,0,2 = h F – min ------------------------------------------- –  2  püK , -------------------------------------------   F2 – p ü
1
 ------------------------------------------
-
with –6
 F1   F  g  10
–6 d
  F1   F  g  h F  10 +  F2  p ü   ---  A 1  A 2   l
vorh 2
K L, d = --------------------------------------------------------------------------------------------------------------------------
-
 s Z, n + s Z, 0   f s 5 Proof of the stability
Proof of the strength in the axial direction in the reinforced
course The axial and shell pressure stabilities are calculated using a
simplifying method without taking account of the reinforcing shell.
It is necessary to comply with the utilisation factors for short-time
and long-time loading.
6 Anchoring
KN,vorh + K KM,vorh
-----------------------------------------
K, d
*
,d
-1
K Kd The anchoring of the two-shell tank is calculated according to
DVS 2205-2, Section 4.1.8. However, it must be ensured in this
with respect that the external weld which is essential for the strength
 F2  p üK  d  F3   G D + G Z  4   F2  M W of the anchoring is executed with only 0.7  sZ,0 instead of
-----------------------------
- – --------------------------------------- + ------------------------------ 0.7  sB. In the denominator of Formulae (36), (37) and (38), (bPr
4 d d -
2
+ sB) sZ,0 must be used instead of (bPr + sB)  sB.
N,vorh
K K, d = ----------------------------------------------------------------------------------------------------------------  A1  A2  l
s Z n + s Z, 0
and
–6
 F1    g  h F  10 +  F2  p üK d
K M,vorh = C  -------------------------------------------------------------------------------  ---  A 1  A 2   l
K, d s Z, n + 0.5  s Z, 0 2
302
7 Appendix
a) b)
a) SB = Szn; a = 0.7 ∙ Szn; a' = 0.7 ∙ Szo b) SB = Szn; a = 0.7 ∙ Szn; a' = 0.7 ∙ Szo; f = 0.3 ∙ Szn
c) d)
c) SB = Szn; f ' = Szn; f = 0.5 ∙ Szo d) SB = Szn; a = 0.7 ∙ Szn; a' = 0.7 ∙ Szo
Computational proof is required for the use of this variant!
Figure 1. Welds for tanks with multiple-walled cylinders.
303
Draft January 2015

FÜR SCHWEISSEN UND
VERWANDTE VERFAHREN E.V. pressurised tanks – Ring-supported DVS 2205-7
conical base Supplement 7
Contents: 2 Structure
1 Scope The lower part of the tank with conical base consists of four
structural elements:
2 Structure
3 Calculation variables – Lower cylinder section
– Conical base
4 Determining the cutting forces for the strength analysis – Frame
5 Strength analysis – Supporting rings

6 Determining the cutting forces for the stability analyses
7 Stability analyses 2.1 Frame connection
8 Dimensioning 2.1.1 Articulated connection
9 Anchor
In the case of tanks manufactured from plates, it makes sense to
10 Appendix manufacture cylinders and frames separately and to arrange the
base between them. The lower section and the frame are
chamfered according to the angle of the conical base.
1 Scope The conical base is manufactured with an outer diameter of
approx. d + 5 · s. The lower section and conical base are joined
internally and externally with an extruder seam a ≥ 0.7 · s.
The frame is only joined to the conical base on the outside with
cylindrical, factory-fabricated thermoplastic tanks with supporting
an extruder seam a ≥ 0.7 · s (articulated frame connection).
frame and conical bases supported by concentric rings. The
cylinder, frame and supporting rings can either be manufactured
from panels or by using a winding process. 2.1.2 Rigid connection
The cylinder and frame are manufactured as a single piece. The
The following prerequisites must be satisfied when using this conical base is fitted and welded from the top and bottom to the
supplement: cylinder and frame to form a rigid connection (rigid frame
connection).
– The conical base ends in a connecting piece with elbow and
flange.
2.2 Supporting rings
– The frame and supporting rings each have an opening that is The supporting rings are arranged concentrically at equidistant
large enough to fit the discharge pipe. The openings in the intervals. The supporting rings must be cut to length precisely;
frame and the rings are reinforced using pipe couplings with a they are welded to the conical base.
length of dA/2, which are welded at both ends with the same
overlap.
2.3 Sub-base
– The openings in the frame and supporting rings should be high A closing sub-base can be welded to the frame from the outside
enough that they can also be used to support the discharge with a continuous extruder seam a ≥ 0.7 · s after fitting the
pipe. discharge pipe. If the tank does not need to be anchored, a tack
weld suitable for transport is sufficient.
– If there are additional openings in the conical base, the frame,
the supporting rings or the lower cylinder section, these must
2.4 Ventilation of the space under the conical base
be analysed separately.
The space under the conical base must be ventilated to enable
– Shut-off valves or other fittings must be arranged outside the pressure equalisation if the temperature changes. This is ensured
frame; there is no access to the space below the conical base. if the discharge pipe is not welded to the frame.
– The calculations are for a tank with a conical base without a The upper part of the tank is designed and calculated in the
receptacle. same way as the flat base tank.
304
filling
3 Calculation variables N Zar,d N Rated value of the global compressive
force from the liquid load in the frame
A1 – Reduction factor for the influence of the snow
N Zar,d N Rated value of the global compressive
specific strength
force from snow load in the frame
A2 – Reduction factor for the liquid during
ps N/mm2 Snow load on the roof
strength analyses
puK N/mm2 Short-term negative pressure
A2I – Reduction factor for the medium during
stability analyses püK N/mm2 Short-term positive pressure
AR mm2 Cross-section area of the open ring pü N/mm2 Long-term positive pressure
d mm Nominal internal diameter of the cylinder r mm Radius of the cylinder/frame
and frame rR mm Radius of the largest supporting ring
ToC
EK N/mm2 Short-term Young's modulus at T°C s mm Thickness of the bottom section, the
20 o C frame, the conical base and the supporting
EK N/mm2 Short-term Young's modulus at 20°C
20 o C rings
EL N/mm2 Long-term Young's modulus at 20°C
sB mm Thickness of the closing sub-base
fsK – Long-term weld strength reduction factor
for a possible horizontal butt weld in the TA °C Average ambient temperature (according to
conical base Miner, see Guideline DVS 2205-1)
g m/sec2 Acceleration due to gravity TAK °C Maximum ambient temperature
GA N Dead load of the additional weight on the TM °C Average temperature of liquid (according
roof to Miner, see Guideline DVS 2205-1)
GD N Dead load of the roof
Design
T Zar °C Max. calculation temperature for the frame
Gges N Dead load of the tank without GA
WR mm3 Moment of resistance of the open ring
zS mm Centroidal distance of the open ring from
GK N Dead load of the conical base the cylinder axis
GZar N Dead load of the frame α Degre Inclination angle of the conical base
hF mm Fill height measured from the tip of the es measured against the horizontal
cone αR – Factor for axial stability, supporting ring
hR mm Height of the supporting ring αZar – Factor for axial stability, frame
hZar mm Height of the frame ηA,R – Utilisation of the axial stability in the
kf – Concentration factor according to [3] supporting ring
K K,d
exist
N/mm2 Rated value of the short-term load ηA,Zar – Utilisation of the axial stability in the frame
exist
K L,d N/mm2 Rated value of the long-term load γF1 – Partial safety factor of the force (dead
filling
load, liquid load)
KR N/mm2 Compressive stress from the liquid load in
the supporting ring γF2 – Partial safety factor of the force
filling
(pressures, wind)
K Zar N/mm2 Compressive stress from the liquid load in
γF3 – Partial safety factor of the force
the frame
(diminishing dead load)
pü
KR N/mm2 Compressive stress from pü in the
γM – Partial safety factor of the resistance/load-
supporting ring
bearing capacity
püK
KR N/mm2 Compressive stress from püK in the g/cm3 Density of the filling medium
supporting ring ρF
exist
pü σ K,d N/mm2 Rated value of the axial compressive
K Zar N/mm2 Tensile load from pü in the frame stress in the conical base
püK
K Zar N/mm2 Tensile load from püK in the frame σ K,d N/mm2 Rated value of the buckling stress in the
MW Nmm Bending moment from the wind load on conical base
the lower frame edge σk,Zar,d N/mm2 Rated value of the axial buckling stress of
n – Number of supporting rings the frame
N R,d
filling
N Rated value of the global compressive σk,R,d N/mm2 Rated value of the axial buckling stress in
force from the liquid load in the supporting the largest supporting ring
exist
ring σ Zar,d N/mm2 Rated value of the axial stress next to the
pü opening in the frame
N R,d N Rated value of the global compressive
exist
force from pü in the supporting ring σ R,d N/mm2 Rated value of the axial stress next to the
püK opening in the supporting ring
N R,d N Rated value of the global compressive
force from püK in the supporting ring
305
4 Determining the cutting forces for the strength analysis 5 Strength analysis
The cutting forces can be determined by using a rotational shell The strength analysis is carried out as detailed in Guideline DVS
program for thin-walled elements with a linear-elastic approach. 2205-2 using the stresses described in Section 4. The average
This allows the wall thicknesses of the cylinder, frame, conical liquid temperature TM or, in the event of short-term forces, the
base and supporting rings to be determined in a manner that highest liquid temperature TMK, must be applied as the effective
optimises the utilisation of the individual elements, i. e., it results wall temperature in the cylinder and in the conical base.
in economical and safe dimensioning.
This supplement provides formulae for manual calculation. When 6 Determining the cutting forces for the stability analyses
using these formulae, the following limitations must be taken into
account: In the case of frames and supporting rings which bear the entire
– The wall thicknesses of the lower cylinder section, the frame, liquid load, the axial stability must be analysed.
the conical base and the supporting rings are identical.
6.1 Filling loading case
– The inclination angle of the conical base must be no more than
15°, 30° or 45°. 6.1.1 Supporting rings
– At least one supporting ring must be used; the factors in The largest compressive stress in the supporting rings can be
boards 1 and 2 apply to up to three supporting rings. calculated from
– For the fill height hF the condition hF ≥ r · (1.5 + tanα) must be
⋅  h F – --- ⋅ r ⋅ tanα ⋅ ---------------------------
filling –6 2 1
KR = ρ F ⋅ g ⋅ 10 N/mm2 (3)
observed.  3  K ⋅ ln  --s- + L
 d
e
– The ratio of the wall thickness to the radius is within the
following limits: 0.04 ≥ s/r ≥ 0.01. Tables 1 and 2 show the constants K and L.
4.1 Filling loading case 6.1.2 Frame
The largest stress resulting from liquid load occurs either in the The largest compressive stress in the frame can be calculated
conical base at the cylinder/frame transition point or in the conical from
base over the supporting rings. Therefore both stresses must be
⋅  h F – --- ⋅ r ⋅ tanα ⋅ -----------------------------
filling –6 2 1
calculated; the larger of the two stresses is decisive. K Zar = ρ F ⋅ g ⋅ 10 N/mm2 (4)
 3  M ⋅ ln  --s- + N
The stresses occur in the longitudinal direction; if the conical  d
base features a horizontal butt weld, weld strength reduction e
factor fsK must be taken into account in the second term. Tables 1 and 2 show the constants M and N.
The following formula for the rated value of the greatest stress 6.2 Overpressure loading case
takes into account the sum of bending and normal stresses.
6.2.1 Supporting rings
–6 ( h F – r ⋅ tanα ) hF
K L,d = γ F1 ⋅ ρ F ⋅ g ⋅ 10 max ------------------------------------ ,----------------------------------------
filling
The largest compressive stress in the supporting rings can be
C ⋅ ln  --- + D
s
A ⋅ ln  --- + B
s
 d d
calculated from
e f sK ⋅ e
1
= p üK ⋅ ----------------------------
püK
KR N/mm2 (5)
P ⋅ ln  --- + Q
s
⋅ A1 ⋅ A2 N/mm2 (1)  d
e
Tables 1 and 2 show the constants A to D. pü
KR is calculated in the same way with pü as the value for
Note: Missing values in the tables indicate that no analysis is
pressure.
required as the stresses are lower and therefore do not affect the
measurement. Tables 1 and 2 show the constants P and Q.
4.2 Overpressure loading case 6.2.2 Frame
The largest stress in the cylinder occurs either at the transition to The largest tensile load in the frame can be calculated from
the base or in the conical base over the supporting rings. 1
K Zar = p üK ⋅ ----------------------------
püK
Therefore both stresses must be calculated; the larger of the two N/mm (6)
U ⋅ ln  --- + V
s
stresses is decisive. The stresses occur in the longitudinal  d
direction; if the conical base features a horizontal butt weld, weld e
strength reduction factor fsK must be taken into account in the pü
K Zar is calculated in the same way with pü as the value for
second term.
pressure.
The following formula for the rated value of the greatest stress
takes into account the sum of bending and normal stresses. Tables 1 and 2 show the constants U and V.
1 1 7 Stability analyses
K L,d = γ F2 ⋅ p ü ⋅ max ---------------------------- ,----------------------------------------
-
pü
G ⋅ ln  --- + H
s
E ⋅ ln  --- + F
s
 d  d
e f sK ⋅ e The rated value of the axial compressive stress next to the
opening must be compared with the rated value of the buckling
⋅ A1 ⋅ A2 N/mm2 (2) stress . Buckling is a short-term process; the analysis must be
carried out using the wall temperatures given by TMK and TAK. In
püK
K K,d is calculated in the same way with püK as the value for the case of direct sunlight, the wall temperature of the
pressure. frame T Design
Zar must be set at 50°C for applications in Germany.
For TAK, a minimum of 20°C must be set for indoor installations
Tables 1 and 2 show the constants E to H. and 35°C for outdoor installations.
306
Compressive stresses according to Sections 6.1 and 6.2 are γ F2 ⋅ M W
converted to global normal forces and, when installed outdoors, are + ---------------------- N/mm2 (17)
WR
applied together with the wind moment Mw on the weakened cross-
section (open ring). To do so, the area AR, the centre of mass zS and Note:
the moment of resistance WR of the ring cross-section must be The analysis with snow and winter temperature does not need to
determined. The axial compressive stresses next to the opening must be carried out as this is not decisive for dimensioning.
be calculated taking the offset of the line of gravity into consideration. The following conditions must be observed for the frame:
7.1 Supporting rings σ Zar,d

exist
η A,Zar = ----------------- ≤ 1 (18)
σ k,Zar,d
Only the largest ring is analysed with the compressive stress as
per Sections 6.1.1 and 6.2.1; to be on the safe side, there is no Note:
exact assignment of the various compressive stresses to the A2I not applicable as it is not in contact with the liquid
individual rings.
whereby for hZar /s > 0.5
 r + --s- ⋅ n
 2 EK s
T°C
The largest ring has a radius of r R = ------------------------
- mm (7) σ k,Zar,d = α Zar ⋅ 0.62 ⋅ -----------
- ⋅ --- (19a)
n+1 γM r
filling
N R,d = γ F1 ⋅ 2 ⋅ π ⋅ r R ⋅ s ⋅
filling
KR N (8) for hZar /s ≤ 0.5
T°C
r 2 s
- ⋅ --- ⋅ 1 + 1.5 ⋅  ----------- ⋅ ---
EK s
püK
= γ F2 ⋅ 2 ⋅ π ⋅ r R ⋅ s ⋅
püK σ k,Zar,d = α Zar ⋅ 0.62 ⋅ ----------- (19b)
N R,d KR N (9) γM r  h Zar  r
The following applies to indoor and outdoor installations: where

zS
⋅  ------- + ---------
exist Liquid load püK 1 0.65
σ R,d = ( N R,d + N R,d ) N/mm2 (10) α Zar = -------------------------------------------------------- (20)
 A R W R 20°C
-------------- ⋅ 1 + ----------------- 
EK r
The following condition must be observed for the supporting ring: 20°C  100 ⋅ s 
EL
σ R,d
exist
Note:
η A,R = -------------- ≤ 1 A2I not applicable as it is not in contact with the liquid (11) and E K
T°C
for a wall temperature of TW
σ k,R,d
as it is not in cotact with the liquid (11)
For indoor installations
whereby for hR /r > 0.5 TMK + TAK
T W = --------------------------- (20a)
T°C 2
s EK
σ k,R,d = α R ⋅ 0.62 ⋅ --------------- ⋅ ----- (12a) For outdoor installations
γM rR
Design
for hR /r ≤ 0.5 TW = max [ TMK ,T Zar ] (20b)
T°C
EK rR 2 s without the effect of wind – MW = 0 in (17) –
σ k,R,d = α R ⋅ 0.62 ⋅ --------------- ⋅ ----- ⋅ 1 + 1.5 ⋅  -------- ⋅ -----
s
(12b)
γM rR  hR  rR
or
where max [ T MK ,T AK ] + ( T AK – 5 )
0.65 T W = ---------------------------------------------------------------------- (20c)
α R = -------------------------------------------------------- (13) 2
20°C rR with the effect of wind.
⋅  1 + -----------------
EK
--------------
20°C  100 ⋅ s
EL 8 Dimensioning
For the effective wall temperature of the supporting rings The largest wall thickness resulting from the strength analyses
TMK + TAK and the stability analyses is to be used for the lower cylinder
max TMK , --------------------------- section, the conical base, the frame and the supporting rings.
2
must be used. 9 Anchors
7.2 Frame If anchors are required, at least 4 anchors should be provided

(z ≥ 4). When carrying out the anchoring analysis, a distinction
The positive pressure load case is not considered, as positive must be made between three cases:
pressure subjects the frame to tension. T MK + T AK
Case 1: Short-term positive pressure at --------------------------- °C,
Design
2
filling filling
N Zar,d = γ F1 ⋅ 2 ⋅ π ⋅ r ⋅ s ⋅ K Zar N (14) but at least T Zar in direct sunlight
snow 2 püK 1
N Zar,d = γ F2 ⋅ π ⋅ r ⋅ p s N (15) [ γ F2 ⋅ 2 ⋅ π ⋅ r ⋅ s ⋅ KZar – γ F3 ⋅ ( G ges – G K + G A ) ] ⋅ ---
z
----------------------------------------------------------------------------------------------------------------------------------- ≤ 1 (21)
For indoor installations K K,d*
( b Pr + s B ) ⋅ s B ⋅ --------------
zS 2 ⋅ A1
= ( NZar,d + γ F1 ⋅ ( G ges + G A ⋅ k f ) ) ⋅  ------- + ---------
exist filling 1
σ Zar,d N/mm2
 A R W R TM + TA
(16) Case 2: Long-term positive pressure at -------------------- °C
2
For outdoor installations
pü 1
Summer [ γ F2 ⋅ 2 ⋅ π ⋅ r ⋅ s ⋅ K Zar – γ F3 ⋅ ( G ges – G K + G A ) ] ⋅ ---
---------------------------------------------------------------------------------------------------------------------------------z- ≤ 1 (22)
zS *
K L,d
σ Zar,d = γ F1 ⋅ ( NZar,d + γ F1 ⋅ ( G ges + G A ⋅ k f ) ) ⋅  ------- + ---------
exist filling 1
 A R W R ( b Pr + s B ) ⋅ s B ⋅ --------------
2 ⋅ A1
307
Case 3: Wind load at The required anchor force (e. g. for the anchor fitting) must be
calculated from the maximum lug force (maximum of the
max [ T MK ,T AK ] + ( T AK – 5 ) numerators from the equations 21 to 23) taking the lever arms
TW = ---------------------------------------------------------------------- – 10 in °C (22a)
2 into account.
(only for outdoor installations)
4 ⋅ γ F2 ⋅ M W pü 1
------------------------------ + γ F2 ⋅ 2 ⋅ π ⋅ r ⋅ s ⋅ K Zar – γ F3 ⋅ ( G ges – G K + G A ) ⋅ ---
d z
----------------------------------------------------------------------------------------------------------------------------------------------------------------------- ≤ 1
K K,d*
( b Pr + s B ) ⋅ s B ⋅ --------------
2 ⋅ A1
(23)
10 Appendix
10.1 Explanations Bibliography

This Supplement 7 to Guideline DVS 2205-2 has been drawn up [1] Tuercke, H.: Herleitung vereinfachter Formeln zur
by DVS-AG W4.3b (structural design/apparatus construction). Schnittkraftermittlung für die Bemessung von ringgestützten
Kegelböden [Derivation of simplified formulas for determining
10.2 References cutting force for dimensioning ring-supported conical bases].
Unpublished.
For regulations see Guideline DVS 2205-2 Section 5.2
Heft 5/1995.
[3] Tuercke, H.: Zur Einleitung axialer Einzellasten am oberen
DIBt-Mitteilungen, Volume 4/2002.
Mathematical dimensions Production dimensions

sD
h′ges = h ges + s B + -----------------
cos α D
′ = a + h Zar – c
h Zar
s
c = ----------------- – s ⋅ tan α K
cos α K
h′Z = h z + b
2 ⋅ sD
h′D = r ⋅ tan α D + -----------------
cos α D
s
r + ---
2-
r R,i = i ⋅ ------------
n+1
s
h′R,i = a – ----------------- + r R,i ⋅ tan α K
cos α K
Figure 1. Overview and dimensions.
Figure 2. Ring connection. Figure 3. Sub-base connection.
308
Figure 4a. Frame connection (articulated). Figure 4b.Frame connection (semi-rigid).
10.4 Tables (Note: Interpolation is not possible for other angles)
Table 1. Articulated frame connection (tanks made of panels).
Number of rings n=1 n =2 n=3

Angle 15° 30° 45° 15° 30° 45° 15° 30° 45°
Strength load A – – 1.3473 1.6639 1.5041 1.3737 1.5018 1.5010 1.4348
case
B – – 1.3115 2.8092 2.1653 1.6632 2.3857 2.3830 2.1390
Liquid load
C 1.7171 1.5384 1.4376 1.9408 1.6851 – 1.9199 1.7545 –
D 2.2817 2.0036 2.1146 4.0025 3.0872 – 4.4227 3.7350 –
Strength load E – 1.3642 1.3072 1.5447 1.3933 1.2956 1.3595 1.3368 1.3009
case
F – 1.0665 0.9797 2.1012 1.4169 1.0225 1.4801 1.3086 1.1203
Positive pressure
G 1.7369 1.5694 – 1.9440 – – 1.8956 – –
H 2.3474 2.1425 – 4.0238 – – 4.2614 – –
nR load case K 1.0530 1.1086 1.1177 1.0160 1.0575 1.0898 1.0444 1.0330 0.9831
Liquid load L 1.6278 1.9900 2.1377 1.8934 2.1291 2.3701 2.3079 2.2804 2.1133
nZar load case M 0.9461 0.9099 0.9188 0.9327 0.8946 0.9010 0.8754 0.8804 0.9000
Liquid load N 1.8353 1.5735 1.5347 2.0845 1.7599 1.6872 2.0236 1.8685 1.8394
nR load case P 1.0616 1.1670 1.3367 1.0429 1.0567 1.1219 1.0294 1.1563 1.1497
Positive pressure Q 1.6848 2.3846 3.6243 2.0345 2.2372 2.9119 2.2399 2.9496 3.1831
nZar load case U 1.0614 1.1670 1.3367 1.0548 1.1428 1.2818 1.0836 1.1482 1.2700
Positive pressure V 2.3768 3.0778 4.3177 2.1140 2.7203 3.7703 2.1543 2.6399 3.5867
309
Table 2. Rigid frame connection (wound tanks).
Number of rings n=1 n=2 n=3

Angle 15° 30° 45° 15° 30° 45° 15° 30° 45°
Strength (load A – – 1.2598 1.7090 1.4956 1.2859 1.5779 1.5323 1.3830
case - liquid load)
B – – 0.9672 2.9862 2.0715 1.2420 2.7387 2.5046 1.8408
C 1.7228 1.5257 1.4901 1.9387 1.6896 – 1.8571 1.7533 –
D 2.3079 1.9492 2.3859 3.9989 3.1098 – 4.1583 3.7311 –
Strength (load E 1.6375 1.4326 1.3571 1.4893 1.4124 1.3451 1.2975 1.3194 1.3308
case - positive
pressure) F 2.2047 1.3821 1.1768 1.9485 1.5450 1.2436 1.2696 1.2682 1.2626
G 1.7478 – – 1.9337 – – 1.8783 – –
H 2.3972 – – 3.9497 – – 4.1860 – –
nR load case K 1.0520 1.0909 1.0993 1.0310 1.0579 1.0750 1.0492 1.0360 0.9811
Liquid load L 1.6165 1.9123 2.0635 1.9566 2.1273 2.2975 2.3335 2.2927 2.0980
nZar load case M 0.9470 0.9251 0.9393 0.9214 0.8967 0.9192 0.8706 0.8706 0.9091
Liquid load N 1.8454 1.6396 1.5920 2.0391 1.7761 1.7760 2.0049 1.8298 1.8951
nR load case P 1.0595 1.1447 1.3100 1.0528 1.0580 1.1016 1.0201 1.1593 1.1423
Positive pressure Q 1.6649 2.2806 3.5202 2.0813 2.2376 2.8204 2.1963 2.9617 3.1486
nZar load case U 1.0596 1.1444 1.3105 1.0623 1.1380 1.2562 1.0889 1.1514 1.2558
Positive pressure V 2.3583 2.9725 4.2157 2.1419 2.6890 3.6538 2.1767 2.6479 3.5183
310
January 2012

FÜR SCHWEISSEN UND
Ring-supported conical bottom Supplement 7
Replaces June 2010 edition
Contents: – lower cylinder course

– conical bottom
1 Scope of application – skirt
2 Design – supporting rings
4 Determination of the sectional forces for the proof of the
2.1 Connection of the skirt
strength
6 Determination of the sectional forces for the proof of the 2.1.1 Flexible connection
stability In the case of tanks fabricated from plates, it is appropriate to
7 Proof of the stability fabricate the cylinder and the skirt separately and to arrange the
8 Dimensioning bottom in between. For this purpose, the lower course and the
9 Anchoring skirt are chamfered according to the angle of the conical bottom.
10 Appendix The conical bottom is fabricated with an outside diameter of

approx. d + 5 · s. The lower course and the conical bottom are
joined with an extruder weld a  0.7 · s on the inside and on the
1 Scope of application outside. The skirt is joined with the conical bottom with an extruder
weld a  0.7 · s from the outside only (flexible connection of the
The following design and calculation rules apply to vertical, cylin- skirt).
drical tanks which are fabricated from thermoplastics in the factory
and are equipped with a vertical skirt and with conical bottoms 2.1.2 Flexurally stiff connection
supported by concentric rings. The cylinder, the skirt and the sup-
porting rings can be either fabricated from panels or manufactured The cylinder and the skirt are fabricated in one piece. The conical
in the winding process. bottom is fitted in and is welded with the cylinder and the skirt in a
flexurally stiff joint from the top and from the bottom (flexurally
For the application of this supplement, it is necessary to satisfy stiff connection of the skirt).
the following prerequisites:
– The conical bottom ends in a nozzle with an elbow and a flange. 2.2 Supporting rings
– For the passage of the drainpipe, the skirt and the supporting The supporting rings are arranged concentrically at equal distances
rings are each provided with an opening as large as required apart. The supporting rings must be cut to length exactly; they
for assembly. The openings in the skirt and in the rings are are welded with the conical bottom.
reinforced with a pipe socket which has the length dA/2 and is
welded on both sides with the same projection. 2.3 Bottom
– The openings in the skirt and in the supporting rings must be After the assembly of the drainpipe, a closing bottom can be
arranged so high that these also serve as a support for the welded with the skirt from the outside with a continuous extruder
drainpipe. weld a  0.7 · s. If the tank does not have to be anchored, it is
– Should any further openings be arranged in the conical bottom, sufficient to execute a tack weld suitable for transport.
in the skirt, in the supporting rings or in the lower cylinder
course, then separate proof must be provided for these. 2.4 Ventilation of the space underneath the conical bottom
– Shut-off valves and miscellaneous fittings must be arranged The space underneath the conical bottom must be ventilated in
outside the skirt; no accessibility to the space below the conical order to permit pressure equalisation in the event of temperature
bottom is planned. changes. This is the case when the drainpipe is not welded with
– A tank with a conical bottom and without a collecting device is the skirt.
calculated. The upper part of the tank is designed and calculated in
analogy to the flat-bottom tank.
2 Design
The lower region of the tank with a conical bottom consists of the
following four structural elements:
311
püK
3 Calculation variables N R,d N Dimensioning value of the global
compressive force resulting from püK in
A1 – Reduction factor for the influence of the the supporting ring
specific toughness for a wall temperature Füllung
N Zar,d N Dimensioning value of the global
effective for a long time
compressive force resulting from the filling
A1K – Reduction factor for the influence of the in the skirt
specific toughness for a wall temperature Schnee
N Zar,d N Dimensioning value of the global
effective for a short time
compressive force resulting from the snow
A2 – Reduction factor for the medium in the load in the skirt
case of the proof of the strength ps N/mm2 Snow pressure on the roof
A2I – Reduction factor for the medium in the puK N/mm2 Partial vacuum effective for a short time
case of the proof of the stability
püK N/mm2 Overpressure effective for a short time
AR mm2 Cross-sectional area of the open ring
pü N/mm2 Overpressure effective for a long time
d mm Nominal inside diameter of the cylinder
and of the skirt r mm Radius of the cylinder/skirt
ToC rR mm
EK N/mm2 Short-time elastic modulus at T°C Radius of the largest supporting ring
20 o C s mm Wall thickness of the lowest course, of the
EK N/mm2 Short-time elastic modulus at 20°C
20 o C skirt, of the conical bottom and of the
EL N/mm2 Long-time elastic modulus at 20°C supporting rings
fsK – Long-time welding factor for a possible sB mm Wall thickness of the closing bottom
transverse weld in the conical bottom
TA °C Mean ambient temperature (according to
g m/sec2 Acceleration due to gravity Miner, see the DVS 2205-1 technical code)
GA N Dead load of the additional weight on the TAK °C Highest ambient temperature
roof
TM °C Mean media temperature (according to
GD N Dead load of the roof Miner, see the DVS 2205-1 technical code)
Gges N Dead load of the tank TMK °C Highest media temperature
GZ N Dead load of the cylinder WR mm3 Resistance moment of the open ring
GK N Dead load of the conical bottom zS mm Distance between the centres of gravity of
the open ring and of the cylinder axis
GZar N Dead load of the skirt
 ° Pitch of the conical bottom measured
hF mm Filling height measured from the tip of the against the horizontal line
cone
R – Factor for the axial stability of the
hR mm Height of the supporting ring supporting ring
hZar mm Height of the skirt Zar – Factor for the axial stability of the skirt
kf – Concentration factor according to [3] A,R – Utilisation of the axial stability in the
vorh supporting ring
K K,d N/mm2 Dimensioning value of the stresses
effective for a short time A,Zar – Utilisation of the axial stability in the skirt
vorh
K L,d N/mm2 Dimensioning value of the stresses F1 – Partial safety coefficient of the effect
effective for a long time (dead load and filling)
Füllung
KR N/mm2 Compressive stresses resulting from the F2 – Partial safety coefficient of the effect
filling in the supporting ring (pressures and wind)
Füllung
K Zar N/mm2 Compressive stresses resulting from the F3 – Partial safety coefficient of the effect
filling in the skirt (reducing dead load)
KR
pü
N/mm2 Compressive stresses resulting from pü in I – Weighting coefficient according to the
the supporting ring DVS 2205-2 technical code, Table 2
KR
püK
N/mm2 Compressive stresses resulting from püK M – Partial safety coefficient of the resistance/
in the supporting ring stressability
K Zar
pü
N/mm2 Tensile stresses resulting from pü in the F g/cm3 Density of the filling medium
skirt vorh
 K,d N/mm2 Dimensioning value of the axial
püK
K Zar N/mm2 Tensile stresses resulting from püK in the compressive stress in the conical bottom
skirt  K,d N/mm2 Dimensioning value of the buckling stress
MW Nmm Bending moment from the wind load at the of the conical bottom
lower edge of the skirt k,Zar,d N/mm2 Dimensioning value of the axial buckling
n – Number of supporting rings stress of the skirt
N R,d
Füllung
N Dimensioning value of the global k,R,d N/mm2 Dimensioning value of the axial buckling
compressive force resulting from the filling stress of the largest supporting ring
vorh
in the supporting ring  Zar,d N/mm2 Dimensioning value of the axial stress next
N R,d
pü
N Dimensioning value of the global to the opening in the skirt
vorh
compressive force resulting from pü in the  R,d N/mm2 Dimensioning value of the axial stress next
supporting ring to the opening in the supporting ring
312
4 Determination of the sectional forces for the proof of the 5 Proof of the strength
strength
The proof of the strength is provided in the way indicated in the
The sectional forces can be determined with a rotational shell DVS 2205-2 technical code with the stresses described in Sec-
program for thin-walled elements with a linear-elastic approach. tion 4. The mean media temperature TM must be estimated as
In this way, it is possible to establish the wall thicknesses of the the effective wall temperature in the cylinder and in the conical
cylinder, of the skirt, of the conical bottom and of the supporting bottom and the highest media temperature TMK in the case of a
rings in such a way that the utilisation of the individual elements short-time effect.
is optimum, i.e. it permits economically viable and safe dimen-
sioning.
In this supplement, formulae are provided for the manual compu- stability
tation. For their application, attention must be paid to the follow-
ing restrictions on the scope of application: For skirts and supporting rings bearing the entire filling load, it is
– The wall thicknesses of the lower cylinder course, of the skirt, necessary to provide proof of the axial stability.
of the conical bottom and of the supporting rings are identical.
6.1 Load case for the filling
– The pitch of the conical bottom is confined to 15°, 30° or 45°.
– It is necessary to arrange at least one supporting ring; for up to 6.1.1 Supporting rings
three supporting rings, the factors are prepared in Tables 1 and The greatest compressive stress in the supporting rings results
2. from:
– For the filling height hF, it is necessary to comply with the con-
  h F – ---  r  tan  --------------------------- N/mm2 (3)
dition hF  r · (1.5 + tan. Füllung –6 2 1
KR =  F  g  10
 3  K  ln  --s- + L
– The wall-thickness-to-radius ratio is within the following limits:  d
0.04  s/r  0.01. e
Tables 1 and 2 show Constants K and L.
6.1.2 Skirt
The greatest stress resulting from the filling arises either in the
conical bottom at the interface between the cylinder and the skirt The greatest compressive stress in the skirt results from:
or in the conical bottom above the supporting rings. Therefore, it
  h F – ---  r  tan  ----------------------------- N/mm2 (4)
Füllung –6 2 1
is necessary to calculate both stresses; the greater of the two K Zar =  F  g  10
 3  M  ln  --s- + N
stresses is crucial. The stresses are effective in the longitudinal  d
direction; if a transverse weld is arranged in the conical bottom, e
the welding factor fsK must be taken into consideration in the second Tables 1 and 2 show Constants M and N.
term.
The following formula for the dimensioning value of the greatest 6.2 Load case for the overpressure
stress takes account of the total of the bending and normal
stresses. 6.2.1 Supporting rings
The greatest compressive stress in the supporting rings results
 h F – r  tan 
–6 hF from:
=  F1   F  g  10 max ------------------------------------ ,----------------------------------------
Füllung
K L,d
A  ln  --- + B C  ln  --- + D
s s 1
= p üK  ----------------------------
püK
 d d KR N/mm2 (5)
e f sK  e P  ln  --- + Q
s
 d
e
 A1  A2  l N/mm2 (1) pü
KR is calculated analogously, with pü as the value for the pres-
Tables 1 and 2 show Constants A to D.
sure.
Remark: Any missing values in the tables mean that it is not nec-
essary to provide any proof since the stresses are lower and Tables 1 and 2 show Constants P and Q.
therefore do not influence the dimensioning.
6.2.2 Skirt
4.2 Load case for the overpressure The greatest tensile stress in the skirt results from:
The greatest stress in the cylinder arises either at the interface to
1
K Zar = p üK  ----------------------------
püK
the bottom or in the conical bottom above the supporting rings. N/mm (6)
U  ln  --- + V
s
Therefore, it is necessary to calculate both stresses; the greater  d
of the two stresses is crucial. The stresses are effective in the e
longitudinal direction; if a transverse weld is arranged in the conical pü
bottom, the welding factor fsK must be taken into consideration in K Zar is calculated analogously, with pü as the value for the pres-
the second term. sure.
The following formula for the dimensioning value of the greatest Tables 1 and 2 show Constants U and V.
stress takes account of the total of the bending and normal
stresses.
1 1 The dimensioning value of the axial compressive stresses next to

=  F2  p ü  max ---------------------------- ,-----------------------------------------
pü
K L,d the opening must be compared with the dimensioning value of the
E  ln  --- + F G  ln  --- + H
s s
 d d buckling stress. Buckling is a short-time process and the proof must
e f sK  e
be provided at the wall temperatures resulting from TMK and TAK.
For the proof of the skirt, (TMK+ + TAK)/2 must be estimated as the
 A1  A2  l N/mm2 (2) effective wall temperature and min. 50°C in the case of direct solar
püK radiation. TMK must be estimated as the effective temperature of
K K,d is calculated analogously, with püK as the value for the
pressure. the supporting rings and min. (TMK + 35)/2 in the case of outdoor
installation. Min. 20°C must be estimated for TAK in the case of
Tables 1 and 2 show Constants E to H. indoor installation and min. 35°C for outdoor installation.
313
Compressive stresses according to Sections 6.1 and 6.2 are con- Remark:
verted into global normal forces and, in the case of outdoor instal- It is not necessary to provide any proof with snow or at a winter
lation, are estimated for the weakened cross-section (open ring) temperature since these do not determine the dimensioning.
together with the wind moment Mw. For this purpose, it is neces-
The following condition must be complied with for the skirt:
sary to establish the area AR, the centre of gravity zS and the re-
vorh
sistance moment WR of the ring cross-section. The axial com-  l   Zar,d
pressive stresses next to the opening must be calculated while  A,Zar = ---------------------
-1 (18)
 k,Zar,d
paying attention to the misalignment of the centroidal axis.
Remark:
A2I is not necessary since there is no wetting with media
Proof of the largest ring only is provided with the compressive
stresses according to Sections 6.1.1 and 6.2.1; using a simplify- where
ing method on the safe side, it is not necessary to exactly assign for hZar/s > 0.5:
the various compressive stresses to the individual rings.
ToC
EK s
 r + --s-  n  k,Zar,d =  Zar  0.62  ------------
-  --- (19a)
 2 M r
The largest ring has the radius r R = ------------------------
- mm (7)
n+1 for hZar /s  0.5
Füllung Füllung ToC
N R,d =  F1  2    r R  s  K R N (8) EK s r 2 s
-  ---  1 + 1.5   -----------  ---
 k,Zar,d =  Zar  0.62  ------------ (19b)
M r  h Zar  r
püK püK
N R,d =  F2  2    r R  s  K R N (9)
with
The following applies to indoor and outdoor installation:
0.65
vorh  1 zS   Zar = --------------------------------------------------------
- (20)
Füllung
 R,d =  N R,d + NpüK
R,d    ------- + --------- N/mm2 (10) 20 o C
-   1 + ---------------- r 
A W EK
R R -------------- -
20 C 
o
100  s
The following condition must be complied with for the supporting EL
ring:
 l   R,d
vorh Remark:
=
 A,R ------------------
-1 A2I is not necessary since there is (11) 8 Dimensioning
 k,R,d no wetting with media
The greatest wall thickness resulting from the proof of the
where for hR /r > 0.5 strength and from the proof of the stability must be executed for
ToC the lower cylinder course, for the conical bottom, for the skirt and
EK
s
 k,R,d =  R  0.62  ----------------  ----- (12a) for the supporting rings.
M rR
for hR /r  0.5
ToC 9 Anchoring
EK rR 2 s
 k,R,d =  R  0.62  ----------------  -----  1 + 1.5   --------  -----
s
(12b)
M rR  hR  rR If anchoring becomes necessary, at least four anchors must be
arranged (z  4). With regard to the proof of the anchoring, a dis-
with tinction must be made between three cases:
0.65
 R = --------------------------------------------------------
- (13) T MK + T AK
20 o C Case 1: Short-time overpressure at --------------------------- °C but min. 50°C
EK rR 
 1 + ----------------
---------------  - 2
20 o C  100  s in the case of direct solar radiation
EL
TMK must be estimated as the effective temperature of the support- püK 1
  F2  2    r  s  K Zar –  F3   G D + G Z + G Zar    ---
ing rings and min. (TMK + 35)/2 in the case of outdoor installation. z
-----------------------------------------------------------------------------------------------------------------------------------  1 (21)
K K,d*
7.2 Skirt  b Pr + s B   s B  ----------------------
2  A1  l
The load case for the overpressure is not considered since the
TM + TA
overpressure subjects the skirt to tensile stresses. Case 2: Long-time overpressure at -------------------- °C
Füllung Füllung
2
N Zar,d =  F1  2    r  s  K Zar N (14)
pü 1
z
Schnee
N Zar,d =  F2    r  p s
2
N (15) ----------------------------------------------------------------------------------------------------------------------------------  1 (22)
*
K L,d
 b Pr + s B   s B  ----------------------
In the case of indoor installation: 2  A1  l
zS 
 Zar,d =  N Zar,d +  F1   G ges + G A  k f     ------- + --------
vorh Füllung 1
- N/mm2 Case 3: Wind load at 20°C (only in the case of outdoor installation)
A W  R R
(16) 4   F2  M W pü 1
ToC
------------------------------ +  F2  2    r  s  K Zar –  F3   G D + G Z + G Zar   ---
d z
with E k for (TMK + TAK)/2°C in Equation (19) -----------------------------------------------------------------------------------------------------------------------------------------------------------------------  1
K K,d*
In the case of outdoor installation:  Pr + s B   s B 
b ----------------------
2  A1  l
Summer: (23)
zS 
 Zar,d =  F1   NZar,d +  F1   G ges + G A  k f     ------- + --------
vorh Füllung 1
- While paying attention to the lever arms, the required anchor
A W  R R force (e.g. for the plugs) must be calculated from the maximum
 F2  M W claw force (maximum of the numerators in Equations 21 to 23).
+ ---------------------
- N/mm2 (17)
WR
ToC
with Ekfor (TMK + TAK)/2 or, in the case of direct solar radia-
tion, for min. 50°C in Equation (19)
314
10 Appendix 10.3 Literature

[1] Tuercke, H.: Derivation of simplified formulae for the determi-
10.1 Explanations nation of the sectional forces for the dimensioning of ring-sup-
This Supplement 7 to the DVS 2205-2 technical code was elabo- ported conical bottoms. Unpublished.
rated by DVS-AG W4.3b ("Structural designing / apparatus engi- [2] Tuercke, H.: On the stability of tanks made of thermoplastics.
neering"). DIBt Communications, No. 5/1995.
10.2 Standards and technical codes [3] Tuercke, H.: On the introduction of axially directed individual
loads into the upper edge of thermoplastic tanks. DIBt Com-
See the DVS 2205-2 technical code, Section 5.2. munications, No. 4/2002.

Computational dimensions Fabrication dimensions
sD
hges = h ges + s B + ----------------
-
cos  D
sD
= 
h Zar a + h Zar – c
DD

s
=c ----------------- – s  tan  K
cos  K
=
hZ hz + b
2  sD
hD = r  tan  D + ----------------
-
cos  D
sZ s
r + ---
2-
r R,i = i  ------------
n+1
cD
s
=
hR,i a – ----------------- + r R,i  tan  K
sK cos  K
DK

sR
Zar
Figure 2. Bonding of the rings.
Figure 3. Bonding of the bottom.
315
All welds All welds

a = 0.7 · s a = 0.7 · s
Figure 4a. Bonding of the cone in the case of the plate tank. Figure 4b. Bonding of the cone in the case of the wound tank.
10.5 Tables (Attention: Interpolation for other angles is not possible!)
Table 1. Flexible connection of the skirt (panel tank).
Number of rings n=1 n =2 n=3

Angle 15° 30° 45° 15° 30° 45° 15° 30° 45°
Strength load case A – – 1.3473 1.6639 1.5041 1.3737 1.5018 1.5010 1.4348
Filling B – – 1.3115 2.8092 2.1653 1.6632 2.3857 2.3830 2.1390
C 1.7171 1.5384 1.4376 1.9408 1.6851 – 1.9199 1.7545 –
D 2.2817 2.0036 2.1146 4.0025 3.0872 – 4.4227 3.7350 –
Strength load case E – 1.3642 1.3072 1.5447 1.3933 1.2956 1.3595 1.3368 1.3009
Overpressure F – 1.0665 0.9797 2.1012 1.4169 1.0225 1.4801 1.3086 1.1203
G 1.7369 1.5694 – 1.9440 – – 1.8956 – –
H 2.3474 2.1425 – 4.0238 – – 4.2614 – –
nR load case K 1.0530 1.1086 1.1177 1.0160 1.0575 1.0898 1.0444 1.0330 0.9831
Filling L 1.6278 1.9900 2.1377 1.8934 2.1291 2.3701 2.3079 2.2804 2.1133
nZar load case M 0.9461 0.9099 0.9188 0.9327 0.8946 0.9010 0.8754 0.8804 0.9000
Filling N 1.8353 1.5735 1.5347 2.0845 1.7599 1.6872 2.0236 1.8685 1.8394
nR load case P 1.0616 1.1670 1.3367 1.0429 1.0567 1.1219 1.0294 1.1563 1.1497
Overpressure Q 1.6848 2.3846 3.6243 2.0345 2.2372 2.9119 2.2399 2.9496 3.1831
nZar load case U 1.0614 1.1670 1.3367 1.0548 1.1428 1.2818 1.0836 1.1482 1.2700
Overpressure V 2.3768 3.0778 4.3177 2.1140 2.7203 3.7703 2.1543 2.6399 3.5867
316
Table 2. Flexurally stiff connection of the skirt (wound tank).
Number of rings n=1 n=2 n=3

Angle 15° 30° 45° 15° 30° 45° 15° 30° 45°
Strength load case A – – 1.2598 1.7090 1.4956 1.2859 1.5779 1.5323 1.3830
Filling B – – 0.9672 2.9862 2.0715 1.2420 2.7387 2.5046 1.8408
C 1.7228 1.5257 1.4901 1.9387 1.6896 – 1.8571 1.7533 –
D 2.3079 1.9492 2.3859 3.9989 3.1098 – 4.1583 3.7311 –
Strength load case E 1.6375 1.4326 1.3571 1.4893 1.4124 1.3451 1.2975 1.3194 1.3308
Overpressure F 2.2047 1.3821 1.1768 1.9485 1.5450 1.2436 1.2696 1.2682 1.2626
G 1.7478 – – 1.9337 – – 1.8783 – –
H 2.3972 – – 3.9497 – – 4.1860 – –
nR load case K 1.0520 1.0909 1.0993 1.0310 1.0579 1.0750 1.0492 1.0360 0.9811
Filling L 1.6165 1.9123 2.0635 1.9566 2.1273 2.2975 2.3335 2.2927 2.0980
nZar load case M 0.9470 0.9251 0.9393 0.9214 0.8967 0.9192 0.8706 0.8706 0.9091
Filling N 1.8454 1.6396 1.5920 2.0391 1.7761 1.7760 2.0049 1.8298 1.8951
nR load case P 1.0595 1.1447 1.3100 1.0528 1.0580 1.1016 1.0201 1.1593 1.1423
Overpressure Q 1.6649 2.2806 3.5202 2.0813 2.2376 2.8204 2.1963 2.9617 3.1486
nZar load case U 1.0596 1.1444 1.3105 1.0623 1.1380 1.2562 1.0889 1.1514 1.2558
Overpressure V 2.3583 2.9725 4.2157 2.1419 2.6890 3.6538 2.1767 2.6479 3.5183
317
Draft January 2015

FÜR SCHWEISSEN UND
VERWANDTE VERFAHREN E.V. pressurised tanks – Example for ring- DVS 2205-2
supported conical base Supplement 8
Contents: The formulae are solved for s with the condition

filling *
K L,d = K L,d = 10.2/1.3
1 Introduction
2 Tank data -6
 γ F1 ⋅ ρ ⋅ g ⋅ 10 ⋅ ( h F – r ⋅ tan α ) ⋅ A 1 ⋅ A 2
3 Strength analysis In  -------------------------------------------------------------------------------------------------------- – B
4 Stability analyses  K *L,d 
-----------------------------------------------------------------------------------------------------------------------------
5 Anchors A
s1 = d ⋅ e
and
1 Introduction
 γ ⋅ ρ ⋅ g ⋅ 10 -6 ⋅ h ⋅ A ⋅ A 
In  -------------------------------------------------------------------------- – D
F1 F 1 2
This example aids the use of Supplement 7 to Guideline DVS  K *L,d ⋅ f sK 
2205-2. -----------------------------------------------------------------------------------------------
s2 = d ⋅ e C
 -6 
1.35 ⋅ 1.29 ⋅ 9.81 ⋅ 10 ⋅ ( 4,000 – 1,000* tan 30° ) ⋅ 1 ⋅ 1
2 Tank data In  ---------------------------------------------------------------------------------------------------------------------------------------------- – 2.1653
10.2
 ----------- 
1.3
Type: Cylinder and frame made of plates ----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1.5041
Geometry: d = 2,000 mm (internal); hGes = 5,000 mm; s 1 = 2,000 ⋅ e
α = 30°; a = 420 mm; 2 supporting rings = 18.25 mm
Installation: Outdoor installation without wind shielding tray  -6 
1.35 ⋅ 1.29 ⋅ 9.81 ⋅ 10 ⋅ 4,000 ⋅ 1 ⋅ 1
collector In  ----------------------------------------------------------------------------------------------- – 3.0872
10.2-
----------
Wind zone 2 inland; snow load zone 2 up to 285  ⋅1 
1.3
----------------------------------------------------------------------------------------------------------------------------------
m 1.6851
s 2 = 2,000 ⋅ e = 19.18 mm
q = 0.65 kN/m2
pS = 0.68 kN/m2, TA = 10°C, TAK = 35°C Selected: s = 20 mm.
Material: PE 100; 25 years
Liquid: Battery acid; TM = TMK = 20°C; hF = 4,000 mm; 3.2 Check
A1 = A1K = A2 = A2I = 1; ρF = 1.29 g/cm3 A check is carried out to determine whether s = 20 mm is also
Ventilation: Closed system püK = pü = 0.01 bar; sufficient for the sum of the liquid load case and pü load case.
puK = 0.01 bar
Openings: dA = 200 mm Filling loading case
Weld: Longitudinal weld as heating element weld, filling -6
K L,d = γ F1 ⋅ ρ F ⋅ g ⋅ 10
no horizontal butt weld in conical base
Anchoring: Lug width bPr = 70 mm
1 1
⋅ max ( h F – r ⋅ tan α ) ⋅ ----------------------------, h F ⋅ -----------------------------------------
A ⋅ In  --- + B C ⋅ In  --- + D
s s
 d  d
3 Strength analysis e f sK ⋅ e
3.1 Initial estimation ⋅ A1 ⋅ A2
filling -6 1
KL,d = γ F1 ⋅ ρ F ⋅ g ⋅ 10 ⋅ ( h F – r ⋅ tan α ) ⋅ ---------------------------- ⋅ A 1 ⋅ A 2
A ⋅ In  --- + B
s 1
d max ( 4,000 – 1,000 ⋅ tan 30° ) ⋅ ---------------------------------------------------------- , 4,000
e 1.5041 ⋅ In  --------------- + 2.1653
20
N/mm²  2,000
and e
filling -6 1
K L,d = γ F1 ⋅ ρ F ⋅ g ⋅ 10 ⋅ h F ⋅ ----------------------------------------- ⋅ A 1 ⋅ A 2 N/mm² 1
⋅ ------------------------------------------------------------------ = max ( 400,115, 428,061 ) = 428,061
C ⋅ In ---  + D
s
1.6851 ⋅ In  --------------- + 3.0872
20
d
f sK ⋅ e 1⋅e
2,000
according to Table 1 of Supplement 7 A = 1.5041, B = 2.1653, filling -6

C = 1.6851, D = 3.0872, fsK = 1 (no horizontal butt weld) K L,d = 1.35 ⋅ 1.29 ⋅ 9.81 ⋅ 10 ⋅ 428,061 ⋅ 1 ⋅ 1 = 7.313 N/mm²
318
Overpressure loading case with the cross-sectional values for the open ring
r = 675 mm; dA = 200 mm
pü 1
K L,d = γ F2 ⋅ p ü ⋅ ---------------------------- ⋅ A 1 ⋅ A 2 AR = 80,808 mm2; zS = 33.41 mm; WR = 24,848,209 mm³,
E ⋅ In  --- + F
s
 d it follows that
e
σ R,d = ( 81,188 + 1,763 ) ⋅  ------------------ + ------------------------------ = 1.13 N/mm²
with E = 1.3933; F = 1.4169, according to Table 1 of Supplement exist 1 33.41
7, it follows that  80,808 24,848,209
pü 1 0.0015 The following condition must be observed for each supporting

K L,d = 1.5 ⋅ 0.001 ⋅ ---------------------------------------------------------- ⋅ 1 ⋅ 1 = ------------------------- ring
1.3933 ⋅ In  --------------- + 1.4169
20 0.006714
 2,000 vorh
e σR,d
η A,R = -------------
-≤1
= 0.223 N/mm² σ k,R,d
where
Utilisation
0.65 0.65
filling pü =αR --------------------------------------------------------
= ------------------------------------------------------
= - 0.3046
KL,d + K L,d 7.313 + 0.223 20°C rR 
---------- ⋅ 1 + --------------------- 
800 675
= -----------------------------------
η --------------------------------- - 0.96 < 1 -------------- ⋅ 1 + ----------------
= = EK
-  
* 10.2 20°C  100 ⋅ s  235 100 ⋅ 20
K L,d ----------- E L
1.3
Condition satisfied. and due to hR /rR > 0.5
T°C
EK s 613 20
4 Stability analyses σ k,R,d = α R ⋅ 0.62 ⋅ -----------
- ⋅ ----- = 0.3046 ⋅ 0.62 ⋅ ---------- ⋅ ----------
γM rR 1.3 675
= 2.64 N/mm²
4.1.1 Filling loading case T°C
E K = 613 N/mm² for (TMK + TAK)/2 = 27.5°C
The largest compressive stress in the supporting rings can be
calculated from it follows that
exist
σ R,d
= ρ F ⋅ g ⋅ 10 ⋅  h F – --- ⋅ r ⋅ tan α ⋅ ----------------------------
Füllung 2 -6 1 1.13
KR N/mm² η= -------------
= - ----------
= - 0.43 < 1 Condition satisfied.
 3  A,R σ k,R,d 2.64
K ⋅ In  --- + L
s
 d
e
where K = 1.0575; L = 2.1291, according to Table 1, it follows 4.2 Frame
that
4.2.1 Filling loading case
= 1.29 ⋅ 9.81 ⋅ 10 ⋅  4,000 – --- ⋅ 1,000 ⋅ tan 30°
filling -6 2
KR The largest compressive stress in the frame can be calculated
 3 
from
1
⋅ ---------------------------------------------------------- filling
K Zar = ρ F ⋅ g ⋅ 10
–6
⋅  h F – --- ⋅ r ⋅ tan α ⋅ -----------------------------
2 1
N/mm²
1.0575 ⋅ In  --------------- + 2.1291
20  3 
M ⋅ In ---  + N
s
2,000
e d
e
filling
KR = 0.000012655 ⋅ 3615.1 ⋅ 15.5 = 0.709 N/mm² where M = 0.8946; N = 1.7599 according to Table 1, it follows
that
4.1.2 Overpressure loading case
⋅  4,000 – --- ⋅ 1,000 ⋅ tan 30°
filling –6 2
K Zar = 1.29 ⋅ 9.81 ⋅ 10
The largest compressive stress in the supporting rings can be  3 
calculated from 1
⋅ -----------------------------------------------------------
0.8946 ⋅ ln  --------------- + 1.7599
püK 1 20
KR = p üK ⋅ ----------------------------- e 2,000
P ⋅ In  --- + Q
s
d
e filling
K Zar = 0.000012655 ⋅ 3615.1 ⋅ 10.59 = 0.484 N/mm²
with P = 1.0567 Q = 2.2372, it follows that
filling filling
püK 1 1 = N Zar,d γ= F1 ⋅ 2 ⋅ π ⋅ r ⋅ s ⋅ K Zar 1.35 ⋅ 2 ⋅ π ⋅ 1,000 ⋅ 20 ⋅ 0.484
KR = 0.001 ⋅ ---------------------------------------------------------- = 0.001 ⋅ ---------------------
1.0567 ⋅ In  --------------- + 2.2372
20 0.07214 = 82108.7 N
 2,000
e 2 2
h ges 0.65 5,000
= 0.01386 N/mm
2 M W = c f ⋅ q ⋅ d ⋅ ------------- = 0.8 ⋅ --------------- ⋅ ( 2,000 + 40 ) ⋅ -----------------
2 1,000 2
The largest supporting ring has a radius = 13,260,000 Nmm
 r + --s- ⋅ n
 2 1,012.5 ⋅ 2 4.2.2 Overpressure loading case
=rR ------------------------
= - ---------------------------
= 675 mm
n+1 2+1 The overpressure load case is not considered as it subjects the
filling Füllung
frame to stress.
N R,d = γ F1 ⋅ 2 ⋅ π ⋅ r R ⋅ s ⋅ K R = 1.35 ⋅ 2 ⋅ π ⋅ 675 ⋅ 20 ⋅ 0.709
= 81,188 N 4.2.3 Dimensioning
püK püK Only the analysis for the summer load case needs to be carried
N R,d = γ F2 ⋅ 2 ⋅ π ⋅ r R ⋅ s ⋅ KR = 1.5 ⋅ 2 ⋅ π ⋅ 675 ⋅ 20 ⋅ 0.01386 out
= 1,763 N zS γ F2 ⋅ M W
Füllung  1
⋅ ------- + ---------  + ----------------------
exist
σ Zar,d = N N/mm²
The following applies to indoor and outdoor installations Zar,d  A R W R  WR
1 zS
+ NR,d ) ⋅  ------- + --------- 
exist Füllung püK with the cross-sectional values for the open ring r = 1,010 mm;
σ R,d = ( NR,d N/mm²
 AR WR  dA = 200 mm
319
AR = 122,914 mm²; zS = 32.87 mm; WR = 58,318,536 mm³ 5 Anchors

T°C
without wind with E k 270 N/mm² at 50°C
The largest tensile load in the frame can be calculated for
82,108.7 ⋅  --------------------- + ------------------------------
exist 1 32.87
σ Zar,d = 0.7143 N/mm² decisive case 3 from
 122,914 58,318,536
pü 1
=α Zar =
0.65
-------------------------------------------------------- =
0.65
------------------------------------------------------
- 0.2872 K Zar = p ÜK ⋅ -----------------------------
U ⋅ In  --- + V
20°C s
---------- ⋅ 1 + --------------------- 
800 1,010
⋅ 1 + ----------------- 
EK r
-------------- e
d
E
20°C  100 ⋅ s  235  100 ⋅ 20 
L
where U = 1.1428; V = 2.7203 according to Table 1, it follows that
and due to hZar /r > 0.5
pü 1
EK s
T°C
270 20 K Zar = 0.001 ⋅ ---------------------------------------------------------- = 0.0127 N/mm²
σ k,Zar,d = α Zar ⋅ 0.62 ⋅ -----------
- ⋅ --- = 0.2872 ⋅ 0.62 ⋅ ---------- ⋅ --------------- 1.1428 ⋅ In  --------------- + 2.7203
20
γM r 1.3 1,010 2,000
e
= 0.7323 N/mm²
For example, 3,500 N is assumed for the weight GD + GZ + GZar.
σexist 0.7143
η A,Zar -----------------
= ----------------- - 0.97 < 1
Zar,d
= = Condition satisfied. sB = 20 mm is chosen for the thickness of the underfloor.
σ k,Zar,d 0.7323
T°C *
with wind with Ek 510 N/mm² at 32.5°C Wind load with K K,d = 13.06/1.3 = 10.05 N/mm² for 27.5°C
1.5 ⋅ 13,260,000
σ Zar,d = 82,108.07 ⋅  --------------------- + -------------------------------- + ------------------------------------------
exist 1 32.87
 122,914 58,318,536  4 ⋅ γ F2 ⋅ M W
- + γ F2 ⋅ 2 ⋅ π ⋅ r ⋅ s ⋅ K Zar – γ F3 ⋅ ( G D + G Z + G Zar ) ⋅ 1
pü
58,318,536 ----------------------------- ---
d z
= 0.7143 + 0.3411 = 1.055 N/mm² ------------------------------------------------------------------------------------------------------------------------------------------------------------------------- ≤ 1
*
K K,d
0.65 0.65 ( b Pr + s B ) ⋅ s B ⋅ --------------
=α Zar --------------------------------------------------------
= ------------------------------------------------------
= - 0.2872 2 ⋅ A1
20°C
800 
---------- ⋅ 1 + --------------------- 
1,010
-------------- ⋅ 1 + ----------------- 
EK r
EL
20°C  100 ⋅ s  235  100 ⋅ 20  4 ⋅ 1.5 ⋅ 13,325,000
-------------------------------------------------- + 1.5 ⋅ 2 ⋅ π ⋅ 1,000 ⋅ 20 ⋅ 0.0127 – 0.9 ⋅ ( 3,500 )
2,000
and due to hZar /r > 0.5 -----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
10.05
( 70 + 20 ) ⋅ 20 ⋅ ---------------
EK s
T°C
510 20 2⋅1
σ k,Zar,d = α Zar ⋅ 0.62 ⋅ -----------
- ⋅ --- = 0.2872 ⋅ 0.62 ⋅ ---------- ⋅ ---------------
γM r 1,3 1,010 = z
= 1.383 N/mm²
39,975 + 2,394 – 3,150
= z ------------------------------------------------------------
= 4.3
σ Zar,d
exist
1.055 9,045
η= -----------------
= --------------
A,Zar σ k,Zar,d 1.383
At least 5 anchors are implemented.
The lower section of the cylinder, the frame, the conical base
and the two supporting rings must be made of 20 mm thick
panels.
320
January 2012

made of thermoplastics –
Example of a ring-supported conical bottom Supplement 8
Replaces February 2011 edition
Contents: Füllung -6 1
K L,d =  F1   F  g  10  h F  -----------------------------------------
C  In ---  + D
s
1 Introduction d 
2 Data for the tank f sK  e
4 Proof of the stability  A1  A2  l N/mm2
5 Anchoring According to Table 1 in Supplement 7, A = 1.5041, B = 2.1653,
C = 1.6851, D = 3.0872 and fsK = 1 (no transverse weld).
1 Introduction The formulae are solved with the condition
Füllung *
K L,d = K L,d = 10.2/1.1 nach s aufgelöst
This example is intended to facilitate the application of Supple-
ment 7 to the DVS 2205-2 technical code. -6
  F1    g  10   h F – r  tan    A 1  A 2   l
In  ----------------------------------------------------------------------------------------------------------------- – B
 K *L,d 
-------------------------------------------------------------------------------------------------------------------------------------
-
A
2 Data for the tank s1 = d  e
Design: Cylinder and skirt fabricated from plates and
Geometry: d = 2,000 mm (inside); hGes = 5,000 mm;  = 30°;      g  10 -6  h  A  A   

In  ---------------------------------------------------------------------------------- – D
F1 F 1 2 l
a = 420 mm; two supporting rings
 K *L,d  f sK 
Installation: Outdoor installation without any wind-shielding --------------------------------------------------------------------------------------------------------
collecting device s2 = d  e C
Wind Zone 2: inland area ; Snow Load Zone 2: up

to 285 m  -6 o 
1.35  1.29  9.81  10   4,000 – 1,000* tan 30   1.2
In  -------------------------------------------------------------------------------------------------------------------------------------------- – 2.1653
q = 0.65 kN/m2  10.2-
----------

 
pS = 0.68 kN/m2, TA = 10°C, TAK = 35°C 1.1
-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1.5041
Material: PE 100; 25 years s 1 = 2,000  e
Filling: Battery acid; TM = TMK = 20°C; hF = 4,000 mm; = 18.43 mm
A1 = A1K = A2 = A2I = 1; F = 1.29 g/cm³
 -6 
1.35  1.29  9.81  10  4,000  1.2
Ventilation: Closed system püK = pü = 0.01 bar; In  -------------------------------------------------------------------------------------------- – 3.0872
 10.2 
 -----------  1 
puK = 0.01 bar 1.1
-------------------------------------------------------------------------------------------------------------------------------
Loading type: Loading Case II; I = 1.2 s 2 = 2,000  e
1.6851
= 19.36 mm
Openings: dA = 200 mm Chosen s = 20 mm.
Welding: Longitudinal weld as a heated tool weld, no trans-
verse weld in the conical bottom 3.2 Checking
Anchoring: Claw width bPr = 70 mm It is checked whether s = 20 mm is also sufficient for the total re-
sulting from the load case for the filling and the load case pü.
3 Proof of the strength Load case for the filling

Füllung -6
3.1 Initial estimation K L,d =  F1   F  g  10
Füllung -6 1
K L,d =  F1   F  g  10   h F – r  tan    ----------------------------
A  In  --- + B
s 1 1
e d  max  h F – r  tan    ----------------------------  h F  -----------------------------------------
A  In  --- + B C  In  --- + D
s s
d d
 A1  A2  l N/mm2 e f sK  e
and  A1  A2  l
321
The largest supporting ring has the radius:

1
max  4,000 – 1,000  tan 30 o   ---------------------------------------------------------- , 4,000  r + --s-  n
1.5041  In  --------------- + 2.1653
20  2 1012.5  2
 2,000 =rR ------------------------
= - -------------------------
= - 675 mm
e n+1 2+1
Füllung Füllung
N R,d =  F1  2    r R  s  KR = 1.35  2    675  20  0.709
1
 ------------------------------------------------------------------ = max  400,115, 428,061  = 428,061
 81,188 N
1.6851  In  --------------- + 3.0872
20
 2,000
1e püK
N R,d =  F2  2    r R  s  K R
püK
= 1.5  2    675  20  0.01386
Füllung -6 2
K L,d = 1.35  1.29  9.81  10  428,061  1.2 = 8.776 N/mm  1,763 N
The following applies to indoor and outdoor installation:
Load case for the overpressure
1 zS 
+ NR,d    ------- + --------
vorh Füllung püK
 R,d =  NR,d - N/mm2
pü 1 A W 
K L,d =  F2  p ü  ----------------------------  A 1  A 2   l R R
E  In  --- + F
s
 d with the cross-section values for the open ring
e r = 675 mm; dA = 200 mm
with E = 1.3933; F = 1.4169 according to Table 1 in Supplement 7 AR = 80,808 mm2; zS = 33.41 mm; WR = 24,848,209 mm³ follows:
follows:
 R,d =  81,188 + 1,763    ------------------ + ------------------------------ = 1.13 N/mm2
vorh 1 33.41
pü 1 0.0018  80,808 24,848,209
K L,d = 1.5  0.001  ----------------------------------------------------------  1.2 = ----------------------------
1.3933  In  --------------- + 1.4169 0.0091998
20
 2,000 It is necessary to comply with the following condition for the sup-
e porting ring:
vorh
 0.267 N/mm
2  l   R,d
 A,R = -------------------- 1
 k,R,d
Utilisation
with
Füllung pü 0.65 0.65
K L,d + K L,d 8.776 + 0.267 = R --------------------------------------------------------
= - ------------------------------------------------------
= - 0.3046
= -----------------------------------
= -----------------------------------
= - 0.98  1 Condition fulfilled! 20 C
o
800  675 - 
* 10.2
----------- EK
-------------- 
-  1 + -----------------
rR  ----------  1 + --------------------
K L,d 235  100  20 
1.1 20 C  100  s 
o
EL
and, because of hR/rR > 0.5:
To C
EK s 800 20
 k,R,d =  R  0.62  ------------  ----- = 0.3046  0.62  ----------  ----------
4.1 Supporting rings M rR 1.1 675
4.1.1 Load case for the filling = 4.07 N/mm²

To C
The greatest compressive stress in the supporting rings results EK = 800 N/mm² for TMK = 20°C
from:
It follows:
=  F  g  10   h F – ---  r  tan   ----------------------------
Füllung -6 2 1 vorh
KR N/mm2  l   R,d 1.2  1.13
 3  =
 A,R --------------------
= -----------------------
= - 0.33  1
K  In  --- + L
s Condition fulfilled!
 d  k,R,d 4.07
e
with K = 1.0575; L = 2.1291 according to Table 1 follows: 4.2 Skirt
= 1.29  9.81  10   4,000 – ---  1,000  tan 30 o

Füllung 2 -6
4.2.1 Load case for the filling
KR
 3 
The greatest compressive stress in the skirt results from:
1
 ----------------------------------------------------------
  h F – ---  r  tan   -----------------------------
Füllung –6 2 1
1.0575  In  --------------- + 2.1291
20 K Zar =  F  g  10 N/mm2
 2,000  3  --s- 
e M  In +N
d 
e
Füllung 2
KR = 0.000012655  3,615.1  15.5 = 0.709 N/mm with M = 0.8946; N = 1.7599 according to Table 1 follows:
  4,000 – ---  1,000  tan 30 o

Füllung –6 2
K Zar = 1.29  9.81  10
4.1.2 Load case for the overpressure  3 
The greatest compressive stress in the supporting rings results 1
from:  -----------------------------------------------------------
0.8946  ln  --------------- + 1.7599
20
 2,000
püK 1 e
KR = p üK  -----------------------------
P  In  --- + Q
s Füllung 2
 d K Zar = 0.000012655  3,615.1  10.59 = 0.484 N/mm
e
Füllung Füllung
with P = 1.0567; Q = 2.2372 follows: =N Zar,d =
F1  2    r  s  K Zar 1.35  2    1,000  20  0.484
püK 1 1 = 82,108.7 N
KR = 0.001  ---------------------------------------------------------- = 0.001  --------------------- 2
1.0567  In  --------------- + 2.2372
20 0.07214 h ges 2
 2,000 0.65 5,000
e M W = c f  q  d  ------------- = 0.8  ---------------   2,000 + 40   -----------------
2 1,000 2
2
= 0.01386 N/mm = 13,260,000 Nmm
322
4.2.2 Load case for the overpressure 0.65 0.65

=  Zar --------------------------------------------------------
= - ------------------------------------------------------
= - 0.2972
o
The load case for the overpressure is not considered since it sub- 20 C 800  1012.5 
-  1 + ---------------- ----------  1 + -------------------- -
-
EK r
jects the skirt to tensile stresses. -------------- 235  100  25 
20 C  100  s 
o
EL
4.2.3 Dimensioning
and, because of hZar/rr > 0.5:
It is only necessary to provide the proof for the summer load case:
To C
1 z S   F2  M W EK s 270 25
= NZar,d   ------- + --------  k,Zar,d =  Zar  0.62  ------------  --- = 0.2972  0.62  ----------  ------------------
vorh Füllung
 Zar,d - + ---------------------- N/mm2 M r
A W  WR 1.1 1012.5
R R
To C = 1.117 N/mm²
with E k for 50°C
vorh
with the cross-section values for the open ring r = 1,010 mm; =  l   Zar,d 1.2  0.857
 A,Zar ---------------------
= - ---------------------------
= 0.92  1 Condition fulfilled!
dA = 200 mm  k,Zar,d 1.117
AR = 122,914 mm²; zS = 32.87 mm; WR = 58,318,536 mm3
1.5  13,260,000
 Zar,d = 82,108,7   --------------------- + ------------------------------ + ------------------------------------------
vorh 1 32.87 5 Anchoring
 122,914 58,318,536 58,318,536
2 For the crucial Case 3, the greatest tensile stress in the skirt results
= 0.7143 + 0.3411 = 1.055 N/mm from:
0.65 0.65 pü 1
 Zar --------------------------------------------------------
= - ------------------------------------------------------
= - 0.2872 K Zar = p ÜK  -----------------------------
U  In  --- + V
o s
----------  1 + --------------------
1,010 
20 C 800  d
EK
-  1 + ----------------
-------------- r 
- -
235  100  20  e
20 C  100  s 
o
EL with U = 1.1428; V = 2.7203 according to Table 1 follows:
and, because of hZar/r > 0.5: pü 1 2
K Zar = 0.001  ---------------------------------------------------------- = 0.00985 N/mm
1.1428  In  --------------- + 2.7203
25
To C
EK s 270 20  2,000
 k,Zar,d =  Zar  0.62  ------------  --- = 0.2872  0.62  ----------  --------------- e
M r 1.1 1,010
pü
K Zar = 0.00985 N/mm2
= 0.8655 N/mm²
As an example, 4,000 N is assumed as the weight GD + GZ + GZar.
vorh
 l   Zar,d 1.2  1,055 sB = 20 mm is chosen as the thickness of the bottom.
=
 A,Zar ---------------------
= - ---------------------------
= 1.46  1
 k,Zar,d 0.8655 *
Wind load with K K,d = 14.8/1.1 N/mm² for 20°C
Condition not fulfilled!
4   F2  M W pü 1
The wall thickness for the cylinder, for the conical bottom, ------------------------------ +  F2  2    r  s  K Zar –  F3   G D + G Z + G Zar   ---
d z
for the skirt and for the supporting rings is increased to -------------------------------------------------------------------------------------------------------------------------------------------------------------------------  1
*
25 mm. K K,d
 b Pr + s B   s B  ----------------------
The next calculation with s = 25 mm supplies: 2  A1  l
Füllung
= 1.29  9.81  10
–6
  4,000 – ---  1,000  tan 30o 
2 4  1.5  13,325,000
K Zar
  -------------------------------------------------- + 1.5  2    1,000  25  0.00985 – 0.9   4,000 
3 2,000
------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
1 14.8
 -------------------------------------------------------------- -----------
0.8946  In  ------------------- + 1.7599
25 1.1
 2,000   70 + 20   20  ------------------------
e 2  1  1.2
= z
Füllung 2
K Zar = 0.000012655  3,615.1  8.673 = 0.3968 N/mm 39,975 + 2,320 – 3,600
= z ------------------------------------------------------------
= - 3.83
10,091
Füllung Füllung
N Zar,d =  F1  2    r  s  K Zar = 1.35  2    1,000  25  0.3968
Four anchors are executed.
= 84,144 N The lower course of the cylinder, the skirt, the conical bottom and
the two supporting rings must be manufactured from panels with
2 2
h ges 0.65 5,000 a thickness of 25 mm.
M W = c f  q  d  -------------- = 0.8  ---------------   2,000 + 50   -----------------
2 1,000 2
= 13,325,000 Nmm
Summer proof:
1 z S   F2  M W
 Zar,d = NZar,d   ------- + --------
vorh Füllung
- + ---------------------- N/mm2
A W  WR
R R
To C
with E k for 50°C
with the cross-section values for the open ring r = 1,012.5 mm;
dA = 200 mm
AR = 154,035 mm2; zS = 32.87 mm; WR = 73,276,623 mm³
1.5  13,325,000
 Zar,d = 84,144   --------------------- + -------------------------------- + ------------------------------------------
vorh 1 32.87
 154,035 73,276,623  73,276,623
= 0.584 + 0.273 = 0.857 N/mm2
323
Draft January 2015

Calculation of containers and apparatus
FÜR SCHWEISSEN UND
made of thermoplastics – upright, round Technical code
VERWANDTE VERFAHREN E.V. pressureless containers – parallel- DVS 2205-2
supported sloping base Supplement 9
This supplement 9 for the DVS 2205-2 guideline was drawn up by the DVS-AG W4.3b (structural design/apparatus construction)
together with the "Plastic containers and pipes" ("Calculation" project group) committee of experts from the German Construction
Institute.
Contents: welded at both ends with the same overlap. If both alternating
stiffeners are welded to the frame, the pipe coupling does not
1 Scope need to be used.
2 Structure
2.1 Frame connection – Shut-off valves or other valves must be arranged outside the
2.1.1 Moveable connection frame; there is no access to the space below the sloping base.
2.1.2 Rigid connection – The calculations are for a container with a sloping base without
2.2 Stiffeners a collecting vessel.
2.3 Underfloor
2.4 Ventilation of the space underneath the sloping base
3 Calculation variables 2 Structure
4 Determining the cutting forces for the strength analysis
4.1 Cylinder
The lower part of the container with sloping base consists of four
structural elements:
4.2 Sloping base – Lower cylinder section,
4.2.1 Filling loading case – Sloping base,
– Frame,
5 Strength analysis
6 Determining the cutting forces for the stability analyses – Stiffeners, supported by partitions.
6.1.1 Stiffeners 2.1 Frame connection
6.1.2 Frame
6.2 Overpressure loading case 2.1.1 Articulated connection
6.2.1 Stiffeners
6.2.2 Frame In the case of containers manufactured from plates, it makes
7 Stability analysis sense to manufacture cylinders and frames separately and to
7.1 Stiffeners arrange the base between them. The lower section and the frame
7.2 Frame are chamfered according to the angle of the sloping base. The
8 Dimensioning sloping base is manufactured with an outer diameter of approx.
9 Anchors d + 5 · s. The lower section and sloping base are connected
10 Structural details internally and externally with an extruder seam a > = 0.7 · s. The
11 References frame is only connected to the sloping base from the outside with
an extruder seam a > = 0.7 · s (moveable frame connection).
1 Scope
2.1.2 Rigid connection
The following structure and calculation rules apply to upright,
cylindrical, factory-fabricated thermoplastic containers with The cylinder and frame are manufactured as a single piece. The
supporting frame and sloping base supported by parallel sloping base is fitted and welded from the top and bottom to the
stiffeners. Cylinder and frame can either be manufactured from cylinder and frame to form a rigid connection (rigid frame
panels or by using a winding process. connection).
The following prerequisites must be satisfied when using this 2.2 Stiffeners
supplement:
The stiffeners are arranged parallel to one another at equidistant
– The stiffeners are arranged parallel to the direction of
intervals. The stiffeners must be cut precisely; they can – but do
inclination of the sloping base (trapezoidal stiffeners).
not need to be – welded to the sloping base. The stiffeners are
– An opening is provided in the sloping base – with an elbow fed supported by partitions, which have the same distances between
through the frame – for the removal of residue. The middle themselves as the stiffeners. Partitions and stiffeners must be
stiffener must bypass the opening on both sides by using a welded to one another. The ends of the stiffeners must be
transverse stiffener. The opening in the frame is reinforced protected against lateral buckling; this can either be done by
using a pipe coupling with a minimum length of dA/2, which is welding to the frame or by means of additional partitions.
324
2.3 Underfloor F
K LB,d N/mm² Rated value of the stress in the case of long-
A final underfloor can be welded to the frame from the outside term effect on the sloping base from the filling
with a continuous extruder seam a > = 0.7 · s. If the container loading case
does not need to be anchored, then a tack weld suitable for pü
K LB,d N/mm² Rated value of the stress in the case of long-
transport is sufficient. term effect on the sloping base from the
overpressure loading case
2.4 Ventilation of the space under the sloping base püK N/mm² Rated value of the stress in the case of short-
K KB,d
The space under the sloping base must be ventilated, to enable term effect on the sloping base from the
pressure equalisation if the temperature changes. This is overpressure loading case
ensured if the discharge pipe is not welded to the frame. * N/mm² Rated value of the strength in the case of
K K,d
The upper part of the tank is designed and calculated in the short-term effect
same way as the flat base tank. pü
K Zar N/mm² Tensile load from pü in the frame
püK
K Zar N/mm² Tensile load from püK in the frame
MW Nmm Bending moment from wind load on lower
a mm Distance between the sloping base and under- frame edge
floor at deepest point
m – Number of stiffeners
A1 – Reduction factor for the influence of the
specific strength n – Number of rings on the replacement container
filling N Rated value of the global compressive force
NR,d
from the liquid load in the supporting ring
A2 – Reduction factor for the medium during
strength analyses filling N Rated value of the global compressive force
NZar,d
from the liquid load in the frame
A2I – Reduction factor for the medium during
stability analyses snow N Rated value of the global compressive force
NZar,d
from snow load in the frame
AR mm² Cross-section area of the open ring
ps N/mm² Snow load on the roof
bPr mm Width of the anchor lug
puK N/mm² Short-term negative pressure
d mm Nominal internal diameter of the cylinder and
frame püK N/mm² Short-term positive pressure
T°C N/mm² Short-term Young's modulus at T°C pü N/mm² Long-term positive pressure
EK
r mm Radius of the cylinder/frame
20°C N/mm² Short-term Young's modulus at 20°C
EK s mm Wall thickness of the bottom section, the frame
20°C N/mm² Long-term Young's modulus at 20°C and the sloping base
EL
sB mm Thickness of the sub-base
g m/sec² Acceleration due to gravity
sS mm Wall thickness of the stiffeners and partitions
GA N Dead load of the additional weight on the roof
TA °C Average ambient temperature (according to
GD N Dead load of the roof Miner, see Guideline DVS 2205-1)
Gges N Dead load of the tank without GA TAK °C Maximum ambient temperature
GZ N Dead load of the cylinder TM °C Average temperature of liquid (according to
GB N Dead load of the sloping base Miner, see Guideline DVS 2205-1)
GZar N Dead load of the frame
Design °C Max. calculation temperature for the frame
hF mm Fill height measured from the deepest point of T Zar
the sloping base
WR mm³ Moment of resistance of the open ring
hS mm Average height of the highest buckling panel of
the stiffeners zS mm Centroidal distance of the open ring from the
cylinder axis
hZar mm Maximum height of the frame
α Degre Inclination angle of the sloping base measured
kf – Concentration factor according to [5] es against the horizontal
F,A
K LZ,d N/mm² Rated value of the stress in the case of long- αZar – Factor for axial stability, frame
term effect in the cylinder from the filling at the
β – Aspect ratio of the buckling panel
loading case point A
ηA,S – Utilisation of the axial stability in the stiffener
F,B
K LZ,d N/mm² Rated value of the stress in the case of long-
term effect in the cylinder from the filling at the ηA,Zar – Utilisation of the axial stability in the frame
loading case point B γF1 – Partial safety factor of the force (dead load,
pü,A
K LZ,d N/mm² Rated value of the stress in the case of long- liquid load)
term effect in the cylinder from the γF2 – Partial safety factor of the force (pressures,
overpressure at point A wind)
pü,B
K LZ,d N/mm² Rated value of the stress in the case of long- γF3 – Partial safety factor of the force (diminishing
term effect in the cylinder from the dead load)
overpressure at point B
γM – Partial safety factor of the resistance/stress
pük,A
K KZ,d N/mm² Rated value of the stress in the case of short- capacity
term effect in the cylinder from the
overpressure at point A μ – Poisson's ratio
pük,B N/mm² Rated value of the stress in the case of short- ρF g/cm³ Density of the filling medium
K KZ,d
term effect in the cylinder from the σe N/mm² Buckling stress in the stiffener
overpressure at point B
325
σk,d N/mm² Rated value of the buckling stress in the 4.1.2 Overpressure loading case
stiffener
σk,Zar,d N/mm² Rated value of the axial buckling stress of the 4.1.2.1 Point A
frame
pü,A r
F N/mm² Rated value of the compressive stress of the K LZ,d = ( 1.87 + 0.5 ) ⋅ γ F2 ⋅ p ü ⋅ --- ⋅ A 1 ⋅ A 2 N/mm² (3)
σ S,d s
stiffener, filling loading case
pük N/mm² Rated value of the compressive stress of the püK,A
σ S,d K KZ,d same with püK
stiffener, overpressure loading case
F
σ Zar,d N/mm² Rated value of the compressive stress of the 4.1.2.2 Point B
frame, filling loading case
exist
σ Zar,d N/mm² Rated value of the compressive stress of the pü,B 1
frame K LZ,d = γ F2 ⋅ p ü ⋅ ----------------------------- ⋅ A 1 ⋅ A 2 N/mm² (4)
C ⋅ ln  --- + D
s
 d
e
4 Determining the cutting forces for the strength analysis püK,B
K KZ,d same with püK
The cutting forces can be determined by using a finite element Tables 1 and 2 show the constants C and D.
program and they can also be approximated using a shell of
rotation program for thin-walled elements with a linear-elastic 4.2 Sloping base
approach. This allows the wall thicknesses of the cylinder, frame
and also the sloping base to be determined in manner that Two points must be considered:
optimises the utilisation of the individual elements, i. e., it results Point B Cylinder wall parallel to the stiffeners, base supported up
in economical and safe dimensioning. to stiffener.
This supplement provides formulas for manual calculation. When The stresses of the sloping base (span moment) are
using these formulae, the following limitations must be taken into calculated based on a fictitious container with a ring-
account: supported flat base. For m stiffeners, we use n = (m –1)/
2 rings.
– The wall thicknesses of the lower cylinder section, the frame
and the sloping base are identical. Point C Sloping base over the outer stiffener (support moment)
is also calculated on the basis of a fictitious container
– The inclination angle of the sloping base must be no more than with a ring-supported flat base. Comparison
10 degrees. calculations on a fictitious continuous beam produced
– 3, 5 or 7 stiffeners must be used. lower stresses.
– The ratio of the wall thickness to the radius is within the
following limits 0.04 > = s/r > = 0.01.
The largest stress resulting from filling occurs either on the
– Only the stiffeners are in contact with the sloping base.
sloping base at the cylinder/frame transition point or on the
– Any weld seams on the sloping base are arranged sloping base over the stiffeners. Therefore both stresses must be
perpendicular to the stiffeners. calculated; the larger of the two stresses is decisive.
The stresses take effect parallel to any weld seam on the base,
4.1 Cylinder a weld strength reduction factor does not need to be applied.
Two points must be considered: The following formula for the rated value of the greatest stress
takes into account the sum of bending and normal stresses.
Point A Cylinder wall perpendicular to middle stiffener, base
supported by stiffener. –6 1 1
⋅ h F ⋅ max ---------------------------- , -----------------------------
F
To calculate the largest stress in the cylinder, it is K LB,d = γ F1 ⋅ ρ F ⋅ g ⋅ 10
E ⋅ ln  --- + F G ⋅ ln  --- + H
s s
assumed that the stiffener is welded to the frame. In  d  d
this case, the lower edge of the cylindercannot rotate; e e
this means that the cylinder must be calculated as fully ⋅ A1 ⋅ A2 N/mm² (5)
rigid.
Tables 1 and 2 show the constants E to H.
Point B Cylinder wall parallel to the stiffeners, base supported
up to outer stiffener.
The stresses of the cylinder are calculated based on a 4.2.2 Overpressure loading case
fictitious container with a ring-supported flat base. The largest stress in the cylinder occurs either at the transition to
For m stiffeners, we use n = (m –1)/2 rings. the base or on the sloping base over the stiffeners. Therefore
both stresses must be calculated; the larger of the two stresses is
4.1.1 Filling loading case decisive. The stresses take effect parallel to the weld seam on
the base, a weld strength reduction factor does not need to be
4.1.1.1 Point A applied.
The following formula for the rated value of the greatest stress
F,A –6 r
K LZ,d = 1.87 ⋅ γ F1 ⋅ ρ F ⋅ g ⋅ 10 ⋅ ( h F + r ⋅ tan α B ) ⋅ --- ⋅ A 1 ⋅ A 2 takes into account the sum of bending and normal stresses.
s
N/mm² (1) pü 1 1
K LB,d = γ F2 ⋅ p ü ⋅ max ----------------------------, ----------------------------- ⋅ A 1 ⋅ A 2 N/mm²
K ⋅ ln  --- + L M ⋅ ln  --- + N
s s
4.1.1.2 Point B  d  d
e e
F,B –6 1 (6)
K LZ,d = γ F1 ⋅ ρ F ⋅ g ⋅ 10 ⋅ h F ⋅ ---------------------------- ⋅ A 1 ⋅ A 2 N/mm² (2)
A ⋅ ln  --- + B
s
 d püK
e K KB,d same with püK
Tables 1 and 2 show the constants A and B. Tables 1 and 2 show the constants K to N.
326
5 Strength analyses the ring cross-section must be determined. The axial

compressive stresses next to the opening must be calculated
The strength analyses are carried out as detailed in the DVS taking the offset of the line of gravity into consideration.
2205-2 guideline using the stresses described in Section 4. The
average media temperature TM, or, in the event of short-term 7.1 Stiffeners
effects, the highest media temperature TMK, must be applied for the Only the greatest stiffener span is analysed using the
effective wall temperature in the cylinder and on the sloping base. compressive stress according to Section 6.1.1 and 6.2.1.
The height of the buckling panel in the centre is
6 Determining the cutting forces for the stability analyses m + 0.5
h S = a + ------------------- ⋅ d ⋅ tan α B mm (11)
m+1
In the case of stiffeners and frames which bear the entire filling
load, the axial stability must be analysed. hS ⋅ ( m + 1 )
The aspect ratio is β = ------------------------------ (12)
d
The rated value of the buckling stress is
6.1.1 Stiffeners kσ ⋅ σe
σ k,d = ---------------- ≤ K *K,d N/mm² (13)
The largest stress on the stiffeners is determined based on a γM
fictitious continuous beam with m + 1 spans. Regardless of the
number of intermediate supports m, the largest supporting force
2
π ⋅ EK
T°C
sS ⋅ ( m + 1 ) 2
where: σ e = ------------------------------
- ⋅ ------------------------------ N/mm² (14)
B can be calculated with the factor 1.15 2 d
12 ⋅ ( 1 – μ )
B = 1.15 · p · l where l = d/(m + 1) and p = ρ · g · 10–6 · hF
and kσ prepared for quick use from the diagrams according to [2]:
This results in a rated value for the stress in the stiffeners of
In the event that the stiffeners are not welded to the sloping base,
–6 d the following applies
σ S,d
F
= 1.15 ⋅ γ F1 ⋅ ρ F ⋅ g ⋅ 10 ⋅ h F ⋅ --------------------------- ⋅ A 1 ⋅ A 2
s ⋅ (m + 1)
k σ = β + 1.1 ≤ 2.3 (15)
N/mm² (7)
or, in the event that the stiffeners are welded to the sloping base,
6.1.2 Frame the following applies
2 ·
At the point B , the largest frame compressive stress is k σ = –3.1 ⋅ β + 5.1 ⋅ β + 0.3 for β < 0.8 (16)
expected. Consider a fictitious continuous beam with m+1 spans.
A simplified calculation for the outer bearing force A can be k σ = –0.37 ⋅ β + 2.7 ≥ 2.3 for β ≥ 0.8 (17)
carried out regardless of m with a factor of 0.4: A = 0.4 · p · l F pük
σ S,d + σ S,d
With l = d/(m + 1) and p = ρ · g · 10–6 · (hF + r · tan αB) it The utilisation is η A,S = --------------------------- ≤ 1 (18)
σ k,d
follows that
For the effective wall temperature of the stiffeners
–6 d
⋅ ( h F + r ⋅ tan α B ) ⋅ ---------------------------
F
σ Zar,d = 0.4 ⋅ γ F1 ⋅ ρ F ⋅ g ⋅ 10 T MK + T AK
s ⋅ (m + 1)
max T MK , --------------------------
⋅ A1 ⋅ A2 N/mm² (8) 2
must be used.
6.2 Overpressure loading case
7.2 Frame
6.2.1 Stiffeners
The positive pressure load case is not considered, as positive
The largest compressive stress in the stiffeners can be calculated pressure subjects the frame to tension.
in a similar manner to equation (7).
The following applies
pük d
σ S,d = 1.15 ⋅ γ F2 ⋅ p ük ⋅ --------------------------- ⋅ A 1 ⋅ A 2 N/mm² (9) filling
= 2 ⋅ π ⋅ r ⋅ s ⋅ σ Zar,d
F
s ⋅ (m + 1) NZar,d N (19)
snow 2
6.2.2 Frame N Zar,d = γ F2 ⋅ π ⋅ r ⋅ p S N (20)
The characteristic value for the largest tensile load in the frame is For indoor installations
needed for the analysis of the anchoring. The stresses are
1 zS
σ Zar,d = ( NZar,d + γ F1 ⋅ ( G ges + G A ⋅ k f ) ) ⋅  ------- + ---------  N/mm²
exist filling
calculated based on a fictitious container with a ring-supported
flat base. For m stiffeners, we use n = (m –1)/2 rings.  AR WR 
(21)
pü 1
K Zar = p ü ⋅ ----------------------------- N/mm² (10) For outdoor installations
U ⋅ ln  --- + V
s
 d Summer
e
1 zS γ F2 ⋅ M W
Tables 1 and 2 show the constants U and V. σ Zar,d = ( N Zar,d + γ F1 ⋅ ( G ges + G A ⋅ k f ) ) ⋅  ------- + ---------  + ----------------------
exist filling
 AR WR  WR
7 Stability analyses N/mm² (22)
Winter
The rated value of the axial compressive stress must be
compared with the rated value of the buckling stress. Buckling is a The analysis with snow and winter temperature does not need to
short-term process; the analyses must be carried out using the be carried out as this is not decisive for dimensioning.
wall temperatures, given by TMK and TAK. In the case of direct The following conditions must be observed for the frame:
sunlight, T Design
Zar – when set-up in Germany 50°C – must be set
for the wall temperature of the frame. For TAK, a minimum of σexist
η A,Zar = ----------------- ≤ 1
Zar,d (23)
20°C must be set for internal set-up and 35°C for outdoor set-up. σ k,Zar,d
Compressive stresses according to Section 6.1 and 6.2 are
converted to global axial forces and, when set up outdoors, Note: A2I not applicable as it is not media-wetted.
applied together with the bending moment from the wind load M w whereby
on the weakened cross-section (open ring). To do so, the area
AR, the centre of mass zS and the moment of resistance WR of for hZar /r > 0.5
327
T°C 9 Anchors
EK s
σ k,Zar,d = α Zar ⋅ 0.62 ⋅ -----------
- ⋅ --- (24a)
γM r
If anchors are required, at least 4 anchors should be provided (z
for hZar /r ≤ 0.5 ≥ 4). When carrying out anchoring analysis, a distinction must be
T°C
made between 3 cases:
r 2 s
- ⋅ --- ⋅ 1 + 1.5 ⋅  ---------- ⋅ ---
EK s
σ k,Zar,d = α Zar ⋅ 0.62 ⋅ ----------- (24b)
T MK + T AK
γM r  hZar  r
Case 1: short-term overpressure at --------------------------
- °C ,
2
where:
Design
0.65 but at least TZar in direct sunlight
α Zar = -------------------------------------------------------- (25)
20°C
1
-------------- ⋅  1 + -----------------
EK r püK
[ γ F2 ⋅ 2 ⋅ π ⋅ r ⋅ s ⋅ K Zar – γ F3 ⋅ ( G ges – G K + G A ) ] ⋅ ---
20°C  100 ⋅ s z-
E L ----------------------------------------------------------------------------------------------------------------------------------
*
≤1 (26)
K K,d
and E K
T°C
for a wall temperature of TW ( b Pr + s B ) ⋅ s B ⋅ --------------
2 ⋅ A1
For indoor installations
TM + TA
Case 2: long-term overpressure at -------------------- °C
T MK + T AK 2
T W = -------------------------- (25a)
2
pü 1
For outdoor installations [ γ F2 ⋅ 2 ⋅ π ⋅ r ⋅ s ⋅ K Zar – γ F3 ⋅ ( G ges – G K + G A ) ] ⋅ ---
z
---------------------------------------------------------------------------------------------------------------------------------
*
-≤1 (27)
K L,d
T W = max [ T MK ,T Zar
Design
] ( b Pr + s B ) ⋅ s B ⋅ --------------
(25b) 2 ⋅ A1
without the effect of wind – MW = 0 in (22) – Case 3: Wind load at

or max [ T MK ,T AK ] + ( T AK – 5 )
T W = ---------------------------------------------------------------------- – 10 in °C (27a)
max [ T MK ,T AK ] + ( T AK – 5 ) 2
TW = ---------------------------------------------------------------------- (25c)
2 (only for outdoor installations)
with the effect of wind 4 ⋅ γ F2 ⋅ M W
------------------------------ + γ F2 ⋅ 2 ⋅ π ⋅ r ⋅ s ⋅ K Zar – γ F3 ⋅ ( G ges – G K + G A ) ⋅ 1
pü
---
d z
-----------------------------------------------------------------------------------------------------------------------------------------------------------------
*
-≤1
K K,d
8 Dimensioning ( b Pr + s B ) ⋅ s B ⋅ --------------
2 ⋅ A1
The larger wall thickness is resulting from the strength analyses (28)
and the stability analyses is to be used for the lower cylinder
section, the sloping base and the frame. The required anchor force (e.g. for the anchor fitting) must be
calculated from the maximum lug force (maximum of the
The wall thickness of the stiffeners and partitions sS results from numerators from the equations 26 to 28) taking the lever arms
the stability analysis according to Section 7.1. into account.
10 Structural details
SD
h′ ges = h ges + S B + -----------------
cos α D
h′ Zar2 = h Zar + r ⋅ tan α B – c

s
c = ----------------- – s ⋅ tan α B
cos α B
h′ Z1 = h Z + r ⋅ tan α B + b
2 ⋅ SD
h′ D = r ⋅ tan α D + -----------------
cos α D
328
Figure 2. Sub-base connection.
Figure 5a. Sloping base connection; moveable frame connection.
Figure 3.
Figure 4. Figure 5b. Sloping base connection; fixed frame connection.
Detail:
Fig. 6. Base with opening and alternating stiffeners.
329
Table 1. Moveable frame connection. 11 References
Number of stiffeners m=3 m=5 m=7 [1] DVS 2205-2: Calculation of containers and apparatus made
of thermoplastics – upright, round, pressureless containers.
A 1.9678 1.7531 1.5201
Cylinder filling [2] Pflüger, A.: Stabilitätsprobleme der Elastostatik (Electrostatics
B 3.6451 3.2719 2.5455 stability problems). Springer Verlag.
Cylinder C 1.8731 1.6173 1.3757 [3] Tuercke, H.: Derivation of simplified formulas for determining
overpressure cutting forces for the dimensioning of parallel-supported
D 3.1001 2.4547 1.6147 sloping bases. Unpublished.
E 1.9363 1.7131 1.4777 [4] Tuercke, H.: Zur Stabilität von Behältern aus Thermoplasten.
Sloping base F 3.4562 3.0336 2.2876
Heft 5/1995.
filling G 1.9913 1.9746 1.9558 [5] Tuercke, H.: Zur Einleitung axialer Einzellasten am oberen
H 3.0130 3.7436 4.2176
K 1.9477 1.712 1.4489 DIBt-Mitteilungen, Volume 4/2002.
Sloping base L 3.5231 3.0454 2.1617

overpressure M 1.9965 1.9805 1.9683
N 3.0402 3.7764 4.2856
nZar U 1.0039 1.0292 1.0524
Overpressure
loading case V 1.9490 1.8881 1.9171
Table 2. Rigid frame connection.
Number of stiffeners m=3 m=5 m=7

A 1.7714 1.5389 1.3639
Cylinder filling
B 3.0288 2.4054 1.8380
Cylinder C 1.6861 1.4494 1.2634

overpressure D 2.5524 1.8686 1.2072
E 1.9545 1.7845 1.5787
Sloping base F 3.4694 3.3195 2.7603

filling G 1.9907 1.9696 1.9469
H 3.0206 3.7236 4.1747
K 1.9451 1.7388 1.4864
Sloping base L 3.4214 3.0767 2.2555

overpressure M 1.9995 1.9857 1.9690
N 3.0682 3.8122 4.2955
nZar U 1.0048 1.0288 1.0528
Overpressure
loading case V 1.9679 1.8962 1.9265
330
January 2012

FÜR SCHWEISSEN UND
Parallel-supported sloping base Supplement 9
This Supplement 9 to the DVS 2205-2 technical code was elaborated by DVS-AG W4.3b ("Structural designing / apparatus engineering")
together with the committee of experts "Plastic tanks and pipes" (project group "Calculation") from the German Institute of Construction
Technology.
Contents: sides of the opening using a transverse gusset. The opening in

the skirt is reinforced with a pipe socket which has the minimum
1 Scope of application length dA/2 and is welded on both sides with the same projection.
2 Design If both the replaceable gussets are welded with the skirt, the
2.1 Connection of the skirt pipe socket is not necessary.
2.1.1 Flexible connection
– Shut-off valves and miscellaneous fittings must be arranged
2.1.2 Flexurally stiff connection
outside the skirt; there is no accessibility to the space below
2.2 Gussets
the sloping base.
2.3 Bottom
2.4 Ventilation of the space underneath the sloping base – A tank with a sloping base and without a collecting device is
3 Calculation variables calculated.
strength
4.1 Cylinder 2 Design
4.1.2 Load case for the overpressure The lower region of the tank with a sloping base consists of the
4.2 Sloping base following four structural elements:
4.2.2 Load case for the overpressure – lower cylinder course
5 Proof of the strength – sloping base
6 Determination of the sectional forces for the proof of the – skirt
stability – gussets, supported by bulkheads
6.1.1 Gussets 2.1 Connection of the skirt
6.1.2 Skirt
6.2 Load case for the overpressure 2.1.1 Flexible connection
6.2.1 Gussets In the case of tanks fabricated from plates, it is appropriate to
6.2.2 Skirt fabricate the cylinder and the skirt separately and to arrange the
7 Proof of the stability bottom in between. For this purpose, the lower course and the
7.1 Gussets skirt are chamfered according to the angle of the sloping base.
7.2 Skirt The sloping base is fabricated with an outside diameter of approx.
8 Dimensioning d + 5 · s. The lower course and the sloping base are joined with
9 Anchoring an extruder weld a > = 0.7 · s on the inside and on the outside.
10 Design-related details The skirt is joined with the sloping base with an extruder weld
11 Literature a > = 0.7 · s from the outside only (flexible connection of the skirt).
2.1.2 Flexurally stiff connection

The cylinder and the skirt are fabricated in one piece. The sloping
The following design and calculation rules apply to vertical, cylin- base is fitted in and is welded with the cylinder and the skirt in a
drical tanks which are fabricated from thermoplastics in the factory flexurally stiff joint from the top and from the bottom (flexurally
and are equipped with a vertical skirt and sloping bases supported stiff connection of the skirt).
by parallel gussets. The cylinder and the skirt can be either fabri-
cated from panels or manufactured in the winding process. 2.2 Gussets
For the application of this supplement, it is necessary to satisfy The gussets are arranged parallel to each other at equal distances
the following prerequisites: apart. The gussets must be cut to the exact dimensions; they can
(but do not have to) be welded with the sloping base. The gus-
– The gussets are arranged parallel to the inclination direction of
sets are supported by bulkheads which are the same distance
the sloping base (trapezoidal gussets).
apart as the gussets. The bulkheads and the gussets must be
– For the draining of the residues, provision is made for an open- welded with each other. The ends of the gussets must be se-
ing in the sloping base - guided through the skirt with an elbow. cured against lateral deflection; this may happen either by welding
For this purpose, the central gusset must be guided past both them on to the skirt or using additional bulkheads.
331
2.3 Bottom pük,B

K KZ,d N/mm² Dimensioning value of the stresses effective for
a short time in the cylinder resulting from the
A closing bottom can be welded on to the skirt from the outside load case for the overpressure at Position B
with a continuous extruder weld a > = 0.7 · s. If the tank does not
have to be anchored, a tack weld suitable for transport is sufficient. F
K LB,d N/mm² Dimensioning value of the stresses effective for
a long time in the sloping base resulting from
the load case for the filling
2.4 Ventilation of the space underneath the sloping base
pü
K LB,d N/mm² Dimensioning value of the stresses effective for
The space underneath the sloping base must be ventilated in a long time in the sloping base resulting from
order to permit pressure equalisation in the event of temperature the load case for the overpressure
changes. This is the case when the drainpipe is not welded with püK N/mm² Dimensioning value of the stresses effective for
the skirt. K KB,d
a short time in the sloping base resulting from
The upper part of the tank is designed and calculated in the load case for the overpressure
analogy to the flat-bottom tank. K K,d
* N/mm² Dimensioning value of the strength effective for
a short time
K Zar
pü N/mm² Tensile stresses resulting from pü in the skirt
K Zar
püK N/mm² Tensile stresses resulting from püK in the skirt
a mm Distance between the sloping base and bottom
at the lowest point MW Nmm Bending moment from the wind load at the lower
edge of the skirt
A1 – Reduction factor for the influence of the specific
m – Number of gussets
toughness for a wall temperature effective for a
long time n – Number of rings on the substitute tank
A1K – Reduction factor for the influence of the specific Füllung N Dimensioning value of the global compressive
N R,d
toughness for a wall temperature effective for a force resulting from the filling in the supporting
short time ring
A2 – Reduction factor for the medium in the case of Füllung N Dimensioning value of the global compressive
N Zar,d
the proof of the strength force resulting from the filling in the skirt
A2I – Reduction factor for the medium in the case of Schnee N Dimensioning value of the global compressive
N Zar,d
the proof of the stability force resulting from the snow load in the skirt
ps N/mm² Snow pressure on the roof
AR mm² Cross-sectional area of the open ring
puK N/mm² Partial vacuum effective for a short time
bPr mm Width of the anchor claw
püK N/mm² Overpressure effective for a short time
d mm Nominal inside diameter of the cylinder and of
the skirt pü N/mm² Overpressure effective for a long time
TC N/mm² Short-time elastic modulus at T°C r mm Radius of the cylinder/skirt
EK
s mm Wall thickness of the lowest course, of the skirt
20C N/mm² Short-time elastic modulus at 20°C and of the sloping base
EK
20C N/mm² Long-time elastic modulus at 20°C sB mm Wall thickness of the bottom
EL
sS mm Wall thickness of the gussets and of the
g m/sec² Acceleration due to gravity bulkheads
GA N Dead load of the additional weight on the roof TA °C Mean ambient temperature (according to Miner,
GD N Dead load of the roof see the DVS 2205-1 technical code)
Gges N Dead load of the tank TAK °C Highest ambient temperature
GZ N Dead load of the cylinder TM °C Mean media temperature (according to Miner,
see the DVS 2205-1 technical code)
GB N Dead load of the sloping base
TMK °C Highest media temperature
GZar N Dead load of the skirt
WR mm³ Resistance moment of the open ring
hF mm Filling height measured from the lowest point
zS mm Distance between the centres of gravity of the
of the sloping base
open ring and of the cylinder axis
hS mm Mean height of the highest buckling field of the
 ° Pitch of the sloping base measured against the
gussets
horizontal line
hZar mm Maximum height of the skirt
Zar – Factor for the axial stability of the skirt
 – Side ratio of the buckling field
F,A
K LZ,d N/mm² Dimensioning value of the stresses effective for A,S – Utilisation of the axial stability in the gusset
a long time in the cylinder resulting from the
load case for the filling at Position A A,Zar – Utilisation of the axial stability in the skirt
F,B N/mm² Dimensioning value of the stresses effective for F1 – Partial safety coefficient of the effect
K LZ,d (dead load and filling)
a long time in the cylinder resulting from the
load case for the filling at Position B F2 – Partial safety coefficient of the effect
pü,A N/mm² Dimensioning value of the stresses effective for (pressures and wind)
K LZ,d
a long time in the cylinder resulting from the F3 – Partial safety coefficient of the effect
load case for the overpressure at Position A (reducing dead load)
pü,B
K LZ,d N/mm² Dimensioning value of the stresses effective for I – Weighting coefficient according to the
a long time in the cylinder resulting from the DVS 2205-2 technical code, Table 2
load case for the overpressure at Position B
M – Partial safety coefficient of the resistance/
pük,A
K KZ,d N/mm² Dimensioning value of the stresses effective for
stressability
a short time in the cylinder resulting from the
load case for the overpressure at Position A  – Poisson's ratio
332
F g/cm³ Density of the filling medium 4.1.2 Load case for the overpressure
e N/mm² Buckling stress in the gusset
4.1.2.1 Position A
k,d N/mm² Dimensioning value of the buckling stress in
the gusset pü,A r
K LZ,d =  1.87 + 0.5    F2  p ü  ---  A 1  A 2   l N/mm² (3)
k,Zar,d N/mm² Dimensioning value of the axial buckling stress s
of the skirt püK,A
F N/mm² Dimensioning value of the compressive stresses K KZ,d in analogy to püK
 S,d
on the gusset, load case for the filling
4.1.2.2 Position B
pük
 S,d N/mm² Dimensioning value of the compressive stresses
on the gusset, load case for the overpressure
pü,B 1
F N/mm² Dimensioning value of the compressive stress- K LZ,d =  F2  p ü  -----------------------------  A 1  A 2   l N/mm² (4)
 Zar,d C  ln  --- + D
s
es on the skirt, load case for the filling  d
vorh N/mm² Dimensioning value of the compressive stress- e
 Zar,d
es on the skirt püK,B
K KZ,d in analogy to püK
Tables 1 and 2 show Constants C and D.
strength
4.2 Sloping base
The sectional forces can be determined not only with a finite element Two positions must be taken into consideration:
program but also approximately with a rotational shell program for
Position B Cylinder wall parallel to the gussets, bottom unsup-
thin-walled elements with a linear-elastic approach. In this way, it
ported as far as the gusset.
is possible to establish the wall thicknesses of the cylinder, of the
As an alternative, the stresses on the sloping base
skirt and also for the sloping base in such a way that the utilisation
(field moment) are calculated on a fictitious tank with
of the individual elements is optimum, i.e. it permits economically
a ring-supported flat bottom. n = (m –1)/2 rings are
viable and safe dimensioning.
estimated for m gussets.
In this supplement, formulae are provided for the manual compu-
tation. For their application, attention must be paid to the following Position C The sloping base above the outside gusset (support-
restrictions on the scope of application: ing moment) is also calculated on a fictitious tank
with a ring-supported flat bottom. Comparative cal-
– The wall thicknesses of the lower cylinder course, of the skirt culations on a fictitious continuous beam resulted in
and of the sloping base are identical. lower stresses.
– The pitch of the sloping base is confined to max. 10°.
– It is necessary to arrange three, five or seven gussets.
The greatest stress resulting from the filling arises either in the
– The wall-thickness-to-radius ratio is within the following limits:
sloping base at the interface between the cylinder and the skirt or
0.04 > = s/r > = 0.01.
in the sloping base above the gussets. Therefore, it is necessary
– Only the gussets are in contact with the sloping base. to calculate both stresses; the greater of the two stresses is cru-
– Any welds in the sloping base are arranged transverse to the cial. The stresses are effective parallel to any weld in the bottom.
gussets. It is not necessary to estimate a welding factor.
The following formula for the dimensioning value of the greatest
4.1 Cylinder stress takes account of the total of the bending and normal
Two positions must be taken into consideration: stresses.
Position A Cylinder wall perpendicular to the central gusset, F –6 1 1

bottom supported by the gusset. K LB,d =  F1   F  g  10  h F  max ----------------------------  -----------------------------
E  ln  --- + F G  ln  --- + H
s s
In order to calculate the greatest stress in the cylinder,  d  d
it is assumed that the gusset is welded with the skirt. e e
Thus, the lower edge of the cylinder cannot be twist-  A 1  A 2   l N/mm² (5)
ed; this means that the cylinder must be calculated
as fully clamped. Tables 1 and 2 show Constants E to H.
Position B Cylinder wall parallel to the gussets, bottom unsup-
ported as far as the outside gusset. 4.2.2 Load case for the overpressure
As an alternative, the stresses on the cylinder are The greatest stress in the cylinder arises either at the interface to
calculated on a fictitious tank with a ring-supported the bottom or in the sloping base above the gussets. Therefore, it
flat bottom. n = (m –1)/2 rings are estimated for m is necessary to calculate both stresses; the greater of the two
gussets. stresses is crucial. The stresses are effective parallel to the weld
in the bottom. It is not necessary to estimate a welding factor.
The following formula for the dimensioning value of the greatest
4.1.1.1 Position A stress takes account of the total of the bending and normal
stresses.
F,A –6 r
K LZ,d = 1.87   F1   F  g  10   h F + r  tan  B   ---  A 1  A 2   l
s pü 1 1
N/mm² (1) K LB,d =  F2  p ü  max ---------------------------- -----------------------------  A 1  A 2   l
K  ln  --- + L M  ln  --- + N
s s
d d
4.1.1.2 Position B e e
F,B –6 1 N/mm² (6)
K LZ,d =  F1   F  g  10  h F  ----------------------------  A 1  A 2   l N/mm² (2)
A  ln  --- + B
s
 d püK
K KB,d in analogy to püK
e
Tables 1 and 2 show Constants A and B. Tables 1 and 2 show Constants K to N.
333
5 Proof of the strength Compressive stresses according to Sections 6.1 and 6.2 are con-
verted into global normal forces and, in the case of outdoor instal-
The proof of the strength is provided in the way indicated in the lation, are estimated for the weakened cross-section (open ring)
DVS 2205-2 technical code with the stresses described in Sec- together with the bending moment resulting from the wind load
tion 4. The mean media temperature TM must be estimated as Mw. For this purpose, it is necessary to establish the area AR, the
the effective wall temperature in the cylinder and in the sloping centre of gravity zS and the resistance moment WR of the ring
base and the highest media temperature TMK in the case of a cross-section. The axial compressive stresses next to the opening
short-time effect. must be calculated while paying attention to the misalignment of
the centroidal axis.
6 Determination of the sectional forces for the proof of the 7.1 Gussets
stability
Only the highest gusset field is proven with the compressive
For gussets and skirts bearing the entire filling load, it is necessary stresses according to Sections 6.1.1 and 6.2.1.
to provide proof of the axial stability. The height of the buckling field at the centre point is:
m + 0.5
6.1 Load case for the filling h S = a + -------------------  d  tan  B mm (11)
m+1
6.1.1 Gussets hS   m + 1 
The side ratio is:  = -----------------------------
- (12)
The greatest stress on the gussets is established on a fictitious d
continuous beam with m + 1 fields. Irrespective of the number of The dimensioning value of the buckling stress is prepared:
intermediate supports m, the greatest supporting force B can be k  e
calculated with the factor 1.15:  k,d = ----------------  K *K,d N/mm² (13)
M
B = 1.15 · p · l with l = d/(m + 1) and p =  · g · 10–6 · hF
This results in the dimensioning value of the stresses in the gussets:
2
  EK
TC
sS   m + 1  2
-  -----------------------------
with  e = ------------------------------ - N/mm² (14)
2 d
–6 d 12   1 –  
 S,d
F
= 1.15   F1   F  g  10  h F  ---------------------------  A 1  A 2   l
s  m + 1 and k for the quick use from the diagrams according to [3]:
N/mm² (7) The following is applicable if the gussets are not welded with the
sloping base:
6.1.2 Skirt
=
k   + 1.1  2.3 (15)
The greatest compressive stress on the skirt is to be expected at
Position B . A fictitious continuous beam with m + 1 fields is or the following is applicable if the gussets are welded with the
considered. Irrespective of m, the external bearing force A can be sloping base:
2
calculated in a simplifying method with the factor 0.4: A = 0.4 · p · l. k  = –3.1   + 5.1   + 0.3 for   0.8 (16)
With l = d/(m + 1) and p =  · g · 10–6 · (hF + r · tan B), it follows: k  = –0.37   + 2.7  2.3 for   0.8 (17)
–6 d
  h F + r  tan  B   ---------------------------
F
 Zar,d = 0.4   F1   F  g  10 +
F
 S,d
pük
 S,d
s  m + 1 The utilisation is:  A,S = ---------------------------  1 (18)
 A 1  A 2   l N/mm² (8)  k,d
7.2 Skirt
6.2 Load case for the overpressure
The load case for the overpressure is not considered since the
6.2.1 Gussets overpressure subjects the skirt to tensile stresses.
The greatest compressive stress in the gussets results in analogy The following is applicable:
to Equation (7). Füllung F
N Zar,d = 2    r  s   Zar,d N (19)
pük d
 S,d = 1.15   F2  p ük  ---------------------------  A 1  A 2   l N/mm² (9) Schnee 2
s  m + 1 N Zar,d =  F2    r  p S N (20)
In the case of indoor installation:
6.2.2 Skirt
1 zS 
vorh Füllung
The characteristic value of the greatest tensile stress in the skirt - N/mm²
A W 
is needed for the proof of the anchoring. As an alternative, the R R
(21)
stresses are calculated on a fictitious tank with a ring-supported TC
with E k for (TMK + TAK)/2°C in Equation (24)
flat bottom. n = (m –1)/2 rings are estimated for m gussets
In the case of outdoor installation:
pü 1
K Zar = p ü  ----------------------------- N/mm² (10) Summer:
U  ln  --- + V
s
 d
1 z S   F2  M W
vorh Füllung
e - + ----------------------
A W  WR
Tables 1 and 2 show Constants U and V. R R
N/mm² (22)
TC
with E k for (TMK + TAK)/2, in the case of direct solar radiation
for min. 50°C in Equation (24)
The dimensioning value of the axial compressive stresses must Winter:
be compared with the dimensioning value of the buckling stress. It is not necessary to provide any proof with snow or at a winter
Buckling is a short-time process and the proof must be provided at temperature since this does not determine the dimensioning.
the wall temperatures resulting from TMK and TAK. For the proof of
the skirt, (TMK+ + TAK)/2 must be estimated as the effective wall The following condition must be complied with for the skirt:
vorh
temperature and min. 50°C in the case of direct solar radiation.  l   Zar,d
TMK must be estimated as the effective temperature of the gus-  A,Zar = ---------------------
-1
 k,Zar,d
sets and min. (TMK + 35)/2 in the case of outdoor installation. Min.
20°C must be used for TAK in the case of indoor installation and min. Remark: A2I is not necessary since there is no wetting with media.
35°C for outdoor installation. (23)
334
where: T MK + T AK
Case 1: Short-time overpressure at --------------------------
- C
for hZar/r > 0.5: 2
but min. 50°C in the case of direct solar radiation
TC
EK s
 k,Zar,d =  Zar  0.62  -----------
-  --- (24a)
M r püK 1
z
for hZar /r  0.5: ----------------------------------------------------------------------------------------------------------------------------------
*
- 1 (26)
K K,d
 b Pr + s B   s B  ----------------------
TC 2 2  A1  l
 ---  1 + 1.5   ----------  ---
EK s r s
 k,Zar,d =  Zar  0.62  ------------ (24b)
M r  hZar  r
TM + TA
with Case 2: Long-time overpressure at -------------------- C
2
0.65
 Zar = -------------------------------------------------------- (25) pü 1
20C   F2  2    r  s  K Zar –  F3   G D + G Z + G Zar    ---
--------------   1 + ---------------- r 
EK z
20C 
- ---------------------------------------------------------------------------------------------------------------------------------
-1 (27)
EL 100  s K L,d*
 b Pr + s B   s B  ----------------------
2  A1  l
8 Dimensioning Case 3: Wind load at 20°C (only in the case of outdoor installation)
The greatest wall thickness s resulting from the proof of the 4   F2  M W pü 1
strength and from the proof of the stability must be executed for ------------------------------ +  F2  2    r  s  K Zar –  F3   G D + G Z + G Zar   ---
d z
the lower cylinder course, for the sloping base and for the skirt. -----------------------------------------------------------------------------------------------------------------------------------------------------------------
*
-1
K K,d
The wall thickness of the gussets and of the bulkheads sS results  b Pr + s B   s B  ----------------------
2  A1  l
from the proof of the stability according to Section 7.1.
(28)
9 Anchoring While paying attention to the lever arms, the required anchor
force (e.g. for the plugs) must be calculated from the maximum
If anchoring becomes necessary, at least four anchors must be claw force (maximum of the numerators in Equations 26 to 28).
arranged (z  4). With regard to the proof of the anchoring, a dis-
tinction must be made between three cases:
10 Design-related details
Computational dimensions Fabrication dimensions
hD
hD
hZ2
hZ h
F
SD
h ges = h ges + S B + ----------------
- hges
cos  D
h Zar2 = h Zar + r  tan  B – c hges
s
c = ----------------- – s  tan  B
cos  B
h Z1 = h Z + r  tan  B + b hZar
hZar2
2  SD
h D = r  tan  D + ----------------
-
cos  D
335
All welds
a = 0.7 · s
Figure 2. Bonding of the bottom.
Sloping base
Figure 5a. Bonding of the sloping base; flexible connection of the skirt.
Gusset
Bulkhead
Flat bottom
Figure 3. All welds

a = 0.7 · s
Gusset
Bulkhead
Figure 4. Figure 5b. Bonding of the sloping base; clamped connection of the skirt.
 dA/2
Change
Opening Detail:
Figure 6. Bottom with opening and replacement of the gussets.
336
Table 1. Flexible connection of the skirt. 11 Literature
Number of gussets m=3 m=5 m=7 [1] DVS 2205-2: Calculation of tanks and apparatus made of
thermoplastics – Vertical round, non-pressurised tanks.
Cylinder A 1.9678 1.7531 1.5201
[2] Pflüger, Alf: Stability problems in elastostatics. Springer Verlag.
Filling B 3.6451 3.2719 2.5455 [3] Tuercke, H.: Derivation of simplified formulae for the determi-
C 1.8731 1.6173 1.3757 nation of the sectional forces for the dimensioning of parallel-
Cylinder supported sloping bases. Unpublished.
Overpressure D 3.1001 2.4547 1.6147 [4] Tuercke, H.: On the stability of tanks made of thermoplastics.
E DIBt Communications, No. 5/1995.
1.9363 1.7131 1.4777
[5] Tuercke, H.: On the introduction of axially directed individual
Sloping base F 3.4562 3.0336 2.2876 loads into the upper edge of thermoplastic tanks. DIBt Com-
Filling G munications, No. 4/2002.
1.9913 1.9746 1.9558
H 3.0130 3.7436 4.2176
K 1.9477 1.712 1.4489
Sloping base L 3.5231 3.0454 2.1617

Overpressure M 1.9965 1.9805 1.9683
N 3.0402 3.7764 4.2856
U 1.0039 1.0292 1.0524
nZar load case
Overpressure V 1.9490 1.8881 1.9171
Table 2. Flexurally stiff connection of the skirt.
Number of gussets m=3 m=5 m=7
Cylinder A 1.7714 1.5389 1.3639

Filling B 3.0288 2.4054 1.8380
Cylinder C 1.6861 1.4494 1.2634

Overpressure D 2.5524 1.8686 1.2072
E 1.9545 1.7845 1.5787
Sloping base F 3.4694 3.3195 2.7603

Filling G 1.9907 1.9696 1.9469
H 3.0206 3.7236 4.1747
K 1.9451 1.7388 1.4864
Sloping base L 3.4214 3.0767 2.2555

Overpressure M 1.9995 1.9857 1.9690
N 3.0682 3.8122 4.2955
nZar load case U 1.0048 1.0288 1.0528

Overpressure V 1.9679 1.8962 1.9265
337
Draft January 2015

FÜR SCHWEISSEN UND
of thermoplastics – Vertical, round non- Technical code
VERWANDTE VERFAHREN E.V. pressurised tanks – Example for parallel- DVS 2205-2
supported sloping base Supplement 10
Contents: 3 Strength analysis
1 Introduction 3.1 Initial estimation

2 Tank data Filling –6 r
3 Strength analysis K L,d = 1.87 ⋅ γ F1 ⋅ ρ F ⋅ g ⋅ 10 ⋅ ( h F + r ⋅ tan α B ) ⋅ --- ⋅ A 1 ⋅ A 2
s
3.1 Initial estimation N/mm²
3.2 Strength analysis in the cylinder and
3.3 Strength analysis on the sloping base
Filling –6 1
4 Stability analyses K L,d = γ F1 ⋅ ρ F ⋅ g ⋅ 10 ⋅ h F ⋅ -------------------------
- ⋅ A 1 ⋅ A 2 N/mm²
A ln  --- + B
s
4.1 Stiffeners d  
4.1.1 Filling loading case e
4.1.2 Overpressure loading case according to Table 1 of supplement 9 A = 1.5201, B = 2.5455.
4.2 Frame The formulas are solved for s with the condition KFilling = K*L,d
L,d
4.2.1 Filling loading case = 10.2/1.3.
–6
4.2.3 Dimensioning 1.87 ⋅ γ F1 ⋅ ρ F ⋅ g ⋅ 10 ⋅ ( h F + r ⋅ tan α B ) ⋅ r ⋅ A 1 ⋅ A 2
5 Anchors s 1 = -------------------------------------------------------------------------------------------------------------------------------------
K*
-----L-
γM
1 Introduction –6
1.87 ⋅ 1.35 ⋅ 1.29 ⋅ 9.81 ⋅ 10 ⋅ 4,087 ⋅ 1,000 ⋅ 1 ⋅ 1
= s 1 ----------------------------------------------------------------------------------------------------------------------------------
= - 16.6 mm
10.2
This example should help you to use supplement 9 to the DVS -----------
2205-2 Guideline. 1.3
and
–6
 γ F1 ⋅ ρ ⋅ g ⋅ 10 ⋅ h F ⋅ A 1 ⋅ A 2
ln  --------------------------------------------------------------------------- – B
2 Tank data  K*L,d 
------------------------------------------------------------------------------------------------
s2 = d ⋅ e A
Type: Cylinder and frame made of plates
 –6 
Geometry: d = 2,000 mm (internal); hGes = 5,000 mm; 1.35 ⋅ 1.29 ⋅ 9.81 ⋅ 10 ⋅ 4,000 ⋅ 1 ⋅ 1
ln  ------------------------------------------------------------------------------------------------ – 2.5455
α = 5°; 7 stiffeners welded to the sloping base 
10.2
----------- 
1.3
-----------------------------------------------------------------------------------------------------------------------------------
Installation: Outdoor installation without wind shielding tray s 2 = 2,000 ⋅ e 1.5201
= 16.5 mm
collector Wind zone 2 inland; snow load zone 2
up to 285 m Selected: s = 20 mm.
q = 0.65 kN/m²
pS = 0.68 kN/m², TA = 10°C, TAK = 35°C 3.2 Strength analysis in the cylinder
Material: PE 100; 25 years A check is carried out to determine whether s = 20 mm in the
cylinder is sufficient for the sum of the filling load case and pü
Filling: Battery acid; TM = TMK = 20°C; hF = 4,000 mm; load case.
A1 = A1K = A2 = A2I = 1; ρF = 1.29 g/cm³
Point A , filling load case
Ventilation: Closed system pÜK = pü = 0.01 bar;
puK = 0.01 bar F,A –6 r
K LZ,d = 1.87 ⋅ γ F1 ⋅ ρ F ⋅ g ⋅ 10 ⋅ ( h F + r ⋅ tan α B ) ⋅ --- ⋅ A 1 ⋅ A 2
s
Openings: dA = 200 mm
F,A –6 1,000
Distance: a = 300 mm K LZ,d = 1.87 ⋅ 1.35 ⋅ 1.29 ⋅ 9.81 ⋅ 10 ⋅ 4,087 ⋅ --------------- ⋅ 1 ⋅ 1 = 6.53
20
Anchoring: Lug width bPr = 70 mm N/mm²
338
Point A , overpressure load case Point C , filling load case
–6 1
⋅ h F ⋅ ----------------------------- ⋅ A 1 ⋅ A 2
r F,C
pü,A
K LZ,d = ( 1.87 + 0.5 ) ⋅ γ F2 ⋅ p ü ⋅ --- ⋅ A 1 ⋅ A 2 K LB,d = γ F1 ⋅ ρ F ⋅ g ⋅ 10
G ⋅ ln  --- + H
s s
 d
e
pü,A 1,000
K LZ,d =
2.37 ⋅ 1.5 ⋅ 0.001 ⋅ --------------- ⋅ 1 ⋅ 1 0.178 N/mm² with G = 1.9558; H = 4.2176, according to Table 1 of supplement 9,
20
it follows that
Point B , filling load case F,C –6
= =
K LB,d 1.35 ⋅ 1.29 ⋅ 9.81 ⋅ 10 ⋅ 4,000 ⋅ 120.2 ⋅ 1 ⋅ 1 8.21
1 –6
⋅ h F ⋅ ---------------------------- ⋅ A 1 ⋅ A 2
F,B
K LZ,d = γ F1 ⋅ ρ F ⋅ g ⋅ 10 N/mm²
A ⋅ ln  --- + B
s
d Point C , overpressure load case
e
pü,C 1
with A = 1.5201; B = 2.5455, according to Table 1 of supplement 9, K LB,d = γ F2 ⋅ p ü ⋅ ----------------------------- ⋅ A 1 ⋅ A 2
M ⋅ ln  --- + N
s
it follows that  d
e
F,B –6
K LZ,d =
1.35 ⋅ 1.29 ⋅ 9.81 ⋅ 10 ⋅ 4,000 ⋅ 86.04 ⋅ 1 ⋅ 1 5.88 with M = 1.9683; N = 4.2856, according to Table 1 of supplement 9,
N/mm² it follows that
pü,C
Point B , overpressure load case =K LB,d =
1.5 ⋅ 0.001 ⋅ 118.96 ⋅ 1 ⋅ 1 0.178 N/mm²
pü,B 1
K LZ,d = γ F2 ⋅ p ü ⋅ ----------------------------- ⋅ A 1 ⋅ A 2 Point B , utilization
C ⋅ ln  --- + D
s
 d F,B pü,B
e K LB,d + K LB,d 6.26 + 0.136
= η --------------------------------
= - --------------------------------
= - 0.82 < 1
with C = 1.3757; D = 1.6147, according to Table 1 of supplement 9, K *L,d 10.2
-----------
it follows that 1.3
Condition satisfied.
pü,B
K LZ,d =
1.5 ⋅ 0.001 ⋅ 112.24 ⋅ 1 ⋅ 1 0.168 N/mm²
Point C , utilization
Point A , utilization F,C
K LB,d + K LB,d
pü,C
8.21 + 0.178
=η --------------------------------
= - --------------------------------
= - 1.07 > 1
F,A
+
pü,A K *L,d 10.2
-----------
K LZ,d K LZ,d 6.53 + 0.178
=η --------------------------------
= --------------------------------
= - 0.85 < 1 1.3
K *L,d 10.2
-----------
1.3 Condition not satisfied.
New selection: s = 25 mm!
Point B , utilization 4 Stability analyses

pü,B
F,B
K LZ,d + K LZ,d 5.88 + 0.168 4.1 Stiffeners
=η --------------------------------
= --------------------------------
= - 0.77 < 1
K *L,d 10.2
-----------
1.3 4.1.1 Filling loading case
Condition satisfied. S = 15 mm, is selected for stiffeners and section s.
The largest compressive stress in the stiffeners can be calculated
3.3 Strength analysis on the sloping base from
A check is carried out to determine whether s = 20 mm on the F –6 d
σ S,d = 1.15 ⋅ γ F1 ⋅ ρ F ⋅ g ⋅ 10 ⋅ h F ⋅ --------------------------- ⋅ A 1 ⋅ A 2 N/mm²
sloping base is sufficient for the sum of the filling load case and s ⋅ (m + 1)
pü load case.
F –6 2,000
σ S,d = 1.15 ⋅ 1.35 ⋅ 1.29 ⋅ 9.81 ⋅ 10 ⋅ 4,000 ⋅ ----------------------------- ⋅ 1 ⋅ 1
Point B , filling load case 15 ⋅ ( 7 + 1 )
= 1.31 N/mm²
F,B –6 1
K LB,d = γ F1 ⋅ ρ F ⋅ g ⋅ 10 ⋅ h F ⋅ ---------------------------- ⋅ A 1 ⋅ A 2
E ⋅ ln  --- + F
s
 d
e The largest compressive stress in the stiffeners can be calculated
with E = 1.4777; F = 2.2876, according to Table 1 of supplement 9, from
it follows that
püK d
σ S,d = 1.15 ⋅ γ F2 ⋅ p üK ⋅ --------------------------- ⋅ A 1 ⋅ A 2
F,B –6 s ⋅ (m + 1)
K LB,d =
1.35 ⋅ 1.29 ⋅ 9.81 ⋅ 10 ⋅ 4,000 ⋅ 91.6 ⋅ 1 ⋅ 1 6.26
püK 2,000
N/mm² σ S,d = 1.15 ⋅ 1.5 ⋅ 0.001 ⋅ ----------------------------- ⋅ 1 ⋅ 1 = 0.0288 N/mm²
15 ⋅ ( 7 + 1 )
Point B , overpressure load case
The height of the largest buckling panel in the centre is
pü,B 1
K LB,d = γ F2 ⋅ p ü ⋅ ---------------------------- ⋅ A 1 ⋅ A 2 ( m + 0.5 ) 7 + 0.5
K ⋅ ln  --- + L
s =hS + ------------------------ ⋅ d ⋅ tan α B
a= 300 + ------------------ ⋅ 2,000 ⋅ tan 5°
 d m+1 7+1
e
= 464 mm
with K = 1.4489; L = 2.1617, according to Table 1 of supplement 9,
The aspect ratio is
it follows that
hS ⋅ ( m + 1 ) 464 ⋅ ( 7 + 1 )
=K LB,d
pü,B
=
1.5 ⋅ 0.001 ⋅ 90.99 ⋅ 1 ⋅ 1 0.136 N/mm² =β -----------------------------
= - -------------------------------
= - 1.856
d 2,000
339
kσ ⋅ σe 2
= 0.2972 ⋅ 0.62 ⋅ ---------- ⋅ -------------------- ⋅ 1 + 1.5 ⋅  ----------------------------------------------------------------
270 25 1,012.5
The rated value of the buckling stress is σ k,d = ---------------- ≤ K K,d
*
γM 1.3 1,012.5  300 + 2 ⋅ 1,012.5 ⋅ tan 5°
where: 25
⋅ -------------------- = 1.103 N/mm²
1,012.5
2
π ⋅ EK
T°C
sS ⋅ ( m + 1 ) 2 2
π ⋅ 613 15 ⋅ ( 7 + 1 -) 2
σe = - ⋅ -----------------------------
------------------------------ - --------------------------------------- ---------------------------- exist
σ Zar,d
12 ⋅ ( 1 – μ )
2 d 12 ⋅ ( 1 – 0.38 )
2 2,000 0.304
η A,Zar
= ------------------
= --------------
= - 0.27 < 1
σ k, Zar,d 1.103
= 2.12 N/mm²
T°C
where: E K = 613 N/mm² for (TMK + TAK)/2 = 27.5°C and kσ = T°C
with wind with E K = 510 N/mm² at 32.5°C
2.3
1.5 ⋅ 13,325,000
43,825 ⋅ --------------------- + ------------------------------  + ------------------------------------------
exist 1 32.87
= ⋅ 2.12 σ Zar,d =
that σ k,d
it follows=
2.3
-----------------------
= - 3.75 N/mm² 154,035 73,276,623  73,276,623
1.3
= 0.3042 + 0.2728 = 0.577 N/mm²
The following conditions must be observed for the stiffeners
0.65 0.65
F pük =α Zar --------------------------------------------------------
= ------------------------------------------------------
= - 0.2972
σ S,d + σ S,d 1.31 + 0.0288 20°C 800 
---------- ⋅ 1 + --------------------- 
1,012.5
η A,R --------------------------
- -----------------------------------
- 0.36 ≤ 1 -------------- ⋅ 1 + ----------------- 
= = = EK r
σ k,d 3.75 20°C  100 ⋅ s  235  100 ⋅ 25 
E L
and since hZar/r < 0.5
4.2 Frame T°C
EK r 2 s
- ⋅ --- ⋅ 1 + 1.5 ⋅  ----------- ⋅ ---
s
=σ k,Zar,d α
= Zar ⋅ 0.62 ⋅ -----------
γM r  h Zar  r
510 25
The largest compressive stress in the frame can be calculated = 0.2972 ⋅ 0.62 ⋅ ---------- ⋅ -------------------- ⋅
from 1.3 1,012.5
⋅ 1 + 1.5 ⋅  ---------------------------------------------------------------- ⋅ -------------------- =

F –6 d 1,012.5 25
σ Zar,d = 0.4 ⋅ γ F1 ⋅ ρ F ⋅ g ⋅ 10 ⋅ ( h F + r ⋅ tan α B ) ⋅ ---------------------------  300 + 2 ⋅ 1,012.5 ⋅ tan 5° 1,012.5
s ⋅ (m + 1)
⋅ A1 ⋅ A2 N/mm² = 2.082 N/mm²
F –6 2,000 σexist 0.577

σ Zar,d = 0.4 ⋅ 1.35 ⋅ 1.29 ⋅ 9.81 ⋅ 10 ⋅ 4,087 ⋅ ----------------------------- ⋅ 1 ⋅ 1 η A,Zar
= -----------------
=
Zar,d
--------------
25 ⋅ ( 7 + 1 ) σ k,Zar,d 2.082
= 0.279 N/mm²
filling filling 5 Anchors
=NZar,d ⋅ π ⋅ r ⋅ s ⋅ σ Zar,d
2= 2 ⋅ π ⋅ 1,000 ⋅ 25 ⋅ 0.279
= 43,825 N The largest tensile load in the frame can be calculated for case 3
from
2 2
h ges 0.65 5,000 pü 1
=MW f ⋅ q ⋅ d ⋅ ----------
c=
2
0.8 ⋅ --------------- ⋅ ( 2,000 + 50 ) ⋅ -----------------
1,000 2
K Zar = p ü ⋅ -----------------------------
U ⋅ ln  --- + V
s
 d
= 13,325,000 Nmm e
where U = 1.0524; V = 1.9171 according to Table 1, it follows that
4.2.2 Overpressure loading case pü 1
= K Zar =
0.001 ⋅ ----------------------------------------------------------- 0.0148 N/mm²
The overpressure load case is not considered as it subjects the 1.0524 ⋅ ln  --------------- + 1.9171
25
frame to stress.  2,000
e
4.2.3 Dimensioning For example, 4000 N is assumed for the weight GD + GZ + GZar.
Only the analysis for the summer load case needs to be carried sB = 20 mm is chosen for the thickness of the underfloor.
out Wind load with K *K,d = 13.1/1.3 = 10.08 N/mm² for 27.5°C
zS γ F2 ⋅ M w 4 ⋅ γ F2 ⋅ M W
= NZar,d ⋅  ------- + --------- + --------------------- N/mm²
exist Füllung 1 pü 1
σ Zar,d ------------------------------ + γ F2 ⋅ 2 ⋅ π ⋅ r ⋅ s ⋅ K Zar – γ F3 ⋅ ( G D + G Z + G Zar ) ⋅ ---
 A R WR  WR d z
------------------------------------------------------------------------------------------------------------------------------------------------------------------------- ≤ 1
*
K K,d
with the cross-sectional values for the open ring r = 1012.5 mm ( b Pr + s B ) ⋅ s B ⋅ --------------
dA = 200 mm 2 ⋅ A1
AR = 154035 mm²; zS = 32.87 mm; WR = 73276623 mm³ 4 ⋅ 1.5 ⋅ 13,325,000

-------------------------------------------------- + 1.5 ⋅ 2 ⋅ π ⋅ 1,000 ⋅ 25 ⋅ 0.0148 – 0.9 ⋅ ( 4,000 )
T°C 2,000
without wind with E K = 270 N/mm² at 50°C -----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
10.08
( 70 + 20 ) ⋅ 20 ⋅ ---------------
σ Zar,d = 43,825 ⋅  --------------------- + ------------------------------ = 0.304 N/mm²
exist 1 32.87 2⋅1
 154,035 73,276,623
= z
0.65 0.65
=α Zar --------------------------------------------------------
= ------------------------------------------------------
= - 0.2972
39,975 + 3,487 – 3,600
EK
20°C
1 + ----------------
r  800  1,012.5=
---------- ⋅ 1 + ---------------------  z ------------------------------------------------------------
= 4.4
-------------- ⋅ -
20°C  100 ⋅ s  235  100 ⋅ 25  9,072
EL
At least 5 anchors are implemented.
and since h Zar /r < 0,5 The lower section of the cylinder, the frame and the sloping
T°C base must be made of 25 mm thick panels. The 7 stiffeners
r 2 s
- ⋅ --- ⋅ 1 + 1.5 ⋅  ---------- ⋅ --- =
EK s
σ k,Zar,d = α Zar ⋅ 0.62 ⋅ ----------- and the associated partitions must be designed with a
γM r  h Zar r thickness of 15 mm.
340
January 2012

made of thermoplastics –
Example of a parallel-supported sloping base Supplement 10
Contents: 3 Proof of the strength
1 Introduction 3.1 Initial estimation

2 Data for the tank Füllung –6 r
3 Proof of the strength K L,d = 1.87   F1   F  g  10   h F + r  tan  B   ---  A 1  A 2   l
s
3.1 Initial estimation N/mm²
3.2 Proof of the strength in the cylinder and
3.3 Proof of the strength in the sloping base
–6 1 -  A  A   N/mm²
4 Proof of the stability KFüllung
L,d =  F1   F  g  10  h F  ------------------------ 1 2 l
Aln  --- + B
s
4.1 Gussets  d
4.1.1 Load case for the filling e
4.1.2 Load case for the overpressure According to Table 1 in Supplement 9, A = 1.5201 and
4.2 Skirt B = 2.5455.
4.2.1 Load case for the filling The formulae are solved with the condition KFüllung = K*L,d
L,d
4.2.2 Load case for the overpressure = 10.2/1.1 according to s.

4.2.3 Dimensioning
–6
5 Anchoring 1.87   F1   F  g  10   h F + r  tan  B   r  A 1  A 2   l
s 1 = --------------------------------------------------------------------------------------------------------------------------------------------
-
K*L
------
1 Introduction M
–6
1.87  1.35  1.29  9.81  10  4,087  1,000  1.2
=
This example is intended to facilitate the application of Supple- s1 --------------------------------------------------------------------------------------------------------------------------------
= 16.9 mm
ment 9 to the DVS 2205-2 technical code. 10.2
-----------
1.1
and
–6
2 Data for the tank   F1    g  10  h F  A 1  A 2   l
ln  ----------------------------------------------------------------------------------- – B
 K*L,d 
---------------------------------------------------------------------------------------------------------
Design: Cylinder and skirt fabricated from plates s2 = d  e A
Geometry: d = 2,000 mm (inside); hGes = 5,000 mm;  = 5°;
seven gussets welded with sloping base  –6 
1.35  1.29  9.81  10  4,000  1.2
ln  --------------------------------------------------------------------------------------------- – 2.5455
 10.2 
Installation: Outdoor installation without any wind-shielding  ----------- 
1.1
collecting device ---------------------------------------------------------------------------------------------------------------------------------
Wind Zone 2: inland area ; s 2 = 2,000  e 1.5201 = 16.7 mm
Snow Load Zone 2: up to 285 m Chosen s = 20 mm.
q = 0.65 kN/m2
pS = 0.68 kN/m2, TA = 10°C, TAK = 35°C 3.2 Proof of the strength in the cylinder
Material: PE 100; 25 years It is checked whether s = 20 mm in the cylinder is sufficient for
Filling: Battery acid; TM = TMK = 20°C; hF = 4,000 mm; the total resulting from the load case for the filling and the load
A1 = A1K = A2 = A2I = 1; F = 1.29 g/cm³ case pü.
Ventilation: Closed system püK = pü = 0.01 bar; Position A , load case for the filling
puK = 0.01 bar
F,A –6 r
Loading type: Loading Case II; I = 1.2 K LZ,d = 1.87   F1   F  g  10   h F + r  tan  B   ---  A 1  A 2   l
s
Openings: dA = 200 mm F,A –6 1,000
Distance: a = 300 mm K LZ,d = 1.87  1.35  1.29  9.81  10  4,087  ---------------  1.2
20
Anchoring: Claw width bPr = 70 mm = 7.83 N/mm²
341
Position A , load case for the overpressure Position C , load case for the overpressure
pü,A r
K LZ,d =  1.87 + 0.5    F2  p ü  ---  A 1  A 2   l pü,C 1
K LB,d =  F2  p ü  -----------------------------  A 1  A 2   l
s
M  ln  --- + N
s
pü,A 1,000  d
K LZ,d =
2.37  1.5  0.001  ---------------  1.2 0.213 N/mm² e
20
with M = 1.9683; N = 4.2856 according to Table 1 in Supplement 9
Position B , load case for the filling follows:
F,B –6 1
K LZ,d =  F1   F  g  10  h F  ----------------------------  A 1  A 2   l pü,C
A  ln  --- + B
s = K LB,d =
1.5  0.001  118.96  1.2 0.214 N/mm²
 d
e
Position B , utilisation
with A = 1.5201; B = 2.5455 according to Table 1 in Supplement 9
follows: F,B pü,B
K LB,d + K LB,d 7.51 + 0.164
F,B –6 =  --------------------------------
= - --------------------------------
= - 0.83  1
K LZ,d =
1.35  1.29  9.81  10  4,000  86.04  1.2 7.06 N/mm² K *L,d 10.2
-----------
1.1
Position B , load case for the overpressure
Condition fulfilled!
pü,B 1
K LZ,d =  F2  p ü  -----------------------------  A 1  A 2   l
C  ln  --- + D
s Position C , utilisation
 d
e F,C pü,C
with C = 1.3757; D = 1.6147 according to Table 1 in Supplement 9 K LB,d + K LB,d 9.86 + 0.214
=  --------------------------------
= - --------------------------------
= - 1.09  1
follows: K *L,d 10.2
-----------
pü,B 1.1
=K LZ,d =
1.5  0.001  112.24  1.2 0.202 N/mm²
Condition not fulfilled!
Position A , utilisation New choice: s = 25 mm!
F,A pü,A
K LZ,d + K LZ,d 7.83 + 0.213
= --------------------------------
= --------------------------------
= - 0.87  1
K *L,d 10.2
----------- 4 Proof of the stability
1.1
Condition fulfilled! 4.1 Gussets
Position B , utilisation 4.1.1 Load case for the filling

F,B pü,B
K LZ,d + K LZ,d 7.06 + 0.202 sS = 15 mm is chosen for the gussets and the bulkheads.
= --------------------------------
= --------------------------------
= - 0.78  1
K *L,d 10.2
----------- The greatest compressive stress in the gussets results from:
1.1
F –6 d
Condition fulfilled!  S,d = 1.15   F1   F  g  10  h F  ---------------------------  A 1  A 2   l N/mm²
s  m + 1
3.3 Proof of the strength in the sloping base
F –6 2,000
 S,d = 1.15  1.35  1.29  9.81  10  4,000  -----------------------------  1.2
It is checked whether s = 20 mm in the sloping base is sufficient 15   7 + 1 
for the total resulting from the load case for the filling and the load = 1.57 N/mm²
case pü.
Position B , load case for the filling 4.1.2 Load case for the overpressure
F,B –6 1 The greatest compressive stress in the gussets results from:

K LB,d =  F1   F  g  10  h F  ----------------------------  A 1  A 2   l
E  ln  --- + F
s püK d
 d  S,d = 1.15   F2  p üK  ---------------------------  A 1  A 2   l
e s  m + 1
with E = 1.4777; F = 2.2876 according to Table 1 in Supplement 9 püK 2,000
follows:  S,d = 1.15  1.5  0.001  -----------------------------  1.2 = 0.0345 N/mm²
15   7 + 1 
F,B –6
K LB,d =
1.35  1.29  9.81  10  4,000  91.6  1.2 7.51 N/mm²
The height of the largest buckling field at the centre point:
Position B , load case for the overpressure  m + 0.5  7 + 0.5
=hS a=
+ ------------------------  d  tan  B 300 + ------------------  2,000  tan 5
pü,B 1 m+1 7+1
K LB,d =  F2  p ü  ----------------------------  A 1  A 2   l
K  ln  --- + L
s = 464 mm
d
e The side ratio is:
with K = 1.4489; L = 2.1617 according to Table 1 in Supplement 9
follows: hS   m + 1  464   7 + 1 
= -----------------------------
= - -------------------------------
= - 1.856
pü,B d 2,000
=K LB,d =
1.5  0.001  90.99  1.2 0.164 N/mm²
The dimensioning value of the buckling stress is
Position C , load case for the filling k  e
 k,d = ----------------  K K,d *
–6 1 M
F,C
K LB,d =  F1   F  g  10  h F  ----------------------------
-  A1  A2  l
G  ln  --- + H
s
 d with
e
with G = 1.9558; H = 4.2176 according to Table 1 in Supplement 9
2
  EK
TC
sS   m + 1  2 2
  800 15   7 + 1  2
=  e ------------------------------
= -  -----------------------------
- --------------------------------------- -----------------------------
follows: 12   1 –  
2 d 12   1 – 0.38 
2 2,000
F,C –6
K LB,d =
1.35  1.29  9.81  10  4,000  120.2  1.2 9.86 N/mm² = 2.77 N/mm²
342
TC 5 Anchoring
with E K = 800 N/mm² for TM = 20°C and k = 2.3
For Case 3, the greatest tensile stress in the skirt results from:
2.3  2.77
=
follows  k,d -----------------------
= - 5.79 N/mm²
1.2 pü 1
K Zar = p ü  -----------------------------
U  ln  --- + V
s
The following condition for the gussets must be complied with: d
e
F pük
l    S,d +  S,d  1.2  = 1.57 + 0.0345 - with U = 1.0524; V = 1.9171 according to Table 1 follows:
= A,R ---------------------------------------
= - ----------------------------------------------------- 0.33  1
 k,d 5.79 pü 1
= K Zar =
0.001  ----------------------------------------------------------- 0.0148 N/mm²
1.0524  ln  --------------- + 1.9171
Condition fulfilled! 25
 2,000
e
4.2 Skirt
pü
K Zar = 0.0148 N/mm²
As an example, 4,000 N is assumed as the weight GD + GZ + GZar.
The greatest compressive stress in the skirt results from:
sB = 20 mm is chosen as the thickness of the bottom.
F –6 d
 Zar,d = 0.4   F1   F  g  10   h F + r  tan  B   --------------------------- Wind load with K *K,d = 14.8/1.1 N/mm² for 20°C
s  m + 1
 A 1  A 2   l N/mm² 4   F2  M W pü 1
------------------------------ +  F2  2    r  s  K Zar –  F3   G D + G Z + G Zar   ---
d z
F –6 2,000 -------------------------------------------------------------------------------------------------------------------------------------------------------------------------  1
 Zar,d = 0.4  1.35  1.29  9.81  10  4,087  -----------------------------  1.2 *
K K,d
25   7 + 1   b Pr + s B   s B  ----------------------
2  A1  l
= 0.3351 N/mm²
4  1.5  13,325,000
=NZar,d
Füllung
2=
   r  s  Zar,d
Füllung
2    1,000  25  0.335 -------------------------------------------------- + 1.5  2    1,000  25  0.0148 – 0.9   4,000 
2,000
= 52,637 N -----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
14.8
-----------
1.1
h ges 2
0.65 5,000
2  70 + 20   20  ------------------------
2  1  1.2
=MW f  q  d  ----------
c=
2
- 0.8  ---------------   2,000 + 50   -----------------
1,000 2 = z
= 13,325,000 Nmm
39,975 + 3,487 – 3,600
= z ------------------------------------------------------------
= 3.95
4.2.2 Load case for the overpressure 10,091
The load case for the overpressure is not considered since it sub- Four anchors are executed.
jects the skirt to tensile stresses. The lower course of the cylinder, the skirt and the sloping
base must be manufactured from panels with a thickness of
4.2.3 Dimensioning 25 mm. The seven gussets and the relevant bulkheads must
It is only necessary to provide the proof for the summer load case: be executed with a thickness of 15 mm.
z S   F2  M w
 Zar,d = NZar,d   ------
1- + --------
vorh Füllung
- + --------------------- N/mm²
A W  W R R R
TC
with E k for 50°C
with the cross-section values for the open ring r = 1,012.5 mm;
dA = 200 mm
AR = 154,035 mm²; zS = 32.87 mm; WR = 73,276,623 mm³
 Zar,d = 52,637   --------------------

vorh 32.87 - + 1.5
1 - + -----------------------------  13,325,000
------------------------------------------
 154,035 73,276,623 73,276,623
= 0.3653 + 0.2728 = 0.638 N/mm²
0.65 0.65
 Zar --------------------------------------------------------
= ------------------------------------------------------
= - 0.2972
20C 800  1,012.5 
--------------  1 + ---------------- r  ----------  1 + --------------------
EK -
20C 
- 235  100  25 
E 100  s 
L
and because h Zar /r  0.5

TC
r 2 s
 ---  1 + 1.5   ----------  ---
EK - s
 k,Zar,d =  Zar  0.62  -----------
M r  h Zar r
= 0.2972  0,62  ----------  --------------------  1 + 1.5   ---------------------------------------------------------------o-

270 25 1,012.5 2
1.1 1,012.5  300 + 2  1,012.5  tan 5 
25
-------------------- = 1.303 N/mm²
1,012.5
vorh
 l   Zar,d 1.2  0.638
=
 A,Zar ---------------------
= - ---------------------------
= 0.59  1
 k, Zar,d 1.303
Condition fulfilled!
343
File-Name: e2205-3.fm
DVS – DEUTSCHER VERBAND Design of thermoplastic tanks Directive D

and apparatus DVS 2205-3
VERWANDTE VERFAHREN E.V. Welded joints (April 1975) S 
Contents: B. General welding principles
A. Scope B.1.
The welds must be dimensioned so that in the case of supporting
B. General welding principles welds the cross-sections present are fully connected or in the
case of fillet welds the diameters required for load transmission
C. Welding rules are present. Butt welds are to be preferred.
1. Frame – base 1.1 to 1.12 B.2.
All joints should be counter-welded at the base of the weld or
2. Shell seams 2.1 to 2.2
welded from both sides. Seams accessible from one side should
3. Nozzles and loose flanges 3.1 to 3.8 have a deep penetration at the base of the weld.
B.3.
4. Collars and flanges 4.1 to 4.2
With butt welds of different wall thicknesses a constant load
5. Supporting flanges and rings 5.1 to 5.4 transmission should be aimed for, e.g. by bevelling the thicker
wall.
6. Stiffeners 6.1 to 6.5
B.4.
7. Other joints 7.1 Accumulations of welds should be avoided. Cross-welds at load-
bearing wall sections are not permissible. When fitting stiffeners
or similar in the zone of load-bearing welds free sections of
A. Scope adequate size should be provided.
B.5.
The following directive specifies the design and construction of Joint forms are subject to the specifications of DIN 16960, sheet
welded joints in tanks, apparatus and pipelines. It supplements 1, insofar as no special rulings are made in the following
the existing standards relating to this equipment. examples. For all welds the dimensions for the joint forms should
be precisely determined as a function of the welding process and
The rules are based on an evaluation of many years of the dimensions of the filler material, taking into account base of
experience. The examples cannot replace the necessary design the weld finish.
calculations for construction. This applies particularly to
deviations from the welding principles specified in section B. B.6.
Load-bearing welds should be accessible for testing. If such
The dimensions of individual components (wall thicknesses, welds are covered by components, then the weld should be
diameters etc.) are to be taken from the specification sheets for tested before the component is welded on or the component
the various tank forms. should be designed to allow testing.
344
C. Welding rules
Figure 1.1 Figure 1.2

Application: Application:
Vertical tanks with weld accessible on both sides Vertical tanks
Conditions: a) weld accessible on one side only
s3 > s1: a = 0.7 s1 s1 > s3: a = 0.7 s3 b) weld accessible on both sides
Conditions:
s1 ≤ 30 mm, f = 0.5 s1
Figure 1.3 Figure 1.4

Application: Application:
Vertical tanks with weld accessible on both sides Vertical tanks
Condition: a) with weld accessible on one side only
f = 0.3 s1, k = 0.1 s1 b) with weld accessible on both sides
Conditions:
a = 0.7 s2, f = 0.5 s1
345
Figure 1.5
Application: Vertical tanks Figure 1.6
a) with weld accessible on one side only Application:
b) with weld accessible on both sides Vertical tanks with inclined bases and intermediate bases
a) weld accessible on one side only
b) weld accessible on both sides
c) weld accessible on both sides
Conditions:
a) f = 0.5 s3
b) s1 > s3: a = 0.7 s3
b) s3 > s1: a = 0.7 s1
c) k = 0.1 s3
b) f = 0.3 s3
Figure 1.8
Application:
Vertical tanks
Figure 1.7
Application: Vertical tanks Conditions:
a) weld accessible on one side only a = 0.7 s2 Figure 1.9
b) weld accessible on both sides a1 = 0.7 s1 Application: Vertical tanks with tapered base
346
Figure 1.12
Application:
Vertical and horizontal tanks with weld accessible on both sides
Conditions:
a) a3 = 0.7 s1, a2 = 0.7 s3, b ≥ s1, c≥3s
Figure 1.10 b) f = 0.5 s1
Application: Vertical tanks with tapered base
Conditions: Shell seams
a) α ≥ 60°: f = 0.5 s3, a1 = 0.7 s3
b) α < 60°: as drawn
Figure 1.11
Application:
Vertical and horizontal tanks
with curved bases
a) weld accessible on both Figure 2.1
b) sides Application:
b) weld accessible on both Vertical tanks with constant wall
b) sides thicknesses
a) s ≤ 6 mm Design calculation necessary!
b) s > 6 mm k = 0.2 s1
347
Figure 2.2
Application:
Vertical tanks with varying wall thicknesses
a) design calculation necessary
b) design calculation necessary
a1 = 0.7 s1
3. Nozzles and loose flanges
Figure 3.1
Application:
Tanks with weld accessible on one side only
a) cannot be used when penetration by liquid
a) results in stress on gap
Conditions:
a) s2 > s1: a1 = 0.5 s1, f1 = 0.5 s1
a) s1 > s2: a1 = 0.5 s2, f1 = 0.5 s2
b) s1 ≤ 15 mm, f2 = 0.2 s1
Figure 3.2
Application:
Tanks with weld accessible
on both sides
Conditions:
a) s2 > s1: a = 0.7 s1
a) s1 > s2: a = 0.7 s2
b) s1 > s2: a1= 0.5 s2
b) s1 > s2: f = 0.5 s2
b) s1 > s2: a = 0.7 s2
b) s2 > s1: a1 = 0.5 s1
b) s1 > s2: f = 0.5 s1
b) s1 > s2: a = 0.7 s1
c) f = 0.3 s1
c) k = 0.1 s1
348
Figure 3.3
Application: tanks
Figure 3.5
Application:
Tanks with weld accessible on both sides
Conditions:
a) a = 0.7 s1
b) a = 0.7 s1, f = 0.5 s1
c) f = 0.3 s1, k = 0.1 s1
Figure 3.4
Application:
Tanks with weld accessible on one side only
a) cannot be used when penetration by liquid results in
a) stress on gap.
Conditions:
a) f = 0.51
b) s ≤ 15, f = 0.2 s1
Figure 3.6
Application: Tanks
a) with weld accessible on one side only
a) Cannot be used when penetration by liquid results in stress
other weld forms possible
a) on gap.
b) with weld accessible on both sides
Figure 3.7 Condition:
Application: Tanks a = 0.7 s1
349
Figure 4.1
Application: Figure 4.2
Collars on connections
a) Socket welding Application:
b) Spin friction welding Collars and flanges on tanks and connections
Conditions:
a = 0.7 s1, a1 = s1
Figure 5.1
Application: Vertical tanks
Conditions:
a1 ≤ 0.5 s4 a2 ≤ 0.5 s5
350
Figure 5.4
worked weld
Figure 5.2
Conditions:
a = 0.7 s1, a1 = 0.7 s1
Figure 6.1
Steel Application:
Flat and curved surfaces
d) only when weld is
Figure 5.3
d) accessible on both sides
Conditions:
Conditions: a = 0.7 s1,
a1 ≤ 0.5 s4, a2 ≤ 0.5 s5 f = 0.2 s1
351
Figure 6.2
Application:
Flat and curved surfaces with and without steel inserts
Condition:
a1 = 0.7 s4
Figure 6.3
Application:
Figure 6.4
Application: Flat and curved surfaces
Conditions:
a = 0.7 s1, f = 0.7 s1
352
Figure 6.5
Application:
Condition:
a = 0.7 s4
Figure 7.1
Application: Pressureless tanks
a) accessible from inside
b) and c) inaccessible from inside
Conditions:
a1 = 0.5 s, a2 = 0.2 s, b = s, c=5s
353
File-Name:
C:\DVS Merkblätter\2205\TEIL4\englisch\e2205t4.fm
DVS – DEUTSCHER VERBAND Calculation of thermoplastic tanks Directive D

and apparatuses – DVS 2205-4
VERWANDTE VERFAHREN E.V. Flanged joints (November 1988) S 
Contents: 2 General
1 Scope This sheet is based on the AD data sheets B7 and B8, see
2 General explanations 8. Attention is to be drawn to the German Accident
3 Design principles Prevention Regulation VBG 17 “Pressure Vessels”.
4 Calculation data The flanged joint is calculated only in association with continuous
5 Calculation of the bolts gasket or O-ring, since other seals lead to very high flexural
5.1 General moments and these in turn give rise to uneconomical flange
5.2 Calculation of the bolt forces in case of a continuous gasket dimensions, Figure 2.
5.3 Calculation of the bolt forces in case of O-rings
6 Calculation of the flanges
6.1 General
6.2 Welding neck flanges and welded-on flanges with conti-
nuous gasket or with O-ring
6.3 Welding neck flanges and welded-on loose collars with con-
tinuous gasket or with O-ring
7 Calculation of metal flanges
8 Explanations
1 Scope
The following design and calculation principles relate to circular

flanged joints of the following thermoplastic materials
Polyethylene high density (PE-HD)
Polypropylene (PP)
Polyvinyl chloride (PVC-U)
Polyvinylidene fluoride (PVDF)
The flanges referred to in the following comprise welding neck
flanges, welding neck collars, welded-on flanges and welded-on
collars, Figure 1.
Figure 2. Application examples of gaskets:

a) Flat gasket, b) O-ring,
c) Flat gasket, d) O-ring.
3 Design principles
The number of bolts should be chosen as large as possible, to

ensure uniform sealing.
The number of bolts should be at least four.
The bolt spacing should not exceed 5 dL, but should maximum
be 80 mm. This does not apply to loose flanges of steel and
pipeline connecting flanges.
At low pressure the calculation may produce a flange height
Figure 1. Practical examples of flanges: which is so small that a uniform seal is difficult to achieve even
a) Welding neck flange, b) Welding neck collar, when the given design principles are applied. For design
c) Welded-on flange, d) Welded-on collar. directions see Supplement.
354
In selecting the gasket material – gaskets of soft material should

P SB
be preferred – ist thermal and chemical resistance must be d K = Z ---------------------
- + c, (1)
considered. K Schr ⋅ n
For flammable and highly toxic gases attention is to be drawn to for the assembled condition:
the German Accidents Prevention Regulation “Compressed,
liquefied gases and gases dissolved under pressure” VBG 62 P SO
§20 section 3. d K = Z ---------------------
- + c. (2)
K Schr ⋅ n
Welded joints see directive 2205 Part 3. Z = 1,75 for solid bolts, for example according to DIN 2509 and
DIN 931, with known yield limit, where p‘ ≤ 1,3 p.
c = 3 mm
4 Calculation data
External forces, for example due to thermal expansion, are not
a, aD arm of bolt force in mm covered by this.
b effective double flange width in mm
bD gasket width in mm 5.2 Calculation of the bolt forces in case of continuous gasket
c corrosion allowance in mm 5.2.1 Working condition
da outside diameter of flange in mm
2
di inside diameter of cylindrical component in mm p  π ⋅ dD 
dt pitch circle diameter in mm P SB = ------  ----------------- + 3,8 d D ⋅ k 1 (3)
10  4 
d1 inside diameter of loose flange in mm
d2 average contact diameter flange/collar in mm 5.2.2 Assembled condition
d3 d1 + 2 x flange rounding diameter in mm
dD average gasket diameter in mm =
P SO =
P DV π ⋅ dD ⋅ ko ⋅ KD . (4)
dK bolt shank diameter in mm
If PSO is higher than PSB, PSO may be reduced:
dL bolt hole diameter in mm
d’L reduced bolt hole diameter in mm P SO = 0,2 P DV + 0,8 P SB ⋅ P DV . (5)
hD gasket height in mm
hF required height of a flange plate in mm The gasket parameters k1 and k0 x KD are to be taken from Table
k0 gasket parameter for predeformation in mm 1.
k1 gasket parameter for working condition in mm
5.3 Calculation of the bolt forces in case of O-rings
La neck height in mm
n number of bolts – 5.3.1 Flanges with O-ring according to Figure 3:
p working pressure above atmospheric in bar 2
p‘ test pressure in bar p ⋅ π ⋅ dD y1
P SB = ------------------------- ⋅ -----. (6)
s1 wall thickness of cylindrical component in mm 40 y2
v weakening coefficient –
y1, y2 lever arms in case of O-ring in mm
C, C1 auxiliary value –
KD deformation resistance of gasket material in N/mm²
A2 reduction factor for the influence of the envi-
ronment –
A4 reduction factor for the influence of the specific
toughness –
K(A1, A3) strength parameter value of the thermoplastic in
working condition in N/mm²
KSchr yield limit of bolt material in N/mm²
KFl yield limit of loose flange material (metal) in N/mm²
K‘(A1, A3) strength parameter of the thermoplastic in test
condition in N/mm²
PDV predeformation force in N
PFI surface pressure in N/mm² Figure 3. Flanges with O-ring.
PSB bolt force in working condition in N
5.3.2 Collars with O-ring according to Figure 4:
P’SB bolt force at test pressure in N
PSO bolt force in assembled condition prior to appli- 2
p ⋅ π ⋅ dD
cation of pressure in N P SB = ------------------------- (7)
40
SM safety factor for metals in working condition –
S’M safety factor for metals in test and assembled
condition –
S safety factor for thermoplastics –
W1, W2, W3 flange resistance in mm³
Z auxiliary value –
5 Calculation of the bolts
5.1 General
The inside diameter of the thread of a rigid bolt results from the
largest value of the following formulae:
for the working condition: Figure 4. Collars with O-ring.
355
Table 1. Gasket parameters for liquids and also for gases and vapours.
Shape4) material gasket parameters1)

of gasket with hole without hole for fluids for gases and vapours
KO ∙ KD k1 KO ∙ KD k1
N/mm mm N/mm mm
EPDM 1 bD 0.5 bD 2 bD 0.5 bD
(Rubber)
PTFE3) 20 bD 1.1 bD 25 bD 1.1 bD
IT 15 bD bD bD 2 ) 1.3 bD
200 -------
hD
1) They apply to machined and undamaged sealing faces and subject to the hardness of the gasket material being lower than that of the flange material.
2) Gas-tight quality assumed.
3) Polytetrafluorethylene.
4) For flanges with continuous gasket, the effective gasket width is: 0,5 b .
D
6 Calculation of the flanges
6.1 General
The design of the flanges is determined by the highest flange

resistance required.
For the working condition:
P SB ⋅ A 2 ⋅ A 4 ⋅ S
W 1 = ------------------------------------------ ⋅ a (8)
K( A A )
1, 3
For the test condition:
P′SB ⋅ A 4 ⋅ S Figure 5.
W 2 = -------------------------------- ⋅ a (9)
K′( A A ) Welding neck
1, 3 flange (gasket not
shown on drawing).
For the assembled condition, the arm aD = 0. Consequently, no
W3 is to be calculated.
The required height of the flange plate is:
The values for K(A1, A3), K‘(A1, A3), A2, A4 and S are to be taken
from the directive DVS 2205 Part 1.
C1 ⋅ W
h F = C -----------------------------
-. (12)
6.2 Welding neck flanges and welded-on flanges with continuous
dt ⋅ π –dL ⋅ n
gasket or with O-ring according to Figure 5 and Figure 6
For welding neck flanges C = 0,9, C1 = 2,
The arm of the bolt force is for working and test condition: for welded-on flanges C = 1,1, C1 = 3.
dt – di – s1 6.3 Welding neck collars and welded-on collars with continuous

a = --------------------------- . (10) gasket or with O-ring according to Figure 7 and Figure 8
2
The arm of the bolt force for working and test condition is:
For the assembled condition aD = 0.
d2 – di – s1
a D = 0. (11) a = ---------------------------- . (13)
2
356
Figure 6. Figure 7. Figure 8.

Welded-on flange Welding neck collar Welded-on collar
(gasket not shown on drawing). (gasket not shown on drawing). (gasket not shown on drawing).
For the assembled condition: For the test condition:

a D = 0. (14) P′SB ⋅ S′M
W 2 = --------------------------- ⋅ a. (19)
K FI
The required height of the collar is
For the assembled condition:
C1 ⋅ W
h F = C ----------------- . (15) P SO ⋅ S′M
d2 ⋅ π W 3 = -------------------------- ⋅ a. (20)
K FI
For welding neck collars C = 0,9, C1 = 2,
for welded-on collars C = 1,1, C1 = 3. If PSO is higher than PSB, the value for PSO is to be entered for
PSB in equation (18). Equation (20) is then left out of account.
The surface pressure between loose flange and collar should be
checked: The values for KFI and SM and S’M are to be taken from the AD-
Data Sheets. The arm of the bolt force for the working, test and
1,27 P SB assembled condition is
P FI = ----------------------------- ≤ K ( A A ) (16)
( d 2a – d 23 ) 1, 3 dt – d2
a = ----------------- . (21)
2
1,27 P SO
P FI = ----------------------------- ≤ K ( A A ) (17) The required height of the flange plate is
( d 2a – d 23 ) 1, 3
W
hF = 1,27 ----- , (22)
b
7 Calculation of loose metal flanges according to Figure 9
wherein
The design of the flange is determined by the highest required = b d a – d 1 – 2d′L (23)
flange resistance.
For the working condition: with d’ L according to Figure 10.
P SB ⋅ S M
W 1 = ----------------------- ⋅ a. (18)
K FI
Figure 10. Reduced bolthole diameter
8 Explanations
The mode of calculation of the collars was drawn up on the basis

of AD-Data Sheet B 8, bearing in mind the difference in elastic
deformation between loose steel flange and plastic collar. This is
Figure 9. Loose flange. reflected also in the calculation of the loose steel flange.
357
File-Name: C:\DVS Merkblätter\2205\TEIL4\BEIBLATT\englisch\e2205t4b.fm

Calculation of thermoplastic tanks and Directive D
appartuses DVS 2205-4
FÜR SCHWEISSEN UND
Welded flanges, welded collars – Supplement V
constructive details (November 1996) S 
Contents: Additionally, the height hF has been calculated under the

following conditions:
1 Scope 1. Pressure p = 0,5 bar as fictitious pressure, in order to get a
2 Design conditions usable height of the welded flange resp. of the welded collar.
3 Tables of dimensions
3.1 Welded flanges 2. Creep strength K(A1, A3) of the material for the loading time of
3.2 Welded collars 25 years at a working temperature of 30°C according to
3.3 Screw starting torque directive DVS 2205-1. The standard DIN 8075 is valid for
polyethylene. DIN 8078 is valid for polypropylene Type 1 and
2, DIN 8061 are considered for polyvinylchloride (PVC-U and
PVC-RI Type 1 and 2).
1 Scope
3. Safety factor S = 2,0
This directive describes the design of pressure-loaded welded If the working conditions differ from the above mentioned, hF has
flanges and welded collars in accordance to the design to be calculated accordingly.
conditions for tanks and apparatuses out of thermoplastics as

mentioned in section 2 Connecting bolts have to be used basically with plain washers
according to DIN 9021. Both, the connecting bolts and the plain
Polyethylene high density (PE-HD) washers should be made of stainless steel (e.g. A2, A4 according
Polypropylene (PP-H, PP-B, PP-R) to DIN 267-11) in order to prevent corrosion.
Polyvinylchloride (PVC-NI, PVC-RI)
Polyvinylidenefluoride (PVDF)
in the general application range: 3 Tables of dimensions
Diameter 500 up to 4000 mm for welded flanges and 3.1 Welded flanges – table 1
Diameter 500 up to 1200 mm for welded collars
3.2 Welded collars – table 2
The welded flanges referred to in the following comprise welded-
on collars (figures 1 and 2) and welded neck flanges (figure 3) 3.3 Screw tightening moments
with flat gaskets.
The required screw tightening moments are as follows:
The welded collars comprise welded-on collars (figures 4 and 5)
and welded neck collars (figure 6) with flat gaskets and O-rings. M 10: 15 Nm
M 12: 25 Nm
M 16: 50 Nm
2 Design conditions The installation of the connection bolts should be performed by
means of a torque wrench. The screws have to be torqued
The design of welded flanges and welded collars is based on the evenly. Exceeding the mentioned tightening moments has to be
directives DVS 2205-1 and -4. avoided.
The heights of the flange plate hF are calculated with continuous The above mentioned screw tightening moments are valid for
gasket out of elastomers (shore-A hardness 60°), because this flange connections out of thermoplastics at the application of flat
gasket material is mainly used for tanks and apparatuses out of gaskets out of elastomers with a shore-A hardness of
thermoplastics. If other gasket materials are specified, hF has to approximately 60°. If profiled gaskets are used, the mentioned
be calculated c. screw starting torques may be reduced by 20 %.
358
Page 2 to DVS 2205-4 Supplement
Table 1. Welded flanges for apparatuses out of thermoplastics – dimensions.
welded-on flanges welding neck flange
Preferably HS
Figure 1 Figure 2 Figure 3
g1 = 0.7 ∙ s1 from tank calculation

g2 ≥ 0.4 ∙ s1 k ≈ 0.2 ∙ hF R = 10 ... 15 mm
up to di = 1000 mm: da and dt according to DIN 2501 PN 6
as from di = 1200 mm: da and dt according DIN 2501 PN 2.5
Abbreviations and symbols see DVS 2205-4
holes hF Flat gasket

di da dt
Number dL PE PP PVC PVDF
500 645 600 20 12 25 20 20 15
600 755 705 24 12 25 25 20 15
700 860 810 28 12 25 25 20 15
800 975 920 32 12 30 30 25 20
900 1075 1020 36 12 30 30 25 20
1000 1175 1120 40 12 35 30 25 20
1200 1375 1320 44 14 35 35 30 20
1400 1575 1520 52 14 35 35 30 20 Design conditions:
1500 1690 1630 56 14 40 40 30 25 Working pressure: 0,5 bar
1600 1790 1730 60 14 40 40 35 25 Working temperature: 30oC
Working time: 25 years
1800 1990 1930 64 14 45 40 35 25 Safety factor: 2,0
2000 2190 2130 72 14 45 45 35 30
2200 2405 2340 80 14 50 50 40 30
2400 2605 2540 84 14 50 50 40 30
2500 2705 2640 88 14 55 50 40 30
2600 2805 2740 88 18 55 50 40 35
2800 3030 2960 96 18 60 60 50 35
3000 3230 3160 104 18 65 60 50 40
3200 3430 3360 112 18 65 60 50 40
3600 3840 3770 120 18 70 70 55 45
3800 4045 3970 124 18 70 70 60 45
4000 4245 4170 132 18 75 70 60 45
359
lizensiert für: SLV Nord gGmbH Page 3 to DVS 2205-4 Supplement
Table 2. Welded collars for apparatuses out of thermoplastics – dimensions.
welded-on flanges welding neck flange
Preferably HS
Figure 4 Figure 5 Figure 6
g1 = 0.7 ∙ s1 g2 ≥ 0.4 ∙ s1 k ≈ 0.2 ∙ hF R = 10 mm b = 5 mm

s1 from tank calculation
Loose flange depending on manufacturers choice (e. g. steel, FRP)
dD hF for flat gasket hF for O-ring gasket

di da for O-ring- PE PE
gasket PVC PVDF PVC PVDF
PP PP
500 585 550 15 12 10 15 12 9
600 690 660 15 15 10 15 12 10
700 790 760 20 15 12 17 14 11
800 900 860 20 15 12 18 15 12
900 1000 960 20 20 15 20 17 13
1000 1100 1070 25 20 15 22 18 14
1200 1300 1270 25 20 15 25 20 15
Kinds of gaskets
A: Flat gasket B: O-ring gasket
360
File-Name: e2205-5.fm
DVS – DEUTSCHER VERBAND Calculation of thermoplastic tanks Directive D

and apparatus – DVS 2205-5
VERWANDTE VERFAHREN E.V. Rectangular tanks (July 1987) S 
Contents: Ec N/mm² modulus of creep (from DVS 2205 Part 1)
1 Scope f m maximum deflection

2 General F N force
3 Calculation values
4 Calculation of various tank constructions J mm4 moment of inertia of edge strengthening
5 Explanations k coefficient
6 Literature
M Nmm bending moment
p N/mm² excess pressure on tank bottom
1 Scope
pm N/mm² mean value of excess pressure for calculation of
The following rules for the design and calculation apply to wall thickness
rectangular tanks for the engineering of apparatus of
thermoplastic materials, in particular pn N/mm² mean value of excess pressure for calculation of
the beam
Polyvinyl chloride (PVC)
Polypropylene (PP) s mm wall thickness
High density polyethylene (PE-HD)
W mm³ moment of resistance of edge strengthening
The tanks may be strengthened from the outside by means of
ribs or frames made of the same or stiffer materials, such as α1...α5 coefficient of deformation
glass-fibre reinforced plastics (GRP) or steel. With the exception β1...β5 coefficient of wall thickness
of hydrostatic pressures, no appreciable pressures occur. For the
calculation, in principle, the plate theory was used. Reference to σzul N/mm² permissible stress (here the stress values given
the membrane theory will be found in subclauses 4.6.2 and 5. in DVS 2205 Part 1 may be used)
2 General 4 Calculation of various tank constructions
In the design and processing in particular the following Data The calculation procedures are given for the following tank
Sheets should be considered: constructions, Figures 1 to 5.
DVS 2205 Part 1
"Calculation of thermoplastic tanks and apparatus, 4.1 Tanks without strengthening, resting evenly on a flat surface
characteristic values" The calculation of the walls depend on their side ratio. The
DVS 2205 Part 3 thickness of the bottom must be at least of the same order of
"Calculation of thermoplastic tanks and apparatus, welded magnitude as that of the side walls, Figure 6.
joints"
4.1.1 Side ratio a/b < 0.5
DVS 2205 Part 4
"Calculation of thermoplastic tanks and apparatus, flanged The required wall tickness is
joints".
2
Welds must be placed into regions of low bending moments; the p⋅a
s = ---------------------- . (1)
maximum moments can be seen in figures 6,7 and 8. Significant 2.5 ⋅ σ zul
differences in expansion between strengthening and wall, caused
by temperature changes, must be allowed for in the design. The maximum deflection is:
4
p⋅a
3 Calculation values f = ----------------------------------- . (2)
3
k ⋅ 32 ⋅ E c ⋅ s
A, B, C, D operands
The factor k is to be chosen between 1 (for a < b) and 2 (for
a mm length of tank or of panel a/b ≈ 0.5)
b, bn mm heights of tank or of panel
4.1.2 Side ratio 0.5 ≤ a/b ≤ 4
a', b' mm lengths and heights of panels assigned to
strengthening The minimum wall thickness results from:
c mm width of tank or of panel 2
p⋅b
E N/mm2 elastic modulus of the beam material (with s = β 1 -------------- (3)
plastics, corresponding to Ec) σ zul
361
Figure 1. Tanks without strengthening.
Figure 2. Tanks with edge strengthening.
Figure 6. Moment curve.
and the maximum deflection is:

4
α1 ⋅ p ⋅ b
f = ------------------------- . (4)
3
Figure 3. Tanks with all-around strengthenings. Ec ⋅ s
The values for β1 and α1 are to be taken from Table 1.
4.1.3 Side ratio a/b > 4
The wall thicknesses result from
2
p⋅b
=s -------------- , (5)
σ zul
and the maximum deflection is:

Figure 4. Tanks with yoke strengthenings.
4
p⋅b
f = ----------------------------- . (6)
3
2.5 ⋅ E c ⋅ s
4.2 Tanks with edge strengthening, resting evenly on a flat surface
4.2.1 Calculation of the side walls
The calculation of the side walls is based on the assumption that

Figure 5. Tanks with cross-ribbed side walls. the upper edge strengthening constitutes a firm support. The
(In view of their high costs, these thickness of the bottom must be at least the same of the side
tanks are not considered here.) walls, Figure 7.
Table 1. Coefficients; use linear interpolation to find intermediate value.
a/b or a/c α1 β1 α2 β2 α3 β3 α4 β4 α5 β5
0.5 0.0009 0.09 0.00092 0.074 0.0019 0.13 0.17 0.19 – –
0.6 0.0020 0.10 0.0020 0.097 0.0037 0.17 0.19 0.21 – –
0.7 0.0035 0.12 0.0032 0.12 0.0061 0.22 0.23 0.22 – –
0.8 0.0055 0.15 0.0049 0.15 0.0090 0.26 0.26 0.23 – –
0.9 0.0075 0.18 0.0068 0.18 0.012 0.29 0.29 0.23 – –
1.0 0.011 0.21 0.0088 0.21 0.015 0.31 0.32 0.21 0.045 0.29
1.2 0.017 0.27 0.013 0.26 0.021 0.39 0-35 0.27 0.063 0.38
1.4 0.028 0.33 0.017 0.31 0.025 0.44 0.37 0.32 0.078 0.45
1.6 0.046 0.43 0.020 0.34 0.028 0.47 0.39 0.34 0.09 0.52
1.8 0.061 0.45 0.022 0.35 0.029 0.49 0.40 0.36 0.10 0.57
2.0 0.082 0.50 0.024 0.36 0.031 0.50 0.40 0.38 0.11 0.61
2.5 0.138 0.64 0.0258 0.37 0.031 0.50 0.41 0.40 0.13 0.68
3.0 0.194 0.74 0.0260 0.37 0.031 0.50 0.42 0.41 0.14 0.71
4.0 0.269 0.87 0.0264 0.38 0.031 0.50 0.42 0.41 0.14 0.74
∞ 0.4 1.0 0.029 0.4 0.031 0.50 0.43 0.41 0.14 0.75
362
4.2.1.1 Side ratio a/b < 0.5 of the wall load as line load. To allow the edge strengthening to
The required wall thickness is: be assumed as a fixed support, its deflection must not be greater
than 1 % of the length or height, the shorter distance being
2 decisive. The deflection is calculated according to:
p⋅a
=s -------------- , (7)
3σ zul 4
p⋅b⋅a
f = ----------------------------- . (13)
and the maximum deflection is: 1280 ⋅ E ⋅ J
4 Resulting from:
p⋅a
f = ----------------------------------- . (8)
3
k ⋅ 32 ⋅ E c ⋅ s  ---------
5
- + ----------
1
·
p  384 384 p 1
----------- ⋅ -------------------------------- = ------ ⋅ ---------- .
The factor k is to be chosen between 1 (for a < b) and 2 (for a/b ≈ 2⋅5 2 10 128
0.5)
The maximum moment in the edge strengthening amounts to:
4.2.1.2 Side ratio 0.5 ≤ a/b ≤ 2 2
p⋅b⋅a
The minimum wall thickness results from: M = --------------------- . (14)
100
2
β2 ⋅ p ⋅ b From this we obtain for W:
s = ------------------------ (9)
σ zul 2
p⋅b⋅a
W = ------------------------ . (15)
and the maximum deflection is: 100 ⋅ σ zul
4
α2 ⋅ p ⋅ b Frequently the deflection f is given for reasons of design. In this
f = ------------------------- . (10) case the formula
3
Ec ⋅ s
4
p⋅b⋅a
The values for β2 and α2 to be taken from Table 1. J = ---------------------------- . (16)
1280 ⋅ E ⋅ f
4.2.1.3 Side ratio a/b > 2 applies.
The wall thicknesses result from:
4.3 Tanks with all around, strengthenings resting evenly on a flat
2 surface
p⋅b
s = ---------------------- , (11) This construction is preferably used for large tanks. The wall
2.5 ⋅ σ zul
thicknesses have to be calculated individually for each panel.
and the maximum deflection is: The heights of the panels can be determined so that, as far as
possible, equal wall thicknesses result. On the other hand the
4
p⋅b panel heights may be fixed so that each strengthening beam is
f = ---------------------------- . (12) subjected to an equal load. The weight of the strengthenings
3
35 ⋅ E c ⋅ s must not represent an undue additional load upon the tank wall. If
necessary they have to be supported independently from the
4.2.2 Calculation of the edge strengthening tank wall.
The deflection of the edge strengthening is to be calculated as a
4.3.1 Calculation of the side walls
mean between freely supported (f = --------- 5 - ...) and fixed beam
384 The manner of calculation of the individual panels depends on
1 their position and their side ratios. The free panel height bn
(f = ---------- ) with line lead. The edge strengthening takes up 1/5th
384 (n = 1,2,3 ...) is to be put for b in the formulae.
363
4.3.1.1 Calculation of the upper panel 4.3.2 Calculation of the strengthening beams
The relations stated under 4.2.1 apply. For this purpose, the
The beams are calculated as a mean between freely supported
pressure at the last strengthening beam under the edge
and constrained bending beams. This statement is correct only
strengthening is entered in the equations for surface pressure p.
for rigid corner joints of the strengthening beams. The
For b, the uppermost panel height is entered.
corresponding panel load is obtained from an excess pressure pn
4.3.1.2 Calculation of the lower panels
averaged over half the upper and lower panel height, Figure 8.
The lowest beam is to be dimensioned so that its deflection does
For this calculation a mean value of excess pressure pm is not exceed 1 % of the lowest panel height, in order to relieve the
assumed, Figure 8. weld on the tank bottom. The equations for calculating the
strengthening beams, with exception of the edge strengthening,
4.3.1.2.1 Side ratio a/b < 0.5 are as follows:
The calculation is as in subclause 4.2.1.1
4
p n ⋅ b′ ⋅ a
4.3.1.2.2 Side ratio 0.5 ≤ a/b ≤ 2 f = -------------------------- , (21)
128 ⋅ E ⋅ J
The formulae
2
β3 ⋅ pm ⋅ b
2 p n ⋅ b′ ⋅ a
s = ----------------------------- (17) M = -------------------------- , (22)
σ zul 10
4 2
α3 ⋅ pm ⋅ b p n ⋅ b′ ⋅ a
and f = ----------------------------- . (18) W = -------------------------- . (23)
Ec ⋅ s
3 10 ⋅ σ zul
apply. The edge strengthening is to be calculated as in subclause 4.2.2.

The values for β3 and α3 are to be taken from Table 1. For this purpose, the pressure at the last strengthening beam
under the edge strengthening is entered in the equations for
4.3.1.2.3 Side ratio a/b > 2 surface pressure p. For b, the uppermost panel height is entered.
The formulae
4.4 Rectangular tank with yoke strengthening
2
pm ⋅ b
=s ------------------ (19) This construction is to be chosen for tanks where the all around
2 ⋅ σ zul frame is no longer appropriate (very long tanks), Figure 9.
4
pm ⋅ b
and f = ---------------------------- (20) 4.4.1 Calculation of the wall thicknesses of the side walls
3
32 ⋅ E c ⋅ s
The side walls are calculated using the formulae according to
apply. subclause 4.2.1
364
Figure 9. Tank with yoke strengthening (moment curve similar to figure 7).
4.4.2 Calculation of the tank bottom be made preferably free of stiffening. If a cover is provided with
stiffenings, these must be fitted on the top of the cover if the
4.4.2.1 Side ratio a/c < 0.5 medium temperature is > 60°C. If the cover is insufficiently non-
The formulae warping, diagonal stiffenings have to be fitted. The letter a always
designates the longer side.
2
p⋅a
s = ----------------- (24) 4.5.1 Freely supported cover, Figure 10
3 ⋅ σ zul
Loading: For example, moving load 0.0025 N/mm² = 0.025 bar.
4 The formulae:
p⋅a
and f = ----------------------------------- . (25)
3 2
k ⋅ 16 ⋅ E c ⋅ s β5 ⋅ p ⋅ c
s = ------------------------ (30)
σ zul
apply.
The factor k is to be chosen between 1 (for a < c) and 2 (for a/c ≈ α5 ⋅ p ⋅ c
4
0.5) and f = ------------------------- (31)
3
Ec ⋅ s
4.4.2.2 Side ratio 0.5 ≤ a/c ≤ 2
apply.
The formulae
2
β3 ⋅ p ⋅ c
s = ------------------------ (26)
σ zul
4
α3 ⋅ p ⋅ c
and f = ------------------------
-. (27)
3
Ec ⋅ s
apply.
4.4.2.3 Side ratio a/c > 2

The formulae
2
p⋅c
s = ----------------- (28)
2 ⋅ σ zul Figure 10. Reference dimensions.
4 4.5.2 Fixed cover

p⋅c
and f = ---------------------------- . (29)
3 Figures 11 and 12 show reference dimensions for internal and
32 ⋅ E c ⋅ s
external pressure.
apply.
4.5.2.1 Side ratio 1 ≤ a/c ≤ 2
4.4.3 Calculation of the yokes The formulae
The yokes are calculated as continuous beams on two supports 2
with cantilevers on either side, the cantilevers being subject to β3 ⋅ p ⋅ c
s = ------------------------ (32)
triangular load and the beam being loaded with an area load at σ zul
the level of the pressure at the bottom.
4
α3 ⋅ p ⋅ c
4.5 Calculation of the cover and f = ------------------------- (33)
3
The plate theory is to be used for the calculation. The cover is to Ec ⋅ s
365
4.5.2.2 respectively.
4.5.3.2 Calculation of cover stiffening

Formula
2
a ⋅c⋅p
W = --------------------- . (36)
8 ⋅ σ zul
applies. Frequently the deflection is given for reasons of design.

In this case the formula
4
p⋅c⋅5⋅a
J = ----------------------------- . (37)
384 ⋅ E ⋅ f
applies.
4.6 Special cases

apply.
Figure 11. Reference dimensions for internal pressure. 4.6.1 Elevated tanks
In cases where the tank does not rest evenly on the ground but
stands in or on a supporting frame, the tank bottom is to be
calculated according to 4.4.2.
4.6.2 Non-rigid designs

Owing to the very low rigidity of plastics, large area components
frequently are not able to take up the external loading deriving
from bending forces. If the deflection of a panel amounts to more
than half the panel wall thickness, a considerable portion of the
loading is absorbed by membrane forces, i.e. tensile forces. This
means that for the calculation a distinction between several
cases will have to be made which derives from a check of the
expression
4
p⋅b
=N ----------------- (38)
4
Ec ⋅ s
Figure 12. Reference dimensions of external pressure.
4.5.2.2 Side ratio a/c > 2

The formulae
2
p⋅c
s = ----------------- (34)
2 ⋅ σ zul
4
p⋅c
and f = ---------------------------- (35)
3
32 ⋅ E c ⋅ s
apply.
Figure 14. Regions of validity of plate and membrane theory.
4.5.3 Stiffened cover, Figure 13
4.6.2.1 Rigidity N ≤ 30
The relations specified in subclauses 4.2 and 4.6.1 apply.
4.6.2.2 Rigidity N > 30

The relations allowing for bending and stress apply. For a plate
fixed on four sides with uniform area load and a side ratio a/b = 1
the following formulae apply:
2
s = A +B–A, (39)
β3 σ zul
where A = ---------- ⋅ b ---------- (40)
2β 4 Ec
2
p ⋅ b ⋅ β3
B = ------------------------ . (41)
Figure 13. Reference Dimensions. σ zul
4.5.3.1 Calculation of wall thickness and deflection
3 2
The calculation is done according to subclause 4.5.2.1 and f = C+ C +D, (42)
366
3 To subclause 4.2.1.3:
α4 p ⋅ b4 The tank wall here is considered on the one hand as a fixed
where C = --------- ⋅ -------------- (43)
2 Ec ⋅ s beam and on the other hand as a freely supported beam with
triangular load.
9 6
α4 ⋅ s To subclause 4.2.2:
=D -------------------- . (44)
27 ⋅ α 3
3 The bending moment of a beam with line load, which is
considered as a mean between freely supported and fixed, is:
4.6.2.3 Rigidity N > 1000

M = F ⋅ a- .
---------- (47)
In the case of very high N values the membrane equations may 10
be used. (For N = 1000 the error is about 6 % as against the The tank wall is considered as fixed at the bottom and as freely
formulation for N > 30 and a/b = 1). supported at the edge strengthening. Consequently the edge
The following formulae load is 1/5th of the wall load
p⋅a⋅b 1
Ec F = ------------------- ⋅ --- , (48)
s = β 4 ⋅ p ⋅ b ⋅ ------------- (45) 2 5
3
α zul
with p being the pressure at the bottom.
4 This leads to
b ⋅p
and f = α 4 ⋅ 3 -------------- (46)
s ⋅ Ec p⋅a ⋅b
2
M = --------------------- . (49)
apply. 10 ⋅ 10
The values for β3, β4 and α3, α4 are to be taken from Table 1. The same procedure is followed for the deflection [see equation
(13)].
To subclause 4.3.1.2.3:
5 Explanations Here the equation for the uniformly loaded plate fixed on all sides
is on hand.
To subclauses 4.1.1 and 4.2.1.1:
In the equation for s the wall has been assumed as a beam fixed
at both ends with uniform line load. This leads to factor 2 in the 6 Literature
denominator. To provide better agreement with measured
values, the factor was increased to 2.5 and 3 respectively. Bittner, E.: Plates and Tanks (Platten und Behälter), Springer
Verlag, Wien, New York 1965
In the equation for the deflection a factor 32 results in the
denominator when a beam fixed at both ends with uniform line Timoshenko, S.: Theory of Plates and Shells. McGraw Hill Book
load is assumed. However, it is possible here to use the plate Comp. New York/London 1959
equations which exactly correspond to the load case and lead to Stieglat, K., and H. Wippell: Massive plates (Massive Platten),
the factor 68 if a/b ≈ 0.5. An additional factor k was introduced, Verlag W. Ernst & Sohn, Berlin/München 1976
therefore, which, depending on a/b, gives rise to satisfactorily
accurate results. Bouche, Ch.: Dubbels Pocketbook for Engineering (Dubbels
Handbuch für den Maschinenbau) Springer Verlag Berlin/
To subclauses 4.1.2, 4.2.1.2 and 4.3.1.2.3: Heidelberg/New York 1966
The equations for s and f and also the coefficients α and β have
been derived from various sources; see clause 6 "Literature". Kunz, A.: Formulae collection (Formelsammlung) VGB
Technische Vereinigung der Großkraftwerksbetreiber e.V. 1976
To subclauses 4.1.3:
The tank wall here is considered as a cantilever with triangular Franz, G.: Concrete-Calender (Beton-Kalender), Part 1, Verlag
load. Ernst & Sohn, Berlin/München/Düsseldorf 1976
367
368
369
370
371
372
September 2011
DVS – DEUTSCHER VERBAND Non-destructive tests on tanks, apparatus

FÜR SCHWEISSEN UND and piping made of thermoplastics – Technical Code
VERWANDTE VERFAHREN E.V. Dimensional checking and visual inspection DVS 2206-1
Replaces DVS 2206 dated November 1975
1 Scope of application 2.1 Requirements on thermoplastic components

2 Requirements
The requirements relate to:
2.1 Requirements on thermoplastic components
2.2 Requirements on testers/inspectors and testing/inspection – dimensions (e.g. lengths, diameters and wall thicknesses)
materials – angular deviations depending on the component size
3 Tests and inspections – out-of-roundness of the component (ovality)
3.1 Visual inspections
3.1.1 Examination of the execution – surfaces (e.g. roughness, scratches and grooves)
3.1.2 Surface inspections – limiting dimensions (tolerances)
3.1.3 Dimensional check – type of joining technology (e.g. welding, adhesive bonding and
3.2 Testing and inspection of the joints bolting processes)
4 Testing and inspection report and evaluation – external appearance of the manufactured joint (e.g. uniformity
5 Bibliography
and shape)
Appendix 1: Specimen testing and inspection report
– assessment of the joint, inside and outside (e.g. non-destruc-
tive defect evaluation according to the DVS 2202-1 technical
code)
Tables 1 and 2 apply to limiting dimensions which are directly
This technical code applies to dimensional checks and visual influenced by the fabrication of the component (e.g. by welding)
inspections on thermoplastic tanks, apparatus and piping. They unless they are stipulated in other sets of rules (e.g. in the
must meet the corresponding stipulations, e.g. in the Pressure DVS 2205 technical code). For example, this does not apply to
Device Directive, the Water Resources Act or the specially thickness or diameter deviations in so far as they are governed
agreed technical terms of delivery / specifications. by standard sheets for semi-finished products.
Table 1. Limiting dimensions L for lengths L.
Area of Dimensions* in mm
Accuracy
application
class
> 315 > 1,000 > 2,000 > 3,000 > 5,000 > 8,000 > 12,000
L > 20,000
up to 1,000 up to 2,000 up to 3,000 up to 5,000 up to 8,000 up to 12,000 up to 20,000
A e.g. structures
with little heat
±2 ±3 ±4 ±5 ±6 ±7 ±8 ±9
input by weld-
ing
B e.g. structures
with a lot of
±4 ±6 ±8 ± 10 ± 12 ± 14 ± 15 ± 16
heat input by L
welding
C e.g. structures
with which a
greater devia- ±8 ± 12 ± 15 ± 18 ± 21 ± 23 ± 25 ± 27
tion can be per-
mitted
* The dimensions apply to 23  2°C.
If no information about permissible limiting dimensions for length

and angular dimensions is provided on the drawings, an accuracy
class appropriate for the application in question must be taken as
the basis.
373
Table 2. Limiting dimensions for angles. Furthermore, all the limiting dimensions are examined. For exam-
ple, these are out-of-roundness, wall thicknesses, angles and the
Dimensions in mm parallel faces of the flanges.
Accuracy bis 315 > 315 > 1,000 > 2,000
L* 3.2 Testing and inspection of the joints
class up to 1,000 up to 2,000 up to 3,000
It must be checked whether the execution of the joints complies
A ±1 ±2 ±3 ±7 with the agreements or coincides with the design drawing. In
B e* ± 3 ±6 ±9 ± 12 principle, the weld execution must be evaluated according to the
DVS 2202-1 technical code and the adhesive-bonded seam exe-
C ±7 ± 10 ± 14 ± 20 cution according to the DVS 2221 guideline.
* The length L of the shorter leg is regarded as the reference for the limit- In the case of joints which are no longer accessible during the final
ing dimension e of the angles (see Fig. 1). This must always be related to acceptance, an intermediate acceptance must be carried out during
the apex. The lengths of the limiting dimensions (e) for angular dimen- the fabrication.
sions are measured at the outermost point of the reference leg. The limit-
ing dimensions apply to 23  2°C.
4 Testing and inspection report and evaluation
It is necessary to draw up a testing and inspection report. An ex-

ample is specified in Appendix 1.
5 Bibliography
DIN EN ISO Welding – General tolerances for welded struc-

13920 tures – Length and angular dimensions; shape
and position
DIN 862 Calliper gauges; requirements, testing and in-
spection
DIN 866 Geometrical product specifications (GPS) –
Figure 1. Limiting dimension (e) of the angle. Graduated rules and rules for working purposes
– Executions and requirements
2.2 Requirements on testers/inspectors and testing/inspec- DIN 875-1 Geometrical product specifications (GPS) – 90°
tion materials try squares – Part 1: 90° steel try squares
The people commissioned for dimensional checks and visual DIN 2276-1 Inclination measuring facilities; level tubes; di-
inspections must possess the plastics technology expertise and mensions and requirements
experience necessary for this purpose.
DIN 2276-2 Inclination measuring facilities; electronic incli-
The testing/inspection materials must satisfy the requirements in nation measuring facilities; shapes and require-
the relevant standards. ments
Examples: DIN 6403 Tape measures made of steel with a winder
frame or a winder case
– calliper gauge according to DIN 862
– graduated rule according to DIN 866 Technical code Defects in welded joints between thermoplas-
– tape measure according to DIN 6403 DVS 2202-1 tics – Characteristics, description and assess-
ment
– steel try square according to DIN 875-1
– inclination measuring facilities according to DIN 2276 Technical code Calculation of tanks and apparatus made of
DVS 2205-1 thermoplastics – Characteristic values
All the testing/inspection materials must be marked as testing/in-
spection materials and must be subjected to regular calibration. Technical code Calculation of tanks and apparatus made of
DVS 2205-2 thermoplastics – Vertical round, non-pressurised
tanks
3 Tests and inspections Technical code Calculation of tanks and apparatus made of
DVS 2205-3 thermoplastics – Welded joints
3.1 Visual inspections Technical code Calculation of tanks and apparatus made of
DVS 2205-4 thermoplastics – Flanged joints
3.1.1 Examination of the execution
Technical code Calculation of tanks and apparatus made of
During the visual inspections, it is necessary to examine the com- DVS 2205-5 thermoplastics – Rectangular tanks
plete and correct execution of the components/installation accord- Technical code Industrial piping made of thermoplastics – De-
ing to the design stipulations. DVS 2210-1 signing and execution – Above-ground pipe
Supplement 3 systems – Flanged joints: Description, require-
3.1.2 Surface inspections ments and assembly
With good illumination, the component surfaces are visually in- Guideline Qualification testing of plastics adhesive bonders
spected with regard to grooves, notches, inhomogeneities (e.g. DVS 2221 – Pipe joints between PVC-U, PVC-C and ABS
smears), sink marks and miscellaneous damage or manufacturing with solvent adhesives
defects. In cases of doubt, it is necessary to use an illuminated
magnifying glass with an adequate magnifying power (e.g. up to
approx. ten times).
3.1.3 Dimensional check

During the dimensional check, all the main dimensions (e.g. the
external dimensions, the geometrical arrangement of the nozzles,
flanges and miscellaneous attachments) are examined first of all.
374
Appendix 1: Specimen testing and inspection report
Component Materials
Documents Remarks
Works testing and inspection
certificates
Welding record sheets
Testing/inspection
Tests and inspections f = fulfilled, nf = not fulfilled Remarks
standard or stipulation
Visual inspections
Dimensional checks
Miscellaneous
Acceptances Name Date Signature

Internal monitoring
Customer
External monitoring
375
lizensiert für: SLV Nord gGmbH May 2014
Draft
DVS – DEUTSCHER VERBAND Non-destructive testing on pressureless

FÜR SCHWEISSEN UND
VERWANDTE VERFAHREN E. V. tanks and apparatus made Technical Code
of thermoplastic – Leak test 2206-2
Objections to be submitted by 31 August 2014
This draft is being published for review and comment purposes. Suggestions for additions or modifications should be submitted to
DVS e.V., Postfach 10 19 65, 40010 Düsseldorf.
Contents: Execution of the leak test

1 Scope Following conclusion of filling (to below the overflow connecting
2 General piece or to the specified fill height), the actual test period begins.
3 Test method The test period is 24 hours unless agreed otherwise. Within 2
4 References hours of the start and prior to the end of the leak test, the tank
must be subjected to a visual inspection to determine if any of
the test liquid is escaping. The preferred method here is to look
1 Scope at the base-casing weld seam and check for any leaks.
This Technical Code applies to leak testing on pressureless abo-
ve-ground tanks and apparatus made of thermoplastics. Leak Note: So as to be more certain of detecting leaks in the base
tests using negative and/or positive pressure are restricted to area, a foil may be laid under the tank base, depending on the
special applications and are not dealt with in this Technical Code. composition of the tank.
Tests with partial negative pressure may be executed on the ba- The tank may only be drained once the specified test period has
sis of Technical Code DVS 2225-2. elapsed. The outcomes of the visual checks, including all ano-
The standards and/or Technical Codes listed in Table 1 may be malies registered, must be documented informally. In all cases,
used for testing above-ground pipeline systems. the test report must include the following data:
2 General – Allocation to the test and test specimen

– Fill height
The tests covered by this Technical Code are used to verify that – Test conditions (e.g. water temperature when filling, ambi-
the connections to the component are tight, as far as the test ent temperature)
liquid is concerned. The prerequisite for the test is that manufac- – Start and end of test
ture of the component to be tested is complete. – Anomalies (e.g. unusual deformation)
Components made from thermoplastics, e.g. horizontal flat base – Result of the leak test
tanks, are generally not suitable for long-term operation with in- – Test date
ternal positive or negative pressure. Accordingly, this test is usu- – Name and signature of the examiner
ally carried out using water filling.
3 Test method 4 References
Preparation of the leak test
Regulations
If a pressureless tank is to be tested using water, the tank should
be at its final installation location, wherever possible. All the con- DIN 1988-200 Codes of practice for drinking water installa-
necting pieces in the casing must be closed using blank flanges tions - Part 200: Installation Type A (closed
or dummy disc, with the exception of the filling opening and the system) - Planning, components, apparatus,
overflow. Connecting pieces that remain closed during operation materials; DVGW code of practice
must be equipped with the planned blank flange, the seal and the
DIN EN 806-4 Specifications for installations inside buildings
full number of screws. If connecting pieces are joined to a fitting,
conveying water for human consumption -
the relevant fitting should be included in the leak test wherever
Part 4: Installation
possible .
DIN EN Construction and testing of drains and sewers
When filling or draining the tank, it must be ensured, by means of
1610
adequate ventilation, that no unacceptable positive or negative
pressure builds up. Once the tank has been prepared for the leak DVS 2210-1 Industrial piping made of thermoplastics –
test, it must undergo a check prior to filling. Here, care must be Supplement 2 Design and execution – Above-ground pipe
taken to ensure that, for example, the flat base is supported over systems – Recommendations for the internal
its entire area and the tank is set-up vertically. pressure and leak tests
Note: For leak testing on a rectangular tank, the deflection of

the side walls may be determined according to Technical Code
DVS 2205-5.
This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of informa-
tion is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on hand is still valid.
DVS, Technical Committee, Working Group „Joining of Plastics“
Orders to: DVS Media GmbH, P. O. Box 10 19 65, 40010 Düsseldorf, Germany, Phone: + 49 (0) 211/1591- 0, Fax: + 49 (0) 211/1591- 150
376
DVS 2206-2 Page 2
DVS 2210-2 Industrial piping made of thermoplastics – De- DVGW G Pressure testing methods for gas transmission/
signing, structure and installation of two-pipe 469 gas distribution
systems
DVGW W Technical rule on water distribution plants
DVS 2210-3 Industrial pipelines made of thermoplastics – 400-2 (TRVW) - Part 2: Construction and testing;
draft Planning and installation – Underground pipe worksheet
systems
Pressure DIRECTIVE 97/23/EC of the European Parlia-
DVS 2205-5 Calculation of thermoplastic tanks and appara- Equipment ment and of the Council of 29 May 1997 on the
tus – Rectangular tanks Directive approximation of the laws of the Member States
97/23/EC concerning pressure equipment
DVS 2225-2 Joining of lining membranes - Made of polymer
materials in geotechnical and hydraulic engi- Amended by Regulation EEC 1882/2003 and
neering - Site testing Regulation EEC 1025/2012
Table 1: Possible leak tests (for pipelines)

Type Operating liquid Standard or Technical Code Explanations
Liquids Gases
Pressurised pipes installed X DVGW G 469 Gas pipelines
underground
X DVGW W 400-2 Drinking water pipelines
X X Pressure Equipment Pressurised pipelines
Directive
X DVS 2210-3 –
Pressurised pipes installed X X Pressure Equipment Pressurised pipelines
above ground Directive
X DVS 2210-1 BB 2 Industrial pipelines
X DVS 2210-2 Two-pipe systems
X DIN 1988-200:2012-05 Domestic installation
DIN EN 806-4
Non-pressure pipes installed X X DIN EN 1610 Waste water pipelines
underground
Non-pressure pipes installed X X DVS 2210-1 BB 2 Industrial pipelines
above ground
Pipes with negative pressure X DVS 2210-1 BB 2 Industrial pipelines
377
September 2011
DVS – DEUTSCHER VERBAND Non-destructive tests on tanks, apparatus

FÜR SCHWEISSEN UND and piping made of thermoplastics – Technical Code
VERWANDTE VERFAHREN E.V. Testing with electrical high voltage DVS 2206-4
Replaces DVS 2206 dated November 1975
Contents: – Testing devices with pulsed direct voltage

They are suitable for all areas of application but require the
1 Scope of application earthing of the counterelectrode.
2 Materials
– Testing devices with constant direct voltage
3 Test procedure
The constant direct voltage may lead to electrical charging and
3.1 Testing devices
to a permanent change in the electrical properties of the tested
3.2 Execution of the test
plastics and may thus produce testing errors. These devices
4 Limits of the test procedure
are not recommended for the applications dealt with in this
5 Safety notes
technical code.
6 Bibliography
3.2 Execution of the test
The weld region must be dry and free from contaminations. These
may form a coat and thus affect the test. It must be ensured that
This technical code applies to the testing of welded joints on
the entire weld cross-section has cooled down to the ambient
components, piping, apparatus and tanks as well as sealing
temperature before the beginning of the test. The acoustic and
sheets and composite structures made of thermoplastics.
optical perception of an imperfection must be guaranteed during
The test serves to find continuous pores or cracks. The test with the testing. It must be ensured that the testing electrode is in con-
electrical high voltage does not replace either a leak test according tact with the surface to be tested throughout the testing operation.
to the DVS 2206-2 technical code or the DVS 2225-2 technical The test may only be carried out by experienced personnel.
code or an evaluation according to the DVS 2202-1 technical code.
Commercially available testing devices may be equipped with
This technical code is not applicable to electrically dissipative various electrode shapes (e.g. brush, pointed electrode, spherical
plastics. electrode, wire net scrim etc.). The electrodes must be selected
according to the weld geometry.
2 Materials The testing speed should be adjusted depending on the weld
geometry and the wall thickness. It may be as much as 200 mm
The technical code refers to the testing of the welded joints between per second on a plane weld. It should be considerably lower than
the following plastics: this at positions with difficult accessibility (e.g. nozzles) or in the
case of higher wall thicknesses (> 10 mm). Lengthy dwelling
– PE
(> 5 s) of the testing electrode at one position is impermissible
– PP
since this may lead to a decrease in the breakdown strength right
– PVC
up to the destruction of the material.
– fluoroplastics
The following table applies to the test on components in the new
condition. The specified values should be viewed as guide values.
3 Test procedure
This test procedure is based on the principle of the gas discharge Table 1. Guide values for testing voltages.
when electrical high voltage is applied to a discharge section.
The prerequisites for its application are an electrically insulating Wall thickness Testing voltage in kV *
material as well as an electrically conductive counterelectrode. PE, PP and PVC
Continuous imperfections give rise to a sparkover between the (mm) fluoroplastics
electrodes which is visible and audible.
up to 3 10 - 15 15 - 20
3.1 Testing devices
>3-6 15 - 25 20 - 30
The following high-voltage testing devices are utilised:
> 6 - 20 25 - 35 30 - 40
– Testing devices with alternating voltage
These devices do not need any earthing of the counterelec- > 20 - 50 > 35 > 40
trode and do not permit any exact limitation of the voltage
peaks according to their level and duration. * The values were established with spherical electrodes.
378
If wide electrodes (e.g. brush electrodes) are used, it must be 6 Bibliography

borne in mind that a drop in the set voltage may arise across the
electrode width. DIN EN 13121-3 Above-ground tanks and vessels made of
glass-fibre-reinforced plastics – Part 3: Design
Deviating testing voltages are chosen in the case of lap welds be- and manufacture
tween sealing sheets since the possible spark path between the
electrode and the counterelectrode deviates from the wall thickness DIN EN 14879-4 Coatings and linings made of organic materials
considerably (values for testing voltages, see the DVS 2225-1 for the protection of industrial installations
technical code and the DVS 2225-4 technical code). against corrosion caused by aggressive media
– Part 4: Linings for components made of me-
The flashover distance is the distance between the electrode and tallic materials
the counterpole as from which a sparkover occurs. In this re-
spect, exclusively air may be between the electrode and the Technical code Defects in welded joints between thermoplas-
counterpole. Since the flashover distance (spark path in free air) DVS 2202-1 tics – Characteristics, description and assess-
increases along with the air humidity, it must be determined with ment
the chosen electrode in air before the beginning of the test. The Technical code Non-destructive tests on tanks, apparatus and
flashover distance must be greater than the maximum possible DVS 2206-2 piping made of thermoplastics – Dimensional
continuity path (component thickness). Moreover, it must not be checking and visual inspection
so high that it results in a breakdown through the component.
Experience from practice shows that components may have Technical code Joining of sealing sheets made of polymeric
changed their dielectric properties after a lengthy operating time DVS 2225-1 materials in earthwork and water engineering –
depending on the operating medium. Therefore, the testing volt- Welding, adhesive bonding and vulcanisation
ages specified in Table 1 must be reduced considerably. Before Technical code Joining of sealing sheets made of polymeric
the test, deposits must be removed from the weld region which DVS 2225-2 materials in earthwork and water engineering –
must be dry. Site tests
Before the beginning of the test, the type and scope of the report- Technical code Welding of sealing sheets made of polyethyl-
ing must be stipulated between the parties involved. The reporting DVS 2225-4 ene (PE) for the sealing of dumps and con-
must include, at least, the utilised device type, the testing voltage, taminated sites
the electrode type, the scope of testing, the flashover distance, Technical code Welding of sealing sheets made of thermo-
the name of the tester, the place, the date and the test result. DVS 2225-5 plastics in tunnel construction
Relevant Electrical equipment of machines
VDE guidelines
4 Limits of the test procedure
e.g. VDE 0113
The only cracks or holes detected are those which are continuous
and also run nearly vertically to the weld. It must be ensured that
the counterelectrode is not completely embedded in the welding
filler material. It must be fixed in such a way that any impairment
of the weld quality is excluded.
Testing devices available on the market at the moment have a
max. testing voltage of approx. 55 kV. The wall thickness to be
tested is limited by this. (Pay attention to Table 1 and the operating
instructions for the devices!)
Defects in welds such as lack of fusion, isolated pores and voids
etc. cannot be recognised with this test procedure.
5 Safety notes
It is necessary to comply with the applicable ordinances, VDE

guidelines and employers' liability insurance association regulations
as well as with the stipulations of the manufacturers.
Before the devices are used, it must be checked that they are in
the proper condition.
When the device is operated, it must be ensured that neither the
operator nor any external personnel comes into direct contact
with the testing electrode. With regard to the testing, attention
must be paid to suitable clothing. It must be ensured that only ex-
perienced personnel is authorised to operate the device. In any
case, the device must not be operated by any people who wear a
hearing aid, are fitted with a pacemaker or have survived a heart
attack.
Ozone and electromagnetic radiation are released during the
test. Attention must therefore be paid to sufficient ventilation and
to a sufficient safe distance away from electronic devices.
The devices must not be operated in an easily inflammable atmo-
sphere since the spark may give rise to an explosion.
379
September 2011
Non-destructive tests on piping

DVS – DEUTSCHER VERBAND made of thermoplastics –
FÜR SCHWEISSEN UND Angle measurement on welded joints executed by Technical Code
VERWANDTE VERFAHREN E.V. means of sleeve welding with an incorporated heating
element (HM) and heated tool sleeve welding (HD) DVS 2206-5
Contents:
2 Tests and inspections
3 Testing and inspection report and evaluation
4 Bibliography
Appendix: Specimen testing and inspection report
This technical code applies to the determination of the angular

deviation of welded joints executed by means of sleeve welding
with an incorporated heating element (HM) and heated tool
sleeve welding (HD). It applies to rod products.

Figure 1. Principle of the structure of an angle measuriing device with
The angular deviation is measured with an angle measuring device the measuring points.
which uses the front faces of the sleeves as the reference point.
The angle measuring device must be designed in such a way that
it can be adjusted to the different sleeve geometries and diame- 3 Testing and inspection report and evaluation
ters. Fig. 1 shows the principle of the structure of an angle meas-
uring device. The distance between both measuring points (M1 It is necessary to draw up a testing and inspection report. An
and M2) must be min. 100 mm. Measuring Point M1 must be example is specified in the appendix.
chosen as close as possible to the front side of the sleeve but
outside the peeled region. The measuring accuracy must be min.
 0.1 mm. 4 Bibliography
During the measurement, the maximum angular deviation around DVS 2202-1 Defects in welded joints between thermoplastics –
the pipe circumference must be established and documented on Characteristics, description and assessment
both sides of the welding sleeve for the sleeve welding with an
incorporated heating element. The measurement may only be
taken with calibrated measuring devices.
This publication has been drawn up by a group of experienced specialists working in an honorary capacity and its consideration as an important source of
information is recommended. The user should always check to what extent the contents are applicable to his particular case and whether the version on
hand is still valid. No liability can be accepted by the Deutscher Verband für Schweißen und verwandte Verfahren e.V., and those participating in the drawing
up of the document.
380
Appendix: Specimen testing and inspection report
Testing and inspection report: Angle measurement according to DVS 2206-5
Firm:
Name of the welder:
Sampling
Sampling location / building site:
Pipes: Marking
Pipes: Material
Moulding: Marking
Moulding: Material
Welding process:
Diameter of the pipes in mm:

(nominal dimension)
Wall thickness of the pipes in mm:

(nominal dimension)
Testing and inspection
Distance between the measuring

points in mm:
Distance between the first

measuring point and the front side
of the sleeve in mm:
Testing and inspection results
Position of the measurement (time):
Dimensions in mm Dimension 1 1. 2. 3. 4. 5. 6.
Dimension 2 1. 2. 3. 4. 5. 6.
Difference between M1 and M2

in mm:
Maximum difference between

M1 and M2 ( max) in mm:
Result:
Remarks:
Date and signature

of the tester/inspector:
381
Draft July 2014
Welding of thermoplastics –
FÜR SCHWEISSEN UND
Heated element welding of pipes,
piping parts and panels Technical Code
made out of polyethylene DVS 2207-1
Objections to be submitted by October 31st 2014
Intended as replacement for issue dated September 2005
Contents: Assuming adherence to the following instructions, then suitability

within the melt mass flow rate MFR2) 190/5 of 0.20 to 1.70 g/
1 Scope 10 min can be assumed. The restrictions set out in section 4.2 must
2 General requirements be observed when carrying out heated plate welding of saddle-
3 Measures prior to welding type connections.
3.1 Welding requirements In the event of a differing melt mass flow rate, the Suitability Cer-
3.2 Cleaning tificate is to be updated following a tensile creep test in line with
3.2.1 Cleaning agent Guideline DVS 2203-4 or Supplement 1.
3.2.2 Cleaning the heating elements

3.2.3 Cleaning the joint surfaces
4 Heated plate welding 2 General requirements
4.1 Heated plate welding of pipes,
piping parts, fittings and panels The quality of the welded joints depends on the qualifications of
4.1.1 Process description the welders, the suitability of the machinery and equipment being
4.1.2 Preparing for welding used and adherence to the welding guidelines. The seam can be
4.1.3 Performing the welding tested using non-destructive and/or destructive methods.
4.1.3.1 Reference values for the heated plate welding of panels The welding work is to be supervised. The extent and type of the
made of polyethylene supervision is to be agreed between the parties to the contract.
4.1.3.2 Reference values for the heated plate welding of pipes We recommend that the process data be documented in welding
and piping parts made of polyethylene protocols (see example in Appendix) or on data media.
4.2 Heated plate welding of saddle-type connections
As part of the quality assurance process, we also recommend
4.2.1 Process description
that sample seams are produced under working conditions be-
4.2.2 Preparing for welding
fore welding work commences and while it is in progress and that
4.2.3 Performing the welding
these seams are tested.
5 Sleeve welding with incorporated electric heating ele-
ment All welders must be trained and possess a valid Qualification
5.1 Process description Certificate. The intended area of application may dictate the type
5.2 Welding equipment of qualification required. Guideline DVS 2212-1 applies for the
5.3 Preparing for welding heated plate welding of panels and in the field of pipeline con-
5.4 Performing the welding struction.
6 Heated element sleeve welding DVGW leaflet GW 330 applies accordingly as a Qualification
6.1 Process description Certificate for the heated plate welding and sleeve welding of gas
6.2 Welding jigs and water pipes. The requirements set out in leaflets DVS 1905-1
6.3 Preparing for welding and -2 also apply when welding plastics in domestic installations.
6.4 Performing the welding The machinery and equipment being used for welding purposes
7 Checking the welded joints must comply with the requirements of Guideline DVS 2208-1.
8 References
9 Explanation
Appendix: Processing Instructions (summaries) 3 Measures prior to welding
Welding protocols
3.1 Welding requirements
The area in the immediate vicinity of the weld must be protected
1 Scope from adverse weather conditions (e.g. wind, moisture, etc.). Pro-
vided that suitable measures have been implemented (e.g. pre-
This Guideline applies to the heated plate welding of panels heating, tenting, heating) to ensure that conditions are suitable
according to DIN EN ISO 14632 and the heated plate welding, for welding, then the work may be carried out regardless of the
socket welding and sleeve welding according to DIN 8074, 8075, ambient temperature – assuming this does not impair the welder's
DIN EN 12201, DIN EN 1555, DIN EN ISO 15494 of pipes, fittings ability to carry out the work. If necessary, trial welds should be
and saddle-type connections made out of polyethylene1) and which produced under the prevailing conditions as additional evidence
are used for the conveying of gases, liquids and solids. (see Section 7).
1) The material designation should be viewed as a generic term in respect of the thermoplastic group; it includes the types PE 63, PE 80 and PE 100.
The information provided corresponds to the current status of standardisation.
2) Old designation MFI = Melt Flow Index
382
Should the semi-finished product be heated unevenly as the result

of sunlight, then temperature compensation should be carried out Preparation
by promptly covering the area around the welding location.
Draughts can cause cooling during the welding operation so must
be prevented. When welding pipes, it is advisable to seal the
ends of the pipes as well.
Pipe Pipe
When they come off the coil, polyethylene pipes are oval and Heating element
curved. Before welding, the end of the pipe to be welded should
be straightened, for example by gently warming it with a hot gas Preheating
device and/or by employing a suitable clamping or rounding device.
The joining surfaces of the parts to be welded must be undam-
aged and free of any contamination (e.g. dirt, grease, swarf).
Refer to the manufacturer's specifications in the case of pipes
that have an external protective sheath.
Finished joint
3.2 Cleaning
A perfect welded joint will only be produced if the joint surfaces,
tools and heating elements are clean and do not exhibit any trac-
es of grease.
Figure 1. Principle of heated plate welding using a pipe as an example.
3.2.1 Cleaning agent
The cleaning fluid, or any cloths that are delivered from the facto-
The heating element temperature necessary for welding purposes
ry premoistened in a resealable plastic box, must be made from a
must be checked before starting the welding operation. This can
100% evaporable solvent, e.g. consisting of 99 parts ethanol with
be done, for example, by using a fast-acting thermometer that is
a degree of purity of 99.8 and 1 part MEK (methyl ethyl ketone,
suitable for surface measurements and has a contact surface of
denaturing). Material tested according to DVGW VP 603 con-
approximately 10 mm. The test measurement must be carried
forms to this specification. The use of white spirit can result in a
out within the area of the heating element corresponding to the
degradation in quality due to the fact that it contains water.
semi-finished product. In order to achieve a state of thermal equi-
The safety data sheet relating to the cleaning agent must be ob- librium, the heating element must not be used until the target
served. temperature has been stable for at least 10 minutes.
The paper used for cleaning purposes must be clean, previously To achieve an optimal welding result, the heating element must
unused, absorbent, lint-free and non-staining. Ventilate after clean- be cleaned as described in section 3.2.2 before every welding
ing. operation. The anti-adhesive coating or lining of the heating element
within the working area must be undamaged.
3.2.2 Cleaning the heating elements The respective joining forces and/or joining pressures for the ma-
chinery being used must be specified. Reference may be made,
The heating elements must be cleaned with paper before every for example, to the manufacturer's specification, calculated or
welding operation. There must no residues of cleaning agent or measured values. When welding pipes, the movement force/
paper on the heating element. pressure required when moving the workpiece slowly is to be
read off the display on the welding machine and added to the
3.2.3 Cleaning the joint surfaces previously determined joining pressure/force. Electronically con-
trolled machines – ideally with logging facilities – are preferred.
Before machining the joint surfaces, ensure that the tools being
used and the parts remain clean and free of grease over the entire The nominal wall thicknesses in the join area of the parts being
weld area. If necessary, clean with a cleaning agent. welded must match.
The machining of the joining surfaces must take place immedi- Pipes and fittings must be aligned axially before they are
ately before the start of welding. clamped into the welding machine. The slight longitudinal play of
the part being welded can be ensured by using, for example, ad-
Any swarf must be removed without touching the joint surfaces. justable roller blocks or a suspension system.
If the surface becomes contaminated after machining, e.g. through The surfaces to be joined should be machined immediately prior
hand contact, the weld contact areas must be treated with a to welding using a clean, grease-free tool so that they are plane-
cleaning agent if further machining is not possible for technical parallel when clamped. See Table 1 for the permitted gap widths
reasons. under equalising pressure.
Table 1. Maximum gap width between the machined weld contact

4 Heated plate welding areas.
4.1 Heated plate welding of pipes, piping parts, fittings and Pipe outside Gap width Panel width
panels diameter d
[mm] [mm] [mm]
4.1.1 Process description 355 0.5
In heated plate welding, the joining surfaces of the parts to be 400 ... < 630 1.0 1,500
welded are equalised under pressure on the heating element
630 ... < 800 1.3 > 1,500  2,000
(equalising), then warmed under reduced pressure to the welding
temperature (preheating), after which the heating element is re- 800 ...  1,000 1.5 > 2,000  2,300
moved (changeover) and the parts joined under pressure (join-
ing). Figure 1 illustrates the principle behind the process. > 1,000 2.0 > 2,300  3,000
383
A check must be carried out for misalignment at the same time as

the gap width is being checked. Any misalignment of the joint sur- Pressure
faces with respect to each other must not exceed the permitted
tolerance of 0.1  wall thickness on the outside of the pipe or Equalising pressure Joining pressure
panel. Quality degradation will result if the misalignment is any
greater than this, resulting in a reduction in the strength of the
joint connections. In this case, a weld assessment in line with
Guideline DVS 2201-1 can be carried out taking into account the Preheating pressure
demands placed on the joint connection. Time
Changeover time
The machined weld contact areas must not be contaminated nor
be touched by the hands, otherwise they will have to be ma- Preheating time Cooling time
chined again. Additional cleaning is not necessary and does
not result in any improvement in quality. Any swarf that has Equalising Joining pressure build-up time
fallen into the pipe must be removed. time Total joining time
Total welding time
4.1.3 Performing the welding
In the case of heated plate welding, the surfaces to be joined are Figure 2. Stages during the heated plate welding process.
brought up to welding temperature using the heating element, which
is then removed. Pressure is subsequently applied to form the Mechanical loading of the joint is not permitted until the end of
joint. The temperature of the heating element is 220°C ± 10°C. the cooling process at the earliest. The full joining pressure must
Equalising be maintained during the cooling time at ambient temperature –
see Table 2 (or Table 3), column 5.
The joint surfaces that are to be welded are pressed against the
heating element until all the surfaces lie plane-parallel to the No further processing involving full mechanical loading of the
heating element. This can be seen from the shape of the bead. joint may take place until the joint has cooled down completely as
Equalising is complete when the heights of the beads around the shown in Table 2 (or Table 3), column 5.
entire circumference of the pipe, or the top of the panel, reach the A consistent double bead must be present after joining. The bead
values shown in Table 2 (or Table 3), column 2. These bead heights formation provides an indication of the consistency of the welds
indicate that the entire joint surfaces are lying flush against the as a whole. Differing bead formations may be the result of various
heating element. The equalising pressure of 0.15 N/mm² is applied flow patterns in the joined materials. Experience with standard
throughout the equalising process. semi-finished products made of PE 80 and PE 100 in the speci-
Preheating fied MFR range provides an indication of weldability, even if this
can result in non-symmetrical weld beads. K must always be > 0
During preheating, the surfaces must rest against the heating ele- (see Figure 3).
ment with very little pressure. The pressure is reduced to practically
zero ( 0.01 N/mm²). The warmth generated during the preheat-
ing process penetrates the surfaces to be welded and raises their
temperature to the welding temperature. Refer to Table 2 (or
Table 3), column 3 for the preheating times.
Changeover
After preheating, the joint surfaces are detached from the heating
element. Take care when removing the heating element so as
not to damage or contaminate the heated joint surfaces, which
should then be brought together quickly or just before they touch.
The changeover time is to be kept as short as possible – see
Table 2 (or Table 3), column 4 – as otherwise the plastified sur-
faces will cool down. This would have an adverse effect on the Figure 3. Bead formation during heated plate welding (principle using a
pipe as an example).
quality of the weld seam.
Joining
When they touch, the surfaces being welded should be moving at
a speed very close to zero. The required joining pressure is applied,
if possible, in an increasing linear manner. The times required for
this can be seen in Table 2 (or Table 3), column 5. The joining
pressure is 0.15 ± 0.01 N/mm².
384
4.1.3.1 Reference values for the heated plate welding of

panels made of polyethylene
Table 2. Reference values for the heated plate welding of panels made of polyethylene at ambient temperatures up to 40°C and moderate air
movement (intermediate values can be interpolated).
1 2 3 4 5
Nominal wall Equalising Preheating Changeover Joining
thickness s
Bead height on heating Preheating time Changeover time Joining pressure Cooling time
element = 10 x nominal wall (maximum) build-up time (minimum values)
at end of equalising time thickness at joining pressure
(minimum values) (preheating p = 0.15 ± 0.01 N/mm²
(equalising p  0.01 N/mm²)
p = 0.15 ± 0.01 N/mm²)
[mm] [mm] [s] [s]s [s] [min]*)
bis 4,5 0.5 bis 45 5 5 6,5
4,5 ... 7 1.0 45 ... 70 5 ... 6 5 ... 6 6.5 … 9.5
7 ... 12 1.5 70 ... 120 6 ... 8 6 ... 8 9.5 … 15.5
12 ... 19 2.0 120 ... 190 8 ... 10 8 ... 11 15.5 … 24
19 ... 26 2.5 190 ... 260 10 ... 12 11 ... 14 24 … 32
26 ... 37 3.0 260 ... 370 12 ... 16 14 ... 19 32 … 45
37 ... 50 3.5 370 ... 500 16 ... 20 19 ... 25 45 … 61
50 ... 70 4.0 500 ... 700 20 ... 25 25 ... 35 61 … 85
70 … 90 4.5 700 … 900 25 … 30 35 85 … 109
90 … 110 5.0 900 … 1,100 30 … 35 35 109 … 133
110 … 130 5.5 1,100 … 1,300 max. 35 35 133 … 157
*) A reduction in the cooling time of up to 50%, i.e. reduction in joining pressure and removal of the welded part from the welding machine, is permitted in
the following circumstances:
– the joint connection was created under workshop conditions and
– the removal of the part from the welding machine and its temporary storage causes negligible loading of the joint connection.
4.1.3.2 Reference values for the heated plate welding of

pipes and piping parts made of polyethylene
Table 3. Reference values for the heated plate welding of pipes and piping parts made of polyethylene with moderate air movement
(intermediate values can be interpolated).
1 2 3 4 5
Nominal wall Equalising Preheating Changeover Joining
thickness s
Bead height on heating
Preheating time
element
= 10 x nominal wall
at end of equalising time Changeover time Joining pressure
thickness Cooling time
(minimum values) (maximum) build-up time
(preheating
(equalising
p  0.01 N/mm²)
p = 0.15 ± 0.01 N/mm²)
[mm] [mm] [s] [s] [s]
bis 4.5 0.5 bis 45 5 5
4.5 ... 7 1.0 45 ... 70 5 ... 6 5 ... 6
7 ... 12 1.5 70 ... 120 6 ... 8 6 ... 8
12 ... 19 2.0 120 ... 190 8 ... 10 8 ... 11
19 ... 26 2.5 190 ... 260 10 ... 12 11 ... 14
26 ... 37 3.0 260 ... 370 12 ... 16 14 ... 19 see Table 4
37 ... 50 3.5 370 ... 500 16 ... 20 19 ... 25
50 ... 70 4.0 500 ... 700 20 ... 25 25 ... 35
70 ... 90 4.5 700 ...900 25 ... 30 35
90 ... 110 5.0 900 ... 1,100 30 ... 35 35
110 ... 130 5.5 1,100 ... 1,300 max. 35 35
385
Table 4. Cooling times of pipes and piping parts made of 4.2.3 Performing the welding
polyethylene as a function of ambient temperature.
The mould heating element, which will have been preheated to
Nominal wall Cooling time (minimum values) welding temperature (220°C ± 10°C), is positioned between the
thickness s at joining pressure p = 0.15 ± 0.01 N/mm² parts to be welded. The equalising pressure is 0.15 N/mm². After
as a function of ambient temperature bead formation according to Table 5, row 1, and during the now
commencing preheating time, the specific pressure for preheating
Up to 15°C 15°C … 25°C 25°C … 40°C is reduced to  0.01 N/mm². The preheating time is based on the
[mm] [min] [min] [min] data provided by the fitting manufacturer. Once the preheating
time has elapsed, the mould heating element is to be removed,
bis 4.5 4.0 5.0 6.5 taking care not to damage or contaminate the joining surfaces.
4.5 … 7 4.0 … 6.0 5.0 … 7.5 6.5 … 9.5 The changeover time should be as short as possible (maximum
value, see Table 5, row 3). The joining surfaces must then be
7 … 12 6.0 … 9.5 7.5 … 12 9.5 … 15.5
joined immediately.
12 … 19 9.5 … 14 12 … 18 15.5 … 24 The welding equipment must not be removed until everything has
19 … 26 14 … 19 18 … 24 24 … 32 cooled down.
26 … 37 19 … 27 24 … 34 32 … 45
Table 5. Reference values for the heated plate welding of saddle-
37 … 50 27 … 36 34 … 46 45 … 61 type connections made of polyethylene at an ambient tem-
perature of 20°C and with moderate air movement.
50 … 70 36 … 50 46 … 64 61 … 85
70 … 90 50 … 64 64 … 82 85 … 109 Equalising at p = 0.15 N/mm²
Bead height on heating element
90 … 110 64 … 78 82 … 100 109 … 133 1 at end of equalising time
110 …130 78 … 92 100 … 118 133 … 157 Minimum value [mm] 1.0
Preheating at p  0.01 N/mm² according to
Refer to the Appendix for a summary of the Processing Instructions. 2 manufacturer's
Preheating time [s]
information
4.2 Heated plate welding of saddle-type connections
3 Changeover Maximum time [s] 10
The heated plate welding of saddle-type connections is appropri- 4 Pressure build-up [s] 5
ate in conjunction with PE pipes in line with DIN 8075 with a melt
Joining
mass flow rate of 0.7 to 1.3 g/10 min. In the case of PE piping Cooling time at joining pressure
parts with a melt mass flow rate of 0.2 to 0.7 g/10 min, the weld- 5 p = 0.15 N/mm²
ing method is only appropriate in conjunction with a fastening that Minimum value [min] 15
encircles the entire pipe. This latter condition also applies if an
allocation, in particular when retrofitting connections, within the Refer to the Appendix for a summary of the Processing Instructions.
scope of this Guideline is not possible.
The heated plate welding of saddle-type connections must be 5 Sleeve welding with incorporated electric heating
carried out using welding jigs. element
4.2.1 Process description 5.1 Process description

The joining surfaces (pipe surface and inside of fitting) overlap
The joining surfaces of the pipe and saddle-type connection are
and are heated to welding temperature, and hence welded, by
equalised and preheated using heating elements under preheat-
electrical energy with the aid of resistance wires (hot sleeve)
ing pressure. After removing the mould heating element, the join-
located inside the fitting (see Figure 4).
ing surfaces are pressed together with the application of joining
pressure. Joining surface Machined
The heating element temperature necessary for welding purpos-
es must be checked as described in section 4.1.2 before starting
the welding operation.
Fitting Insertion Pipe
To achieve an optimal welding result, the heating element must depth
be cleaned as described in section 3.2.2 before every welding
operation. The anti-adhesive coating of the heating element with-
in the working area must be undamaged.
Immediately before opening the welding equipment, the joint sur-
face of the pipe is to be machined using a scraper or another suit-
able tool. Swarf must be removed without touching the joint sur- Joining plane
face. If the surface is contaminated following machining, e.g. by
touching it with the hands, the joint surface must be cleaned as Figure 4. Sleeve welding with incorporated electric heating element
described in section 3.2.3. The saddle-type connection is always (principle).
to be cleaned as described in section 3.2.3.
5.2 Welding equipment
The roundness of the pipe is to be checked using the clamping
device on the welding equipment or by using separate rounding The welding equipment being used must be suitable for the parts
clamps. Check that the area of the saddle-type connection is ap- being welded. Automatic welding equipment – ideally with log-
propriate. ging facilities – are preferred. The welding equipment must be
able to deliver the parameters required for the fitting being weld-
Before starting to weld, refer to the table provided by the welding ed in each case, namely welding time, amperage and voltage.
equipment manufacturer to determine the forces required for The equipment must shut down automatically as soon as the
equalising and joining. weld zone has received the necessary amount of heat.
386
5.3 Preparing for welding using suitable measures or clamping jigs where necessary. The
components must not be able to move.
Clean surfaces and tension-free installation are critical to the pro-
duction of flawless welded joints. Fittings are much easier to fit if The welding equipment is connected to the fitting to be welded by
pipes with a limited diameter tolerance to DIN 8074 are used. a cable. During welding, the welding cables must be supported
For axial pipe connections, the pipes may have to be cut off at and not left to hang freely. The electrode contact area must be
right angles using a suitable tool. In the case of pipes with a conical clean. The fitting or saddle-type connection data needed to execute
cut edge, the unmachined pipe must have the nominal diameter the weld is generally recorded by scanning a component-specific
d in the planned insertion depth for at least the area of the heated barcode to import the information into the welding equipment.
sleeve (Figure 5). Where necessary the pipe end may have to be The data displayed (e.g. dimensions) must match the component
shortened accordingly immediately before the weld. data. After the welding operation is started this is performed auto-
matically. The duration of welding is normally shown on the welding
The ovality of the pipe must not exceed 1.5% of the outer diameter equipment. Together with other data displayed on the machine,
in the weld area, maximum 3 mm. Suitable rounding clamps may this information must be recorded in the welding protocol, assum-
have to be used where necessary. ing the data is not being saved by any other means.
The surface of the pipe and pipe ends on the fitting must be fully
Note error message! If the current supply is interrupted, a weld
machined in the weld zone. An area larger than the insertion
operation ended prematurely can be repeated once provided that
depth of the sleeve must be processed so that the surface dress-
there are no defects on the fitting or welding equipment (error
ing is still evident after the welding operation. Rotational scrapers
message) and this action is permitted by the fitting manufacturer.
must be used. Approx 0.2 mm of material must be evenly removed.
The full cooling time must be observed before welding is resumed.
Manual scrapers may only be used in exceptional and justi-
fied circumstances. The cables can be removed after the machine has been switched
Check for small annular gaps. off. Any indications of welding on the fitting must be checked. The
joint can only be moved after it has cooled down. More informa-
The end of the pipe must be deburred on the inside and outside, tion on this is provided by the fitting manufacturer. Drilling work
swarf must be removed without the disturbing the joint surface. on saddle-type connections can only begin after the cooling time
The fitting may only be removed from its protective packaging im- has elapsed.
mediately prior to assembly. See the manufacturer's specifications for information on additional
Any contamination that occurs on the machined pipe surface cooling times, e.g. the time required until pressure testing can be
after dressing must be cleaned in accordance with section 3.2.3. started.
Take care to ensure that no impurities are rubbed into the weld
zone. The joint surface of the fitting or saddle-type connection Refer to the Appendix for a summary of the Processing Instructions.
must be cleaned in accordance with section 3.2.3.
6 Heated element sleeve welding
6.1 Process description

Heated element sleeve welding (see Figure 6) is the overlapping
welding of pipe and fitting. Pipe end and fitting are heated to the
Still acceptable Wrong proper welding temperature using a sleeve or spigot-shaped
heating element before being welded together.
The dimensions of the heating elements and fittings are calibrated
to each other so that a joining pressure is built up during joining.
Heating element sleeve welding connections can be executedor
diameters in excess 63 mm due to the amount of joining force re-
quired.
Heated Heated Preparation Heating element

sleeve sleeve
zone zone
Figure 5. Conical pipe end shape.
It must be possible to check the insertion depth of the pipe by

means of either a marking applied to the pipe or a suitable tool.
Sleeve Heating spigot
The fitting must not be inserted at an angle or with any excessive Pipe
force applied to the pipe end (tension-free assembly). The saddle-
Heating bush
type connection must be clamped to the pipe using a suitable jig Preheating
in line with the manufacturer's specifications.
The contact sockets for connecting the welding lead must be
easily accessible.
Fitting and pipe must be at the same temperature before welding
begins. When using welding equipment with an automatic tem-
perature compensation function, it must be ensured that the
measured ambient temperature matches the conditions in the
Finished joint
weld location. It may be necessary to protect the welding equip-
ment, pipe and fitting from direct sunlight, etc.
5.4 Performing the welding

The correct insertion depth must be checked based on the marking.
The components to be welded must be firmly secured in position, Figure 6. Heated element sleeve welding (principle).
387
6.2 Welding jigs

The heating elements are electrically heated and finished with an
anti-adhesive coating.
approx. 15°
6.3 Preparing for welding
The inside of the fitting and the exterior of the pipe must be
cleaned in line with section 3.2.3. The machining of the joining
surfaces on the parts to be welded must take place immediately
before the start of welding. The pipe end must be bevelled as
shown in Figure 7 and Table 6.
The weld seam area of the pipe is not mechanically dressed in
method A.
Method B requires the surfaces of the pipes to be mechanically Figure 7. Bevelling of the pipe end.
dressed in the weld seam area before welding begins.
6.4 Performing the welding
The joining surface on the pipe must be dressed in accordance
with the fitting supplier's specifications. For manual welding oper- For preheating, the fitting and pipe are pushed onto the tools
ations, the insertion depth must then be marked on the pipe end attached to the heating element and fixed in place. How far they
in accordance with the distance l in Table 6. are pushed on depends on the welding method: in the case of
machine welding, the fitting and pipe are pushed on quickly and
Before the start of welding, the heating element temperature of
axially until the set limit stop, while for manual welding they are
250 to 270°C must be checked on the heating elements as per
pushed on up to the marking. The pipe fusion face of the pipe
section 4.1.2.
must not touch against the end of the heated socket under
The heated bush and mandrel must be free of impurities and any circumstances. The preheating time then begins for the
cleaned in accordance with section 3.2.2 before every weld oper- durations listed in Table 7, Column 2.
ation. The anti-adhesive coating of the heated mandrel and socket
Once the preheating time has elapsed, employ a jerking action to
must be undamaged in the weld area.
remove the fitting and pipe from the heated tools and immediately
push them together as far as they will go/to the marking without
twisting (max. changeover time: see Table 7, Column 3).
For manual welds, the parts must be clamped in place for the
time specified in Table 7, Column 4. Only once the cooling time
has been observed (Table 7, Column 5) can the connection be
placed under stress during the remaining installation work.
Refer to the Appendix for a summary of the Processing Instructions.
Table 6. Dimensions for pipe bevel and insertion depth.
Pipe outside Pipe bevel Insertion depth Insertion depth

diameter b Method A Method B
d without mechanical with mechanical
dressing dressing
L l
[mm] [mm] [mm] [mm]
16 13 13
20 14 14
25 15 16
2
32 16.5 18
40 18 20
50 20 23
63 24 27
75 26 31
90 3 29 35
110 32.5 41
125 35 46
388
Table 7. Reference values for the heated element sleeve welding of pipes and fittings made of polyethylene at an ambient temperature of 20°C
and with moderate air movement.
1 2 3 4 5
Heating element
Changeover Cooling
Pipe outside preheat temperature 250 to 270°C
diameter
Preheat time for Preheat time for Changeover time Cooling time
d
SDR2) 11, SDR 7.4, SDR 6 SDR2) 17, SDR 17.6 (maximum) fixiert gesamt
[mm] [s] [s] [s] [s] [min]
16
5 6
20 4 2
25 7
1)
10
32 8
40 12 6 4
20
50 18
63 24
30
75 30 18 8 6
90 40 26 40
110 50 36 50
10 8
125 60 46 60
1) The welding process is not recommended due to the very thin wall thickness.
2) Standard Dimension Ratio ~ d/s. (ratio of outside diameter/wall thickness)
Table 8. Test method for welded joints.
Sleeve welding with

Heated element
Heated plate welding incorporated electric
sleeve welding
Test method heating element
Saddle-type
Plates, pipes, fittings Saddle-type connections Fittings Pipes, fittings
connections
The weld seam must be uni-
DVS 2202-1 DVS 2202-1
form across its entire length.
Visual inspection DVS 2202-1 DVS 2202-1
Mechanical dressing of the pipe surface must be visible
beyond the weld contact area.
DVS 2203-2
Short-term tensile test weld
Tensile test Not applicable
strength reduction factor
DVS 2203-4 Tensile creep
Tensile test weld strength reduction
creep test factor
DVS 2203-5
Minimum bend angle to
DVS 2203-1 Supplement 3,
Technological
Figure 1 and 2. Not applicable
bend test
Minimum bend path to
Figure 7 and 8.
DIN EN ISO DIN 3544-1, DIN EN ISO
Creep rupture
DIN EN ISO 15494, DIN EN ISO 15494, 15494, Section 15494,
internal pressure
Appendix for PE Appendix for PE Appendix for 2.3 and 3.2 Appendix for
test
PE at 80°C PE
Combined torsion
Not applicable DVS 2203-6
shear test
Radial peel test Not applicable DVS 2203-6
DIN EN 12814-4, Section 8;

Crush test Not applicable
also suitable as construction site test
Peel separation Not
Not applicable DIN EN 12814-4, Section 7
test applicable
389
7 Checking the welded joints DIN 3544-1 High-density polyethylene (HDPE) valves; tapping
valves; requirements and test
Different test methods are used for the individual welding pro- DIN 8074 Polyethylene (PE) – Pipes PE 80, PE 100 –
cesses. A distinction is made between non-destructive and de- Dimensions
structive test methods. These are listed in Table 8. Inspections
DIN 8075 Polyethylene (PE) pipes – PE 80, PE 100 – Gen-
and sampling should – insofar as has been agreed – be conducted
eral quality requirements, testing
on a random basis while the welding work is being carried out.
DVGW Welding polyethylene pipes and piping parts
GW 330 (PE 80, PE 100 and PEXa) for gas and water
8 References pipelines; Training and test plan
DVGW Welding supervision of welding work on pipelines
DIN EN ISO Polyethylene (PE) moulding and extrusion materi- GW 331 of PE for gas and water supply; Training and test
1872-1 als. Part 1: Designation system and basis for plan
specifications
DVGW Provisional testing specification for cleaning agents
DIN EN ISO Extruded boards from polyethylene (PE-HD). VP 603 and their containers, for preparation of welded
14632 Requirements and test methods joints on polyethylene pipes
DIN EN ISO Plastics piping systems for industrial applications. Leaflet Quality requirements on businesses – Welding of
15494 Polybutene (PB), polyethylene (PE) and polypro- DVS 1901-1 support structures, rail vehicles and pressure
pylene (PP). Specifications for components and equipment
the system. Metric series
Leaflet Quality requirements on welding companies to
DIN EN Plastics piping systems for the supply of gaseous DVS 1901-2 DIN EN ISO 3834
1555-1 fuels. Polyethylene (PE). Part 1: General
Guideline Imperfections in thermoplastic welding joints –
DIN EN Plastics piping systems for the supply of gaseous DVS 2202-1 Features, descriptions, evaluation
1555-2 fuels. Polyethylene (PE). Part 2: Pipes
Guideline Testing of welded joints of thermoplastic plates
DIN EN Plastics piping systems for the supply of gaseous DVS 2203-1 and tubes – Requirements in the tensile test –
1555-3 fuels. Polyethylene (PE). Part 3: Fittings Supplement 1 Short-term tensile weld strength reduction factor fz
DIN EN Plastics piping systems for the supply of gaseous Guideline Testing of welded joints of thermoplastic plates
1555-4 fuels. Polyethylene (PE). Part 4: Valves DVS 2203-1 and tubes – Requirements in tensile creep test
DIN EN Plastics piping systems for the supply of gaseous Supplement 2 (tensile creep test weld strength reduction factor fs)
1555-5 fuels. Polyethylene (PE). Part 5: Fitness for the Guideline Testing of welded joints of thermoplastic plates
purpose of the system DVS 2203-1 and tubes – Requirements in technological bend
DIN EN Plastics piping systems for water supply, and for Supplement 3 test – Bending angle/bending path
12201-1 drainage and sewerage under pressure. Polyethyl- Guideline Testing of welded joints of thermoplastic panels
ene (PE). Part 1: General DVS 2203-2 and pipes – Tensile test
DIN EN Plastics piping systems for water supply, and for Guideline Testing of welded joints of thermoplastic plates
12201-2 drainage and sewerage under pressure. Polyethyl- DVS 2203-3 and tubes – Tensile impact test
ene (PE). Part 2: Pipes
DIN EN Plastics piping systems for water supply, and for DVS 2203-4 and tubes – Tensile creep test
12201-3 drainage and sewerage under pressure. Polyethyl-
ene (PE). Part 3: Fittings
DVS 2203-4 and tubes – Tensile creep test – Testing of socket
DIN EN Plastics piping systems for water supply, and for Supplement 1 joints
Guideline Testing of welded joints of thermoplastics plates
ene (PE). Part 4: Valves
DVS 2203-5 and tubes – Technological bend test
DIN EN Plastics piping systems for water supply, and for
Guideline Testing of joints between polymeric materials –
DVS 2203-6 Shear and peel tests
ene (PE). Part 5: Fitness for the purpose of the
system Guideline Welding of thermoplastics – Machines and
DVS 2208-1 devices for the heated tool welding of pipes, piping
DIN EN Plastics piping systems for non-pressure under-
parts and panels
12666-1 ground drainage and sewerage. Polyethylene
(PE). Part 1: Specifications for pipes, fittings and Guideline Qualification testing of plastics welders – Qualifi-
the system DVS 2212-1 cation test groups I and II
DIN EN Testing of welded joints of thermoplastics semi- BetrSichV German Ordinance on Industrial Health and Safety
12814-4 finished products. Part 4: Peel test
390
9 Explanation 17. Preheat under reduced pressure  0.01 N/mm², preheat time
as per Table 2 or 3, Column 3.
The guideline has been adapted to present the latest state of the
18. After the end of the preheating phase, detach the joining sur-
art, especially with respect to heated element temperature and
faces to be welded from the heating element and remove the
the cooling times in heated plate welding.
heating element from the welding position.
The heating element temperature for butt welding has been
19. Quickly move the surfaces to be welded together until they
standardised at 220°C for types PE 80 and PE 100. This change
are almost touching within the changeover time (Table 2 or 3,
has simplified usage in real life scenarios.
Column 4). When they touch, they should be moving at a
The cooling times for butt-welded joints on pipes and piping parts speed very close to zero. Immediately afterwards start build-
depend on the ambient temperature. This can result in shorter ing up the joining pressure in a linear manner during the
welding times. build-up time (Table 2 or 3, Column 5).
Depending on the setup (e.g. heating element under the joining 20. A bead must be present after joining at a pressure of 0.15 N/mm².
partners), this ambient temperature-dependent reduction in the As per Figure 3, K must be > 0 at every location.
cooling time cannot be observed when welding plates.
21. Cool down under joining pressure as per Table 2 or 3, Col-
Welding thermoplastic materials in ambient temperatures of less umn 5.
than 5°C is generally considered to be problematic. This has less
to do with the material-specific properties of the plastic than the 22. Release the welded parts after the cooling time has elapsed.
restricted dexterity of the welder. Welding outdoors in any ambi- 23. Complete the welding protocol.
ent temperature therefore requires an environment in which the
welding personnel are able to carry out the individual work steps For 4.2 Heated plate welding of saddle-type connections
without any quality-reducing influences. The manufacturer's
specifications and dewpoint curve must be observed. Each of the
Processing Instructions (summary)
parts to be joined must be at the same temperature. Test welds
must be performed and checked. 1. Establish permissible working conditions, e.g. welding tent.
Any frost, ice and moisture in the joining zone at the end of the 2. Check function of welding equipment.
pipe ( 0.5  fitting length) must be removed during the weld
preparations through the application of heat (e.g. hot-gas ma- 3. Ensure roundness of pipe using a clamping device or round-
ing clamps.
chine). Fittings and saddle-type connections must be stored in
closed, frost-free rooms and only taken to the welding point in the 4. Align and clamp the parts to be welded, e.g. using roller
quantity needed at the time. blocks.
5. Clean the joint surface in the weld area and beyond using a
Appendix: Processing Instructions (summaries) cleaning agent according to sections 3.2.1 and 3.2.3 with
unused, absorbent, lint-free and non-staining paper. Machine
For 4.1 Heated plate welding of pipes, piping parts, fittings and the pipe surface.
panels
6. Remove any swarf in the weld area without touching the joint
Processing Instructions (summary) surface.
1. Establish permissible working conditions, e.g. welding tent. 7. Check that the area of the saddle-type connection is appro-
2. Connect the welding equipment to the mains or the AC gen- priate.
erator and check proper function. 8. Secure the welding equipment to the pipeline.
3. Align and clamp the parts to be welded, e.g. using roller blocks.
9. Clamp and align the saddle-type connection.
4. Seal the pipe ends against draughts.
10. Source a suitable mould heating element.
5. Clean the joint surface in the weld area and beyond using a
11. Clean surfaces to be joined – if not already clean – and the
cleaning agent according to sections 3.2.1 and 3.2.2 with
unused, absorbent, lint-free and non-staining paper. Machine heating element using a cleaning agent according to sections
the surfaces to be joined, e.g. with a planer on pipes. 3.2.1, 3.2.2 and 3.2.3 with unused, absorbent, lint-free and
non-staining paper. Ventilate after cleaning.
6. Remove the planer on the pipe welding machine.
12. Determine the force settings for equalising and joining (table
7. Remove any swarf in the weld area without touching the joint of equipment manufacturer).
surfaces.
13. Check heating element temperature (220°C ± 10°C).
8. Check the parallelism of the planes by placing the joint sur-
faces against each other (maximum gap width as per Table 1). 14. Bring the heating element into the welding position.
9. Check misalignment (maximum 0.1  wall thickness). 15. Equalise the surfaces to the heating element until a bead of
roughly 1 mm forms.
10. Check heating element temperature 220°C ± 10°C.
16. Preheat under reduced pressure  0.01 N/mm², preheat time
11. Clean the heating element using a cleaning agent according as per manufacturer's specifications.
to sections 3.2.1 and 3.2.2 with unused, absorbent, lint-free
and non-staining paper. Ventilate after cleaning. 17. After the end of the preheating phase, detach the joint surfac-
es to be welded from the heating element and move into the
12. Determine the movement pressure/movement force before welding position.
every weld and document it in the welding protocol.
18. Join the surfaces to be welded within the maximum permitted
13. Determine the settings for the equalising pressure, preheat- changeover time of 10 seconds.
ing pressure and joining pressure.
19. Quickly and evenly apply the joining pressure for 5 seconds.
14. Define reference values as per Tables 2 or 3.
20. Allow to cool for at least 15 minutes under joining pressure.
15. Bring the heating element into the welding position.
21. Release the welded parts after the cooling time has elapsed.
16. Equalise the surfaces to the heating element until a bead (in
accordance with Table 2 or 3, Column 2) appears. 22. Complete the welding protocol.
391
For 5 Sleeve welding with incorporated electric heating For 6 Heated element sleeve welding
element
Processing Instructions (summary) Processing Instructions (summary)
1. Establish permissible working conditions, e.g. welding tent. 1. Establish permissible working conditions, e.g. welding tent.
2. Connect the welding equipment to the mains or the AC gen- 2. Connect the welding equipment to the mains or the AC gen-
erator and check proper function. erator and check proper function.
3. Deburr the outside of the pipe end cut at right angles. If the 3. Clean the heating tools using a cleaning agent according to
pipe-end incidence protrudes too far, shorten the pipe. See sections 3.2.1 and 3.2.2 with unused, absorbent, lint-free and
Figure 5. non-staining paper.
4. Ensure the roundness of the pipes using rounding clamps – 4. Check the welding temperature (250 to 270°C).
permissible ovality  1.5%, max. 3 mm. 5. Clean all unmachined joint surfaces using a cleaning agent
5. Clean the joint surface in the weld area and beyond using a according to sections 3.2.1 and 3.2.3 with unused, absor-
cleaning agent according to sections 3.2.1 and 3.2.3 with un- bent, lint-free and non-staining paper. Ventilate after clean-
used, absorbent, lint-free and non-staining paper. Machine ing.
the pipe surface over the insertion depth and beyond using a 6. Bevel the pipe end cut at right angles (see Figure 7 and Ta-
rotational scraper and remove approx. 0.2 mm of wall material. ble 6) and machine according to the fitting manufacturer's
Remove swarf without touching the pipe surface. specifications. Mark the insertion depth if necessary.
6. Clean the machined pipe surface – provided it has subse- 7. Push the fitting and pipe at the same time onto the heating
quently become soiled – and (if specified by the manufacturer) spigot/into the heating bush as far as it will go/up until the
the interior of the fitting using a suitable cleaning agent in line marking. Do not push the pipe end up to the end of the heat-
with 3.2.1 and 3.2.3 with unused, absorbent, lint-free and ing socket.
non-staining paper. Ventilate after cleaning.
8. Maintain the preheat time in accordance with Table 7, Col-
7. Insert the pipes in the fitting and check the insertion depth by umn 2.
means of the marking or a suitable tool. Fasten the saddle-
type connection to the pipe. Ensure low-tension assembly. 9. Employing a jerking action, pull off the fitting and pipe from
Secure the pipe to prevent it moving. the heating elements and immediately push them together to
the marking/as far as they will go (see Table 7, Column 3 for
8. Connect the cable to the fitting. Support the weight of the ca- maximum changeover time) and fix in this position (see Table
ble. 7, Column 4).
9. Input the welding data e.g. using a barcode optical wand. 10. Allow joint to cool. Only subject the welded joint to mechani-
Check the display on the device and start the welding pro- cal load after the cooling time stipulated in Table 7, Column 5
cess. has elapsed.
10. Check the correct welding sequence on the welding ma- 11. Complete the welding protocol.
chine, e.g. by monitoring the display and – if present – weld-
ing indicators. Note error messages.
11. Detach the cable from the fitting.
12. Release the welded parts after the cooling time specified by
the manufacturer has elapsed. Remove the clamping devices
used.
13. Complete the welding protocol, unless the data has been
logged automatically.
392
Material Sheet of
Protocol for heated plate welding of panels
Client Contractor (company) Welding machine:
Title of order Welder’s name ID no. Make:

Type:
Order no. Name and company of welding super- Machine no(s).

visor
Year of construction
Seam Date Plate Measured heating element Settings 2) Preheating Change-over Joining pressure Cooling time under Ambient Remarks
no. thickness temperature 1) time 3) time 3) build-up time 3) joining pressure temperature
Minimum Maximum Equalising Preheating Joining

[mm] [°C] [°C] [bar] [bar] [bar] [s] [s] [s] [min] [°C]
Signature of welder: Date and signature of supervisor:
1) At regular intervals, frequency according to Section 4.1.2.

2) According to the welding machine manufacturer's specifications or the machine inspection.
3) The measured values must be entered.
393
394
Protocol for heated plate welding of pipeline  Installed above ground Material Sheet of
components  Installed underground
Client Contractor (company) Welding machine: Weather Safety precautions:
1 = Sonny 1 = None
Title of order Welder’s name ID no. Make: 2 = Dry 2 = Screem
Type: 3 = Rain or snow 3 = Time
Order no. Name and company of welding Machine no(s).: 4 = Wind 4 = Heating
supervisor
Year of construction: For multiple responses, specify the numbers in the same sequence as above
(e.g. 34 = rain and wind)
Seam Date Pipe data Measured heating Movement Joining pressure Settings 2) Preheating Change-over Joining pressure Cooling time Ambient Code no.
no. dxs element temperature 1) pressure (machine table) time 3) time 3) build-up time 3) under joining pressure temperature
Minimum Maximum Equalising Preheating Joining Weather Protection

[mm] [°C] [°C] [bar] [bar] [bar] [bar] [bar] [s] [s] [s] [min] [°C]
Signature of welder:: Date and signature of supervisor:
1) At regular intervals, frequency according to Section 4.1.2.

2) According to the welding machine manufacturer's specifications or the machine inspection.
Protocol for sleeve welding with incorporated electric  Installed above ground Material Sheet of
heating element of pipeline components  Installed underground
1 = Sonny 1 = None
supervisor
Seam Date Pipe data Moulding data Equipment setting Moulding Secondary Welding times Ambient Code no. Operating mode
no. resistance voltage temperature
A B Serial no. Manual Automatic Heating Cooling Weather Safety precautions Mains Generator
[mm] [Ohm] [Volt] [s] [min] [°C]
⌀dxs
1) Where required, entries for the system used. A = Manufacturer abbreviation 1 = Sleeve 2 = Bracket 3 = T-piece 4 = Reducer
2) The measured values must be entered. B = Moulding code number 5 = Calliper 6 = Cap 7 = Transition piece
395
396
Protocol for heated sleeve welding of pipeline  Installed above ground Material Sheet of
components  Installed underground
1 = Sonny 1 = None
supervisor
Seam Date Pipe data Moulding data 1) Measured temperature Preheating Change-over Cooling time Ambient Code no. Remarks
no. time time temperature
A B Serial no. Heating spigot Heating bush Fixed Total Weather Protection
[mm] [°C] [°C] [s] [s] [s] [min] [°C]
⌀dxs
1) Where required, entries for the system used. A = Manufacturer abbreviation 1 = Sleeve 2 = Bracket 3 = T-piece 4 = Reducer
2) The measured values must be entered. B = Moulding code number 5 = Calliper 6 = Cap 7 = Transition piece
File-Name:
D:\Eigene Dateien\Kunden\DVS\Ri+Me\2207\e2207-1\e2207-1.fm
August 2007
DVS – DEUTSCHER VERBAND Welding of thermoplastics

FÜR SCHWEISSEN UND Heated tool welding of pipes, pipeline Technical Code
VERWANDTE VERFAHREN E.V. components and sheets made of PE-HD DVS 2207-1
Translation of the German version september 2005
Content: 2 General requirements
1 Scope The quality of welded joints depends on the qualification of the

2 General requirements welder, the suitability of the utilized equipment and devices as
3 Measures before welding well as on compliance with the welding standards. The welded
3.1 Requirements for welding joint can be tested by means of non-destructive and/or
3.2 Cleaning destructive methods.
3.2.1 Cleaning agents
The welding work must be monitored. Type and range of
3.2.2 Cleaning of heated tools
supervising has to be agreed between the contract partners. It is
3.2.3 Cleaning of joining areas
recommended to record the welding data in welding protocols
4 Heated tool butt welding
(sample see appendix) or on data carriers.
4.1 Heated tool butt welding of pipes, pipeline components,
fittings and sheets Within the framework of the quality assurance it is recommended
4.1.1 Description of the process to produce and test samples of joints before and during welding.
4.1.2 Preparation of welding
4.1.3 Welding procedure Every welder has to be trained and has to be in possession of a
4.2 Heated tool welding of tapping tees valid qualification certificate. The intended application range may
4.2.1 Description of the process be decisive for the kind of qualification. For the heated tool butt
4.2.2 Preparation of welding welding of sheets as well as in the industrial piping system
4.2.3 Welding procedure construction, the technical code DVS 2212-1 is valid. The
5 Electro-socket welding DVGW-specification GW 330 applies analogously as qualification
5.1 Description of the process proof for heated tool butt and heated tool socket welding at the
5.2 Welding device construction of gas and water supply systems. The welding of
5.3 Preparation of welding plastics for indoor applications is described in the technical codes
5.4 Welding procedure DVS 1905-1 and -2.
6 Heated tool socket welding The equipment and devices which are used for welding must
6.1 Description of the process comply with the requirements in DVS 2208-1.
6.2 Welding devices
6.3 Preparation of welding
6.4 Welding procedure 3 Measures before welding
7 Testing of welded joints
8 Standards and directives 3.1 Requirements for welding
9 Explanations
The welding zone must be protected against bad weather
Appendix:
influences (e.g. wind, moisture). If it is ensured by suitable
Processing instructions (short versions)
measures (e.g. preheating, tent, heating) that the conditions are
suitable for welding, work may be carried out at any outside
Welding protocols
temperature insofar as the welder is not hindered in his handling
(see explanation). If necessary, an additional proof must be
1 Scope provided by carrying out sample welds under the mentioned
conditions (section 7).
This technical code applies to the heated tool butt welding of
sheets according to DIN EN ISO 14632 and for the heated tool If the semi-finished product is heated up unevenly under
butt-, the heated tool socket- and the electro-socket welding of influence of sunshine, a temperature compensation in the area of
pipes, fittings and tapping tees made from PE-HD1) according to the welding joint can be reached by covering. A cooling down
DIN 8074 and 8075, DIN 16 963, DIN 3543-4 and DIN 3544-1, during the welding process by ventilation has to be avoided.
being used for the conduction of gas, fluids and solids. During welding the pipe ends have to be closed additionally.
With regard to the following instructions, suitability within the melt PE-HD-pipes from coils are oval and bent immediately after
flow rates MFR2) 190/5 of 0,3 up to 1,7 g/10 min or 0,2 up to 0,7 uncoiling. The pipe end must be prepared before welding, e.g. by
g/10 min respective may be assumed. For the heated tool butt careful heating up with a hot-air equipment and/or use of a
welding of tapping tees restrictions according to section 4.2 have suitable clamping res. re-rounding device.
to be attended.
The joining zones of the components to be welded must be
Deviating MFR values require an additional proof by tensile creep undamaged and have to be free of contaminations (e.g. dirt,
tests according to DVS 2203-4 or supplement 1. grease, shavings).
The material indication is the specification of thermoplastics group and includes the types PE 63, PE 80 and PE 100. The information complies to the
current standards.
old indication MFI = Melt Flow Index
DVS, Technical Committee, Working Group ″Joining of Plastics″
397
3.2 Cleaning 4.1.2 Preparation of welding
For the production of perfect welded joints it is very important that Prior to the start of the welding process, the welding temperature
the joining areas as well as the tools and heated tools are clean of the heated tool is to be checked. This is done e.g. by means of
and free of grease. a fast-indicating measuring device with a contact surface of 10
mm for measuring the surface temperature. The control
3.2.1 Cleaning agents measurement must be done within the area on the heated tool
which corresponds to the semi-finished product. For adjusting a
The cleaning agents or already moistened cloths in a lock-up thermal balance, the heated tool may be inserted at the earliest
plastic box have to consist of a 100 % vaporizing solvent, e.g. 99 10 minutes after reaching the set temperature.
parts ethanol with a purity grade of 99,8 % and 1 part MEK
(methylethylketone, denaturation). Agents tested according to To ensure an optimum welding connection the heated tool has to
DVGW 603 comply with this requirement. The use of ethyl be cleaned according to section 3.2.2 before every welding
alcohol could result in a reduction of quality because of the operation. The anti-adhesive coating or covering of the heated
contained water. tool must be free of damages in the working zone.
The paper for cleaning has to be clean, unused, absorbent, non- The joining forces and joining pressures have to be specified for
fuzzy and non-coloured. Exhaust the air afterwards. the machines to be used. These can be based on e.g. manu-
facturer information, calculated or measured values. Additionally,
3.2.2 Cleaning of heated tools at the welding of pipes, the work piece moving force res. moving
The heated tools have to be cleaned with paper before every pressure is taken from the indicator of the welding machine
welding process. No residues of cleaning agents or paper may during the slow displacement of the part to be welded and have
remain on the heated tool. to be added to the prior determined joining force res. joining
pressure. Electronically controlled equipment is preferred, if pos-
sible with recording.
3.2.3 Cleaning of joining areas
Before machining the joining areas it has to be ensured that the The nominal wall thickness of the parts to be welded must match
utilized tools and components are clean and free of grease even in the joining area.
outside the welding zones, if necessary use a cleaning agent. Pipes and fittings have to be aligned in axial direction in the
The treatment of the joining areas has to be done directly before welding machine before the clamping. The easy axial movement
the welding process starts. of the part to be welded-on can be ensured e.g. by means of
dollies or swinging suspension.
Any shavings have to be removed without contacting the joining
areas. The joining areas have to be planed with a clean and grease-free
tool directly before the welding so that they are coplanar in
In case of contamination of the surface after machining, e.g. by clamped condition. Permissible gap width under alignment
contact with hands, the joining areas have to be treated with a pressure see table 1.
cleaning agent if a further machining is impossible.
Table 1. Maximum gap width between the treated welding zones.

Pipe outside diameter d Gap width Sheet width
mm mm mm
4.1 Heated tool butt welding of pipes, pipeline components,
fittings and sheets ≤ 355 0,5
4.1.1 Description of the process 400 ... < 630 1,0 ≤ 1500
With the heated tool butt welding process, the joining zones of 630 ... < 800 1,3 > 1500 ≤ 2000
the components to be welded are aligned under pressure on the
heated tool (alignment), heated up to the welding temperature 800 ... ≤ 1000 1,5 > 2000 ≤ 2300
with reduced pressure (heating up) and joined under pressure
> 1000 2,0 > 2300 ≤ 3000
(joining) after removal of the heated tool (changeover). Figure 1
shows the principle of this procedure.
Both, the gap width and the misalignment have to be controlled.
The misalignment of the joining areas on the pipe outside or
sheet respectively may not exceed the permissible size of 0,1 x
wall thickness. A reduction of the quality arises in case of larger
misalignment which limits the strength of the joint. In this case,
the evaluation according to DVS 2202-1 under consideration of
requirements to the joint can be done.
The treated welding areas should be neither dirtied nor touched
by hand, as a retreatment would be necessary then. An
additional cleaning is not necessary and means no quality
improvement. Shavings fallen into the pipe have to be removed.
4.1.3 Welding procedure

With heated tool butt welding the joining areas are heated-up to
the welding temperature by means of the heated tool and joined
under pressure after removing the heated tool. The heated tool
temperature is 200 to 220 °C. In principle the upper temperature
limit is to be aspired for smaller wall thickness, the lower
temperature limit for bigger ones (see figure 2). The upper
temperature has to be chosen for PE 100 as well. The different
Figure 1. Principle of the heated tool butt welding of a pipe. steps of the welding process are illustrated in figure 3.
398
when the bead heights have reached the mentioned values in

table 2, column 2 on the total pipe circumference or the total
sheet surface respectively. The bead sizes are an index for a
complete contact of the joining areas on the heated tool.
Heating-up
For heating-up, the joining areas must contact the heated tool
with low pressure. The pressure is reduced to nearly zero (≤ 0,01
N/mm2). During heating-up, the heat penetrates the joining areas
and the welding temperature is reached. Heating-up times are
given in table 2, column 3.
Changeover
After heating-up, the joining areas are to be detached from the
heated tool. The heated tool should be withdrawn without
damage or contamination of the heated joining zones. The joining
areas should be joined together quickly until they almost have
Figure 2. Recommended values for the heated tool temperatures as contact. The changeover time should be as short as possible
function of the wall thickness.
(see table 2, column 4), as otherwise the plasticized areas will
cool down. The welding joint quality would be influenced
negatively.
Joining
The areas to be welded should meet with a speed of nearly zero.
The demanded joining pressure is built possibly linear. The
required times are shown in table 2, column 5. The joining
pressure is 0,15 ± 0,01 N/mm2.
Raised mechanical loads during or directly after the declamping
are allowed only after finished cooling. The joining pressure has
to be kept completely during the cooling time at ambient
temperature (see table 2, column 5).
The reduction of the cooling time up to 50 %, that means joining
pressure release and removal of the welded part from the
welding equipment, is allowed under the following requirements:
– the welding is done under workshop conditions
Figure 3. Process steps of heated tool butt welding.
– the removal from the welding equipment and the temporary
storage are causing only slight loads to the joint
Alignment
– it concerns components with a wall thickness of ≥ 15 mm.
The joining areas of the welding components are pressed to the
heated tool until all areas are coplanar on the heated tool. This A further treatment with full mechanic load of the joint is allowed
fact is visible on the formation of beads. The alignment is finished only after complete cooling down according to table 2, column 5.
Table 2. Recommended values for the heated tool butt welding of pipes, fittings and sheets made of PE-HD at an outside temperature of
approx. 20 °C and moderate air flow (interim values have to be interpolated).
1 2 3 4 5
Nominal wall Alignment Heating-up Changeover Joining
thickness s
Heated tool temperature see figure 2 Changeover time Joining pressure Cooling time
(Maximum time) build-up time under joining pressure
Bead height on Heating-up time (minimum values)
heated tool =10 x wall
p = 0,15 N/mm2 ± 0,01
on the end of the thickness
alignment time p= ≤ 0,01 N/mm2)
(alignment p =
0,15 N/mm2)
mm mm s s s min
up to 4,5 0,5 up to 45 5 5 6
4,5 ... 7 1,0 45 ... 70 5 ... 6 5 ... 6 6 ...10
7 ... 12 1,5 70 ... 120 6 ... 8 6 ... 8 10 ...16
12 ... 19 2,0 120 ... 190 8 ... 10 8 ... 11 16 ... 24
19 ... 26 2,5 190 ... 260 10 ... 12 11 ... 14 24 ... 32
26 ... 37 3,0 260 ... 370 12 ... 16 14 ... 19 32 ... 45
37 ... 50 3,5 370 ... 500 16 ... 20 19 ... 25 45 ... 60
50 ... 70 4,0 500 ... 700 20 ... 25 25 ... 35 60 ... 80
399
After the joining, a uniform double-bead must appear. The bead heating-up is reduced to ≤ 0,01 N/mm2 during the now starting
size shows the regularity of the welds. Different beads could be heating-up time. The heating time depends on data provided by
caused by different melt flow behaviour of the joined materials. the manufacturer of the fitting. When the heating time has
Based on the experience with commercial semi-finished products elapsed the shaped heating tool is to be withdrawn without
made from PE 80 and PE 100 with the mentioned MFR-range the damaging and contamination of the joining area. The changeover
weldability can be assumed, even if it results in asymmetric time should be as short as possible (maximum value see table 3,
welding beads. K has to be always > 0 (see figure 4). line 3). The joining areas should be joined together promptly
afterwards.
After complete cooling the welding device may be removed.
Table 3. Recommended values for the heated tool butt welding of

tapping tees made of PE-HD at outside temperature of
20 °C and moderate air flow.
1 Alignment under p = 0,15 N/mm2

Bead heights on heated tool
at the end of the alignment time
Min. value [mm] 1,0
2 Heating-up under p ≤ 0,01 N/mm2 acc. to
Figure 4. Bead formation at heated tool butt welding (principle) of a pipe. Heating-up time [s] manufacturer
data
Short version of processing instructions see appendix.
3 Changeover Max. time [s] 10
4.2 Heated tool butt welding of tapping tees 4 Joining pressure build-up time 5
The heated tool butt welding of tapping tees is applicable with
Joining
Cooling time under joining
PE-HD pipes according to DIN 8075 of melt-flow index values of
pressure
0,7 up to 1,3 g/10 min. For piping system components made of
PE-HD with MFI values of 0,2 up to 0,7 g/10 min the welding 5 p = 0,15 N/mm2
process is applicable only in conjunction with a reinforcement
embracing the pipe. The last-mentioned condition is also valid if, Min. value [min] 15
especially in the case of fittings attached at a subsequent stage,
an attribution within the scope of this standard is not possible. Short version of processing instructions see appendix.
Heated tool butt welds of tapping tees have to be carried out by
means of welding devices. 5 Electro-socket welding
4.2.1 Description of the process 5.1 Description of the process
The connection zones of pipe and tapping tee are aligned and The joining areas (pipe surface and inside of the fitting) are
heated up by means of a shaped heated tool under alignment overlapped and welded by resistance wires inside the fitting
pressure. After removal of the shaped heated tool the joining (heating coils) which are heated up by electrical energy (see
faces are joined under joining pressure. figure 5).
4.2.2 Preparation of welding
Prior to the start of the welding process, the welding temperature
set on the heated tool is to be checked according to section
4.1.2.
To ensure an optimum welding connection the heated tool has to
be cleaned according to section 3.2.2 before every welding
operation. The anti-adhesive coating of the heated tool must be
free of damages in the working zone.
Prior to clamping into the welding equipment the joining surface
of the pipe has to be scraped with a trimming blade or another
suitable tool. Shavings have to be removed without contacting
the joining area. The treated welding areas should be neither
dirtied nor touched by hand, otherwise cleaning of the joining Figure 5. Electro-socket welding (principle).
areas according to section 3.2.2 is necessary. The tapping tee
always has to be cleaned according to section 3.2.3. 5.2 Welding equipment
The roundness of the pipe is to be ensured by the clamps of the Only welding equipment adjusted to the parts to be welded may
welding equipment or special re-rounding devices. The fit of the be used. Automatic welding equipment is preferred – possibly
tapping tee face is to be controlled. with recording. The welding equipment must supply the required
Prior to welding the required forces for alignment and joining welding parameters for the fitting to be welded such as welding
have to be determined from the table provided with the time, current and voltage. The device must switch off as soon as
equipment. the necessary quantity of heat has been fed to the welding zone.
4.2.3 Welding procedure 5.3 Preparation of welding

The shaped heated tool, heated to the welding temperature (200 Clean surfaces and a stress free installation are very important
up to 220 °C) is introduced between the welding components. for the fabrication of perfect welded joints. With the choice of
The alignment pressure is 0,15 N/mm2. After beads have formed pipes with limited diameter tolerance according to DIN 8074 the
according to table 3, column 1, the specific set pressure for installation of fittings is easier.
400
For axial pipe connections the pipes have to be cut rectangular welding process it runs automatically. The welding time is usually
by means of a suitable device. In case of a bevelled shrinkage of shown on the welding equipment. It has to be transferred to the
the pipe cut edge the un-treated pipe has to show the nominal welding protocol as well as other data from the welding machine,
diameter d (figure 6) at the designated insert depth minimum in if no data recording is done.
the area of the heated socket. If necessary the pipe end should Consider error message! If there should be any interruption to the
be shortened immediately before welding. power supply in the early part of the welding process, the welding
may be repeated as long as no visible defects on the fitting or
error messages with the welding equipment have appeared, and
the fitting manufacturer has given his permission for re-welding to
take place.
The joining area (pipe and fitting) must be cooled down
completely before the welding process is started again.
The cables can be removed after switching off the equipment.
Check the welding indicators if available on the fitting. The
connection may be moved only after cooling down. The fitting or
mounting manufacturer supplies corresponding information. The
drilling of tapping tees may be done only after finished cooling
time.
Details from the manufacturer about additional cooling times, e.g.
till the pressure test, have to be considered.
Short version of handling instructions see appendix.
6 Heated tool socket welding

Figure 6. Bevelled shrink of the pipe end.
6.1 Description of the process
The ovality of the pipe may not exceed 1,5 % of the outside At heated tool socket welding (see figure 7), pipe and pipeline
diameter, max. 3 mm. If necessary, re-rounding devices can be components are welded in overlapped condition. Pipe end and
used. fitting are heated up to welding temperature by a socket or
The surface of the pipe or fitting in the welding zone has to be spigot-shaped heated tool and subsequently joined together.
completely machined. A scraping tool with a constant wall Heated tools and fittings are dimensionally adapted so that on
thickness removal of approx. 0,2 mm should be used. Take care joining a joining pressure will be built-up. Heated tool socket
for a small annular gap! welding can be performed manually up to 50 mm pipe diameter.
At diameters as from 63 mm, a welding device is required
The pipe end has to be deburred inside and outside, shavings
because of the higher joining force.
have to be removed without contacting the joining areas.
The fitting may only be removed from the protective package
immediately before the installation.
In case of contamination of the pipe surface after machining it
must be cleaned according to section 3.2.3. It has to be
considered that no contamination is rubbed into to the welding
zone. The joining area of the fitting or tapping tee respectively
has to be cleaned according to section 3.2.3.
The insert depth of the pipe has to be controllable by an added
mark or suitable device. The fitting may neither be tilted nor
pushed onto the pipe end with force (low stress installation). The
tapping fitting has to be clamped on the pipe by means of a
suitable device under consideration of the manufacturer’s
instructions.
The contact socket for the connection of the welding cable must
be easy reachable.
Fitting and pipe have to show the same temperature level before
the welding process. Concerning welding equipment with
automatic temperature compensation, take care that the
measured environmental temperature corresponds to the
conditions of the welding location. If necessary the welding Figure 7. Heated tool socket welding (principle).
equipment as well as the pipe and fitting have to be protected
e.g. against direct sun radiation. 6.2 Welding device
5.4 Welding procedure The heated tools are heated electrically and are coated anti-
adhesively.
The correct insert depth has to be controlled by means of the
mark. The components to be welded should be secured against 6.3 Preparation of welding
dislocation.
The fitting has to be cleaned inside and outside according to
The welding equipment is connected by a cable with the part to section 3.2.3. The treatment of the joining areas of the welding
be welded. The welding cable has to be placed without weight components should take place immediately before welding is
loaded. The contact areas must be clean. The required data of started. The pipe end has to be bevelled according to figure 8
the fitting or tapping tee for the welding process are taken and table 4. The joining area of the pipe is to be treated
automatically from the welding equipment by scanning the according to the manufacturers guidelines. Concerning manual
specific component barcode. The shown data (e.g. dimension) welds the insert depth is to be marked on the pipe with distance I
have to comply with the component data. After starting the according to table 4.
401
Before welding starts the welding temperature (250 to 270 °C)
set on the heated tool has to be controlled according to section
4.1.2.
Heating socket and heating spigot must be free of
contaminations and should be cleaned before welding according
to section 3.2.2. The anti-adhesive coating of the heating spigot
and heating socket must be free of damages in the welding area.
6.4 Welding procedure

For the purpose of heating, fitting and pipe are pushed swiftly and
axially onto the devices fitted on the heated tool and held until the
stop at machine welding or until the mark at manual welding. It
has to be absolutely avoided that the pipe is pushed onto
the end of the heating socket. Afterwards the heating-up time
starts according to the time values in table 5, column 2.
Figure 8. Bevelling of the pipe end. After the heating time has elapsed, the fitting and pipe should be
withdrawn sharply from the heated tool and pushed together
immediately without any twisting until the stop or mark (maximum
Table 4. Values for pipe chamfer and insert depth. adjusting time see table 5, column 3).
At manual welding the joined components have to be kept fixed
Pipe outside diameter Pipe chamfer Insert depth according to the time mentioned in table 5, column 4. The
d [mm] b [mm] l [mm] connection may be loaded by further installation works only after
16 13 cooling time is over (table 5, column 5).
20 14 Short version of handling instructions see appendix.
25 16
2 7 Testing of welded joints
32 18
40 20 Various tests can be used to test the quality of individual welding
processes. Differentiation is made between destructive and non-
50 23 destructive tests. For details see table 6. Tests and sampling can
63 27 be carried out prior to or during welding work according to
agreement.
75 31
90 3 35
110 41
125 46
Table 5. Recommended values for the heated tool socket welding of pipes and pipeline components made of PE-HD at outside temperature of
20 °C and moderate air flow.
1 2 3 4 5
Pipe outside Heating-up Changeover Cooling
diameter d
Heated tool temperature 250 up to 270 °C
Heating up time for Heating up time for Changeover time Cooling time
SDR2) 11, SDR 7,4, SDR 6 SDR2) 17, SDR 17,6 (Maximum time)
fixed total
mm s s s s min
16
5 6
20 4 2
25 7
1)
10
32 8
40 12 6 4
20
50 18
63 24
30
75 30 18 8 6
90 40 26 40
110 50 36 50
10 8
125 60 42 60
1) Due to the low wall thickness this welding method is not recommended.
2) Standard Dimension Ratio ~ d/s (ratio outside diameter / wall thickness).
402
Table 6. Test methods for weld joints.
Test method Heated tool butt welding Electro socket welding Heated tool socket welding
Sheets, pipes, fittings Tapping tees Fittings Tapping tees Pipes, fittings
DVS 2202-1 Smooth welding joint on DVS 2202-1 DVS 2202-1 DVS 2202-1
Table 1 the complete Table 3 Table 3 Table 2
Visual test circumference
Mechanical treatment of pipe surface has to be visible also
outside of the welding area.
Radiographic
applicable. Statement about e.g. voids is possible, but not about the quality.
and X-ray test
DVS 2203-2;
Short-term welding
Tensile test non applicable
factor
DVS 2203-1, Suppl. 1
DVS 2203-4;
Tensile creep tensile creep welding
test factor
DVS 2203-5.
Minimum bending
angle acc. to
DVS 2203-1, Suppl. 3,
Technological
Figures 1 and 2 non applicable
bending test
Minimum bending
distance acc. to
DVS 2203-1, Suppl. 3,
Figures 7 and 8
DIN 16963-5, section
5.4.3.1,
Internal Length of each pipe DIN 3544-1,
DIN 16963-5,
pressure piece DIN 3544-1, sections 2.3 sections 2.3 DIN 16963-5,
section
creep rupture acc. to table 6. and 3.2 at 80 °C and 3.2 section 5.4.3.1
5.4.3.1
test Non meaningful for at 80 °C
long-term welding
factor > 0,5
Torsion shear
non applicable see appendix. Also applicable as site test for pipe wall thickness ≥ 4 mm.
test
Radial
non applicable see appendix. Also applicable as site test for pipe wall thickness ≥ 4 mm.
peeling test
Compression
non applicable DIN EN 12814-4, section 8. Also applicable as site test.
test
Peeling test non applicable DIN EN 12814-4, section 7 non applicable
8 Standards and technical codes DIN EN ISO Thermoplastic piping systems for industrial
15494 applications; Polybutene (PB), Polyethylene
DIN 3543-4 Tapping tee fittings made from rigid PE for (PE), Polypropylene (PP); Requirements to
pipes made from rigid PE; dimensions pipeline components and to the piping system;
DIN 3544-1 Fittings made from rigid PE, type 1 and 2, Metric sizes
requirements and testing of tapping tee fittings DIN 16 963 Pipe joints and pipeline components for pres-
DIN 8074 Pipes made from polyethylene (PE); PE 63, sure pipelines made from polyethylene high
PE 80, PE 100, PE-HD; dimensions density (PE-HD)
DIN 8075 Pipes made from polyethylene (PE); PE 63, DIN 19537 Pipes and fittings made from polyethylene high
PE 80, PE 100, PE-HD; General quality requi- density (PE-HD) for sewage channels and
rements, testing pipelines ;
DIN EN ISO Thermoplastics; Polyethylene (PE)-moulding -1 –, dimensions
1872-1 materials; designation systems and basics for -2 –, technical delivery conditions
specifications
DVGW GW 330 Welding of pipes and pipeline components
DIN EN 12814-4 Testing of welding joints made from thermopla- made from polyethylene (PE80, PE 100 and
stics; Part 4: Peeling test PE-Xa) for gas- and water system welders;
DIN EN ISO Extruded sheets made from polyethylene (PE- Training and testing scheme
14632 HD); Requirements and test methods DVGW GW 331 Supervisor for welding of pipelines made from
PE-HD for gas and water supply; Training and
testing scheme
403
DVGW VP 603 Preliminary test basis for cleaning agents and 6. Take off the planing tool at the pipe welding machine.
their tanks for the preparation of welding joints
on polyethylene pipes 7. Remove shavings from the welding area without touching
the joining zones.
DVS 2202-1 Failures on welded joints of thermoplastics;
features, description, evaluation 8. Check the coplanarity by moving the joining areas together
(maximum gap width according table 1).
DVS 2203-1 Testing of welded joints on sheets and pipes of
thermoplastics; testing methods – requirements 9. Check the misalignment (maximum 0,1 x wall thickness).
Suppl. 1 Requirements for tensile test 10. Check the heated tool temperature subject to the wall
Suppl. 2 Requirements for tensile creep test thickness (see figure 2).
Suppl. 3 Requirements for technological bending test, 11. Clean the heated tool with a cleaning agent according
bending angle/bending distance sections 3.2.1 and 3.2.2 with unused, absorbent, non-fuzzy
and non-coloured paper and exhaust it.
-2 –, tensile test
-4 –, tensile creep test 12. Determine the moving pressure res. moving force before
each welding and record it in the welding protocol.
-4 Suppl. 1 –, tensile creep test; testing of socket welding
connections on pipes 13. Determine the values for aligning, heating-up and joining
pressure.
-5 Technological bending test
DVS 2208-1 Welding of thermoplastics; Machines and 14. Set the reference values according to table 2.
equipment for the heated tool welding of pipes, 15. Bring the heated tool to the welding position.
pipeline components and sheets
16. Align the welding areas to the heated tool until a bead is
DVS 2212-1 Testing of plastic welders; Test group I and II formed (according to table 2, column 2).
Betr.Sich.V Regulation of industrial safety
17. Heating-up with reduced pressure ≤ 0,01 N/mm2, heating-
up time according to table 2, column 3.
9 Explanation 18. After heating-up is finished, withdraw the joining areas from
the heated tool and remove it from the welding position.
This technical code has been adjusted according to the state-of-
the-art with regard to improved cleaning agents and the 19. The joining areas should be joined together quickly within
development of larger pipeline components. The non-contact the changeover time (table 2, column 4) until they almost
heated tool welding is explained in DVS 2207-6. touch. At contacting, they have to meet with a speed of
nearly zero. Build up a linear joining pressure (table 2,
The welding of thermoplastics at environmental temperatures column 5) immediately afterwards.
below 5 °C is generally problematic. This concerns less the
20. After joining with a pressure of 0,15 N/mm2 a bead must
material specific properties of the thermoplastics but the limited
exist. According figure 5, K has to be > 0 on every section.
manual skill of the welder. Welding outside at any temperature
requires an environment which enables the welding staff to 21. Cooling down under joining pressure according to table 2,
perform the individual work steps without quality reducing column 5.
influences. The parts to be welded must have the same
temperature level. Test welds have to be performed and tested. 22. Declamping of the welded parts after cooling time. For shop
works see joining in section 4.1.3.
Regarding the pipe end condition it has to be considered that the
welding preparations include also the remove of frost, ice and 23. Complete the welding protocol.
moisture from the joining area (≥ 0,5 x fitting length) by means of
heat (e.g. hot gas device). Fittings and tapping tees must be
stored in closed, frost-free rooms and provided / used for welding Ad 4.2 Heated tool butt welding of tapping tees
only in the required quantity.
Processing instruction (short version)
The quality evaluation of socket welding joints by the internal
pressure creep test is only insufficiently possible. In combination 1. Establish acceptable working conditions, e.g. welding tent
with the tensile creep test a first sign is contained in DVS 2207-1, 2. Control the function of the welding equipment.
suppl. 1 (draft), table 1.
3. Ensure the roundness of the pipe by the clamps of the
welding equipment or corresponding re-rounding devices.
Appendix: Processing instructions (short versions)
4. Adjust and clamp the parts to be welded, e.g. by dollies.
Ad 4.1 Heated tool butt welding of pipes, pipeline compon- 5. Clean the joining areas even outside of the welding zone by
ents, fittings and sheets means of cleaning agents according to sections 3.2.1 and
3.2.3 with unused, absorbent, non-fuzzy and non-coloured
Processing instruction (short version) paper. Machine the pipe surface.
1. Establish acceptable working conditions, e.g. welding tent 6. Remove shavings from the welding area without touching
the joining zones.
2. Connect the welding equipment to the mains or alternating
7. Control the surface fit of the tapping tee.
current generator and control the function.
8. Fix the welding equipment onto the pipe.
3. Adjust and clamp the parts to be welded, e.g. by dollies.
9. Clamp and adjust the tapping tee.
4. Close the pipe ends against air movement.
10. Choose the correctly shaped heated tool.
5. Clean the joining areas even outside of the welding zone by
means of cleaning agents according to sections 3.2.1 and 11. Clean the connection surfaces –if contaminated – and the
3.2.3 with unused, absorbent, non-fuzzy and non-coloured heated tool according to sections 3.2.1, 3.2.2 and 3.2.3 by
paper. means of unused and absorbent, non-fuzzy and non-
Machine the joining zones, at pipes e.g. with planing tool. coloured paper and exhaust it.
404
12. Determine forces for alignment and joining (table of Ad 6 Heated tool socket welding
manufacturer).
13. Check the welding temperature (200 up to 220 °C).
1. Establish acceptable working conditions, e.g. welding tent.
14. Set the heated tool to the welding position.
2. Connect the welding equipment to the mains or alternating
15. Align the welding areas to the heated tool until a bead of 1 current generator and control the function.
mm arises.
3. Clean the heating tools by means of a cleaning agent
16. Heating-up with reduced pressure ≤ 0,01 N/mm2, heating-up according to sections 3.2.1 and 3.2.2 with unused,
time according to manufacturers data. absorbent, non-fuzzy and non-coloured paper.
17. Withdraw the connection areas to be welded from the 4. Check the welding temperature (250 up to 270 °C).
heated tool after heating-up time is finished and bring them 5. Clean all non-treated joining areas with a cleaning agent
into welding position. according to sections 3.2.1 and 3.2.3 with unused,
absorbent, non-fuzzy and non-coloured paper and exhaust
18. The joining areas should be joined together within the
it.
changeover time of maximum 10 seconds.
6. Machine the rectangular cut pipe end according to figure 8
19. Build-up joining pressure speedy and smooth within 5 and table 4 or according to the fitting manufacturer
seconds. instruction. If necessary mark the insert depth.
20. Cooling down under joining pressure, minimum 15 minutes. 7. Insert the fitting and pipe simultaneously into the heating
spigot / the heating socket till the stop / mark. The pipe end
21. Declamping of the welded parts after cooling time.
may not contact the end of the heating socket.
22. Complete the welding protocol. 8. Observe the heating-up time according to table 5, column 2.
9. Pull off the fitting and pipe and push them swiftly and axially
Ad 5.3 Electro-socket welding of fittings and tapping tees together to the stop / mark (maximum changeover time see
table 5, column 3) and fix this position (see table 5, column
4).
10. Cool down the connection. Mechanical load of the
1. Establish acceptable working conditions, e.g. welding tent. connection only after finished cooling time according to table
2. Connect the welding unit to the mains or the alternating 5, column 5.
current generator and check function. 11. Complete the welding protocol.
3. Deburr the outside of the rectangular cut pipe end. Shorten
the pipe in case of too much pipe end shrinkage. See figure Ad 7 Testing of welded joints
6.
4. Ensure that pipe ends are round using re-rounding clamps, The torsion shear test and radial peeling test are applicable for a
permitted ovality up to ≤ 1,5 %, max. 3 mm. quick check of the welding quality of PE-HD pipe connections.
The wall thickness of the pipe should be ≥ 4 mm.
means of cleaning agents according to sections 3.2.1 and
3.2.3 with unused, absorbent, non-fuzzy and non-coloured
paper. Machine the pipe surface in the welding area if
possible with a scraping tool and wall thickness removal of
approx. 0,2 mm. Remove the shavings without touching the
pipe surface.
6. Clean the treated pipe surface – if contaminated and if
necessary, according to manufacturers instructions, also the
inside of the fitting – with a cleaning agent according to
sections 3.2.1 and 3.2.3 with unused, absorbent, non-fuzzy
and non-coloured paper and exhaust it.
7. Insert the pipes into the fitting and control the insert depth by
means of the mark or suitable device. Fix the tapping tee on
the pipe. Take care for low stress installation. Secure the
pipe against dislocation.
8. Connect cable to fitting. Cable must be free of weight load.
Figure 9. Test sample from electro-socket or heated socket welding
9. Enter welding data e.g. by means of barcode scanner, joint.
check the displayed data on the equipment and start the
welding process. Four test specimen are evenly removed from the whole
circumference by longitudinal spacing. The contact sockets have
10. Control the correct welding procedure on the welding to be omitted at electro-socket welding. The dimensions are:
equipment e.g. by control of the display information and if
Test specimen length = socket length + 2 x 200 mm pipe length
available with the welding indicators. Consider error
messages. Test sample length = socket length + 2 x ≈ 10 mm pipe length
11. Disconnect cable from fitting. Test sample width b = 3 up to 6 mm at pipe wall thickness
≤ 10 mm
12. Declamping of the welded parts after cooling time. Remove b = 5 up to 6 mm at pipe wall thickness
fixing device. > 10 mm
13. Complete the welding protocol form if no automatic protocol Torsion shear test: The torsion shear test is used for the
is made. evaluation of the fracture behaviour and the fracture appearance
405
of the welding joint. For this purpose the test sample (see figure Evaluation is done according to table 7.
9) is fixed completely in a bench vice with one part e.g. socket
cross section. The other part e.g. pipe cross section, is caught Radial peeling test: For this test the pipe cross section of the test
with a suitable tool and twisted for 90° in the welding section (see sample (see figure 9) which is fixed by the socket cross section in
figure 10). The pitch rate is very low in order to widely exclude the the winch vice by means of a suitable pliers or another clamping
fracture behaviour of the test sample. The clamping areas should device is radially peeled at possibly low speed (see figure 11).
be slightly undercut in order to insert the twisting moment Evaluation is done according to table 7.
directed to the welding joint section.
Figure 10. Application of force during torsion shear test.
Figure 11. Application of force during radial peeling test.
Table 7. Evaluation criteria for torsion shear and radial peeling test.
Fracture behaviour Type, characteristic Evaluation

High release forces, ductile fracture, > 80 % Very structured fracture appearance with plastic and No resp. minor faults
of the welding zone ductile yield
Welding zone is partly or completely melt, but Isolated delaminations, contaminations, insufficient sur- Unacceptable faults
only spot-welded face peeling
Brittle fracture Release zone is large-pored, fine structured, intersper-
sed with a lot of voids, partly burnt, overheated welding
joint
Pipe surface is not melt, welding joint too cold, too large
welding gap
406
Protocol form for the Heated tool butt welding of pipes o laid overground Material Sheet of
and pipelines components o laid underground
Customer Executive company Welding equipment: Weather Preventive measures
1 = sunny 1 = none
Name of order Name of welder Identifi- Label: 2 = dry 2 = umbrella

cation No.
Type: 3 = rain or snow 3 = tent
No. of order Name and company of the welding Machine No.: 4 = windy 4 = heating
supervisor
Year of construction: Order as above in case of multiple nominations
(e. g. 34 = rain and wind)
Weld Date pipe checked workpiece Joining Set values heating-up Joining Change- Cooling Environmental Code-No. Notes
No. dimensions heated tool movin pressure time pressure over time time under temperature
ød×s temperature pressure (data of heating up alignment build-up joining Weather Preventive
manufacturer) joining time pressure measures
mm C min/max bar bar bar bar s s s s C
Welder signature: Date and signature of welding supervisor:
From periodic interval, frequency according to 4.1.2.

According to data of equipment manufacturer resp. welding equipment test plus workpiece moving pressure.
Enter measured values.
407
408
Protocol form for the Heated tool butt welding of sheets Material Sheet of
Customer Executive company Welding equipment:
Name of order Name of welder Identification Label:

No.
Type:
No. of order Name and company of the welding Machine No.

supervisor
Weid Date Sheet checked Set values heating-up Joining Changeover Cooling time Environmental Notes
No. thickness heated tool time pressure time under joining temperature
temperature alignment heating up joining build-up time pressure
mm C min/max bar bar bar s s s s C

From periodic interval, frequency according to 4.1.2.

According to data of equipment manufacturer resp. welding equipment test plus workpiece moving pressure.
Enter measured values.
Protocol form for the Electrofusion welding of pipes o laid overground Material Sheet of
and pipeline components o laid underground
1 = sonny 1 = none
Name of order Name of welder Identifi- Label: 2 = dry 2 = umbrella

cation No.
supervisor
Weld Date pipe Fitting data Unit setting Resistance Secondary Welding times Environmental Code-No. Operating mode
No. dimension of the fitting voltage temperature
ød×s A B Serial No. manual automatic joining Cooling Weather Preventive Mains Gene-
mm Ohm Volt s s C measures rator
Welding signature: Date and signature of welding supervisor:
Enter where applicable according to system used. A = Manufacturer’s code 1 = Coupler 2 = Angle 3 = T-piece 4 = Reduction
Enter measured values. B = Fitting code 5 = Saddle 6 = Cap 7 = Connecting piece 8 = Fitting
409
410
Protocol form for the Heated tool socket welding of o laid overground Material Sheet of
pipes and pipeline components o laid underground
1 = sonny 1 = none
Name of order Name of welder Identification Label: 2 = dry 2 = umbrella

No.
supervisor
Weld Date pipe Fitting data checked tem- heating up Change- Cooling Environmental Code-No. Notes
No. dimensions perature on time over time temperature
ød×s A B Batch-No. heated spigot Cooling time Colling Weather Preventive
and socket (pie and time measures
coupler fixed) (total)
mm C s s s min C
These data is to be completed by agreement. A = Manufacturer’s code 1 = Coupler 2 = Angle 3 = T-piece 4 = Reduction
Enter measured values. B = Fitting code 5 = Cap 6 = Connecting piece 7 = Fitting

File-Name: D:\Eigene Dateien\Kunden\DVS\Ri+Me\2207\englisch\e2207-1-Bb1.fm
Oktober 2007

FÜR SCHWEISSEN UND Heated tool welding of pipes made of PE-Xa Technical Code
VERWANDTE VERFAHREN E.V. with pipeline components made of PE-HD DVS 2207-1
Supplement 1
Translation of the German version from December 2005
Contents: recommended to record the welding data in welding protocols

(sample see appendix) or on data carriers.
1 Scope
2 General requirements Within the framework of the quality assurance it is recommended
3 Measures before welding to produce and test samples of joints before and during the
4 Electro-socket welding welding works.
4.1 Description of method Every welder has to be trained and has to be in possession of a
4.2 Welding device valid qualification certificate. The intended application range may
4.3 Preparation of welding be decisive for the kind of qualification.
5 Testing of welded joints The DVGW-specification GW 330 applies analogously as
7 Other applicable standards and technical codes qualification proof for heated tool socket welding at the
8 Explanations construction of gas and water supply systems. The specification
Appendix: can in turn be used as a proof of qualification for welding plastics
Brief instructions for welding for indoor applications.
Welding record sheets The equipment and devices which are used for welding must
correspond to the requirements in DVS 2208-1.
1 Scope
3 Measures before welding
This technical code applies for the electro socket-welding of
fittings and tapping tees made of PE-HD1) according to DIN The welding zone must be protected against bad weather
16963, DIN 3543-4 and DIN 3544-1 with pipes made of PE-Xa influences (e.g. wind, moisture). If it is ensured by suitable
(degree of cross-linking 75% to 90%) and PE-Xc (degree of measures (e.g. preheating, tent, heating) that the conditions are
cross-linking 60% to 75%) according to DIN 16892/93, that are suitable for welding, work may be carried out at any outside
being used for the conduction of gas, fluids and solids. temperature insofar as the welder is not hindered in his handling
The electro socket-welding of PE-HD fittings with pipes made of (see explanation). If necessary, an additional proof must be
PE-Xa or PE-Xc requires an additional proof by tensile creep provided by carrying out sample welds under the mentioned
tests according to DVS 2203-4 Supplement 1. conditions (section 7).
The maximum load of joints made with fittings of PE 80 and PE If the semi-finished product is heated up unevenly under
100 corresponds with the allowed operating pressure according influence of sunshine, a temperature compensation in the area of
to tables 8 to 13 in DIN 8074 and DIN 16893. the welding joint can be reached by covering. A cooling down
during the welding process by ventilation has to be avoided by
closing the pipe-ends during welding. During the welding the pipe
2 General requirements ends have to be closed additionally.
The quality of welding joints depends on the qualification of the PE-HD-pipes from coils are oval and bent immediately after
welder, the suitability of the utilized equipment and devices as uncoiling. The pipe end must be prepared before welding, e.g. by
well as on compliance with the welding standards. The welded careful heating up with a hot-air equipment and/or use of a
joint can be tested by means of non-destructive and/or suitable clamping or re-rounding device.
destructive methods.
The joining zones of the components to be welded must be
The welding work must be monitored. Type and range of undamaged and have to be free of contaminations (e.g. dirt,
supervising has to be agreed between the contract partners. It is grease, shavings).
The material indication is the specification of thermoplastics group and includes the types PE 63, PE 80 and PE 100. The information complies to the
current standards.
411
4 Electro-socket welding
4.1 Description of method

The joining areas (pipe surface and inside of the fitting) are
overlapped and welded by resistance wires inside the fitting
(heating coils) which are heated up by electric energy (see figure
1and 2).
Figure 3. Bevelled shrink of the pipe end.
The ovality of the pipe may exceed 1,5% of the outside diameter,
max. 3 mm. If necessary, re-rounding devices can be used.
The surface of the pipe or fitting in the welding zone has to be
completely machined. A scraping tool with a constant wall
thickness removal of approx. 0,2 mm must be used. Take care
Figure 1. Electro-socket welding of a coupler (principle). for a small annular gap!
The pipe end has to be deburred inside and outside, shavings
have to be removed without contacting the joining areas.
The fitting may only be removed from the protective package
immediately before the installation.
The treatment of the joining areas has to be done immediately
before the welding process starts.
In case of contamination of the pipe surface after machining it
must be cleaned. It has to be considered that no contamination is
rubbed to the welding zone. The cleaning agents or already
moistened cloths in a lock-up plastic box have to consist of a
100% vaporizing solvent, e.g. 99 parts ethanol with a purity grade
of 99,8% and 1 part MEK (methylethylketone, denaturation).
Agents tested according to DVGW 603 comply with this
requirement. The use of ethyl alcohol could result in a reduction
of quality because of the contained water.
The paper for cleaning has to be clean, unused, absorbent, non-
fuzzy and non-coloured. Exhaust the air afterwards.
The joining area of the fitting or tapping tee has to be cleaned
similar to the pipe.
The correct insert depth of the pipe has to be controlled by
means of a mark or suitable device. The fitting may neither be
Figure 2. Electro-socket welding of a tapping tee (principle).
tilted nor pushed onto the pipe end with force (low stress instal-
lation). The tapping fitting has to be clamped on the pipe by
4.2 Welding equipment means of a suitable device under consideration of the manu-
facturer’s instructions.
Only welding equipment adjusted to the parts to be welded may
The contact socket for the connection of the welding cable must
be used. Automatic welding equipment is preferred – possibly
be easy reachable.
with recording. The welding equipment must supply the required
welding parameters for the fitting to be welded such as welding Fitting and pipe have to show the same temperature level before
time, current and voltage. The device must switch off as soon as the welding process. Concerning welding equipment with auto-
the necessary quantity of heat has been fed to the welding zone. matic temperature compensation take care that the measured
environmental temperature corresponds to the conditions of the
4.3 Preparation of welding welding location. If necessary the welding equipment as well as
the pipe and fitting have to be protected e.g. against direct sun
Clean surfaces and a stress free installation are very important radiation.
for the fabrication of perfect welding joints. With the choice of
pipes with limited diameter tolerance according to DIN 16893 the
installation of fittings is easier.
5 Testing of welding joints
For axial pipe connections the pipes have to be cut rectangular
by means of a suitable device. In case of a bevelled shrinkage of Various tests can be used to test the quality of individual welding
the pipe cut edge the untreated pipe has to show the nominal processes. Differentiation is made between destructive and non-
diameter d (figure 3) at the designated insert depth minimum in destructive tests. For details see table 1. Tests and sampling can
the area of the heated socket. If necessary the pipe end should be carried out prior to or during welding work according to
be shortened immediately before welding. agreement.
412
Table 1. Test method for welding joints.
Test method Electro socket welding

Fittings Tapping tees
Visual test DVS 2202-1, Table 3 DVS 2202-1, Table 3
Mechanical treatment of pipe surface has to be visible even outside of the welding area.
Tensile creep test DVS 2203-4, Suppl. 1
Fitting material stress rupture life part of fracture in the
[h] 1) heating wire plane 2)
PE 80 40 min. 75%
PE 80 400 evaluation omitted
PE 100 120 min. 75% non applicable
PE 100 1200 evaluation omitted
Testing temperature ϑ=80°C
Testing load σ=3 N/mm²
1) average of 6 circumferential specimens
2) average of all 6 specimens
Internal pressure creep rupture test In combination with Tensile creep test acc. to DIN 3544-1,
acc. to DIN 16963-5, section 3.2.3.1 and 4.2, sections 2.3 and 3.2
PE 80: σ=4,6 N/mm², Testing time ≥ 165 h
PE 100: σ=5,5 N/mm², Testing time ≥ 165 h
alternatively σ=5,0 N/mm², Testing time ≥ 1000 h
Testing temperature 80°C
Torsion shear test see appendix DVS 2207-1. Also applicable as site test.
Radial peeling test see appendix DVS 2207-1. Also applicable as site test.
Compression test DIN EN 12814-4, section 8.
Peeling test DIN EN 12814-4, section 7
6 standards and technical codes DVS 2207-1 Welding of thermoplastics – Heated tool
welding of pipes, pipeline components and
DIN EN 12201-3 Plastics piping systems for water supply - sheets made of PE-HD
Polyethylene (PE); Fittings
DVS 2208-1 Welding of thermoplastics; Machines and
DIN EN 12814-4 Testing of welding joints made of thermo- equipment for the heated tool welding of
plastics; Peeling test pipes, pipeline components and sheets
DIN 3543-4 Tapping tee fittings made of rigid PE for pipes DVS 2212-1 Testing of plastic welders; Test group I and II
made of rigid PE; dimensions
DVGW GW 330 Welding of pipes and pipeline components
DIN 3544-1 Fittings made of rigid PE, type 1 and 2, requi- made of polyethylene (PE80, PE 100 and PE-
rements and testing of tapping tee fittings Xa) for gas- and water system welders;
DIN 8074 Polyethylene (PE) - Pipes PE 63, PE 80, Training and testing scheme
PE 100, PE-HD – Dimensions DVGW GW 331 Supervisor for welding of pipelines made of
DIN 16892 Pipes made of cross linked polyethylene of PE-HD for gas and water supply; Training and
high density (PE-X); General quality require- testing scheme
ments, testing DVGW VP 603 Preliminary test basis for cleaning agents and
DIN 16893 Pipes made of cross linked polyethylene of their tanks for the preparation of welding joints
high density (PE-X); dimensions on polyethylene pipes
DIN 16963 Pipe joints and pipeline components for pres- Betr.Sich.V Regulation of industrial safety (Betriebssicher-
sure pipelines made of polyethylene of high heitsverordnung)
density (PE-HD)
Part 5 – General quality requirements, testing
Part 7 – Electro-socket fitting, dimensions 7 Explanation
DVS 2202-1 Failures on welded joints of thermoplastics;
features, description, evaluation Note: A Research program of the DVGW in connection with tests
by DVS showed, that fittings and tapping tees made of PE-HD
DVS 2203-1 Testing of welded joints on sheets and pipes
can be welded to pipes made of PE-Xa, using electro socket
of thermoplastics; testing methods – require-
welding. An independent test-institute analysed the same
ments
welding method with pipe made of polyethylene crosslinked by
DVS 2203-4 Testing of welded joints on sheets and pipes electron-beam (PE-Xc). The fracture pattern is similar to PE-HD/
Suppl. 1 of thermoplastics – tensile creep test; testing PE-HD and consulted as an assessment criterion.
of socket welding connections on pipes
The welding of thermoplastics at environment temperatures
below 5°C is generally problematic. This concerns less the
material specific properties of the thermoplastics but the limited
413
manual skill of the welder. Welding outside at any temperature 6. Clean the treated pipe surface – if contaminated and if
requires an environment which enables the welding staff to necessary, according to manufacturers instructions also the
perform the individual work steps without quality reducing inside of the fitting – with a cleaning agent according to
influences. Manufacturer’s notes and the dew point curve have to section 4.3 with unused, absorbent, non-fuzzy and non-
be taken in account. coloured paper and exhaust it.
The parts to be welded must have the same temperature level. 7. Insert the pipes into the fitting and control the insert depth by
Test welds have to be produced and tested. means of the mark or suitable device. Fix the tapping tee on
the pipe. Take care for low stress installation. Secure the pipe
against dislocation.
Appendix:Processing instructions (short versions) 8. Connect cable to fitting. Cable must be free of weight load.
Ad 4 Electro-socket welding of fittings and tapping tees 9. Enter welding data e.g. by means of barcode scanner, check
the displayed data on the equipment and start the welding
Processing instruction (short version) process.
1. Establish acceptable working conditions, e.g. welding tent. 10. Control the correct welding procedure on the welding equip-
2. Connect the welding unit to the mains or the alternating ment e.g. by control of the display information and if available
current generator and check function. with the welding indicators. Consider error messages.
11. Disconnect cable from fitting.
3. Deburr the outside of the the rectangular cut pipe end.
Shorten the pipe in case of too much pipe end shrinkage. 12. Declamping of the welded parts after cooling time. Remove
fixing device.
4. Ensure that pipe ends are round using re-rounding clamps,
permitted ovality up to ≤1,5%, max. 3 mm. 13. Complete the welding protocol form as far as no automatic
protocol is made.
means of cleaning agents according to section 4.3 with
unused, absorbent, non-fuzzy and non-coloured paper.
Machine the pipe surface in the welding area with a scrap-
ping tool and wall thickness removal of approx. 0,2 mm.
Remove the shavings without contacting the pipe surface.
414
Protocol for electro-socket welding laid overground Material Sheet of
of pipeline components laid underground

1 = sunny 1 = none
Name of order Name of welder Identifica- Product: 2 = dry 2 = umbrella

tion
No. of order Name and company of welding Machine no.: 4 = wind 4 = heating
supervisor
Year of construction: in case of multiple nominations arrange numbers as above
Joint Date Pipe Fitting data Unit setting Fitting Secondary Welding times Environment Code-no. Operation mode
No. dimension resistance voltage temperature
Ød×s A B Batch no. manual automatic heating cooling Weather Preventive Mains Gene-
[mm] [Ohm] [Volt] [s] [min] [ C] measures rator
Signature of the welder: Date and signature of the welding supervisor:
Enter where applicable according to the used system. A = Manufacturer’s code 1 = Coupler 2 = Elbow 3 = Tee 4 = Reducer
Enter measured values. B = Fitting code 5 = Saddle 6 = Cap 7 = Transition fitting
415
August 2013
Heated tool butt welding of

FÜR SCHWEISSEN UND
pipes and piping parts with Technical Code
high wall thicknesses or diameters DVS 2207-1
made of PE Supplement 2
Contents: If the semi-finished product is heated non-uniformly due to solar

radiation, the temperatures must be equalised by covering the ar-
1 Scope of application ea of the welding point in good time. It is necessary to avoid any
2 General requirements draught-induced non-uniform cooling during the welding opera-
3 Measures before the welding tion, e.g. by closing the pipe ends.
4 Indications about the process sequence
4.1 Temperature checking
4 Indications about the process sequence
4.2 Minimise the misalignment of the joining faces
4.3 Handling of the pipe trains When thick-walled pipes are welded, it is necessary to pay ex-
4.4 Removal of the welding bead plicit attention to the points described below:
4.1 Temperature checking

In order to be certain to achieve a suitable welding temperature,
a heated tool temperature of 220°C (± 10°C) is stipulated for

This supplement applies to the heated tool butt welding of pipes and
thick-walled piping. The uniform temperature of the heated tool
piping parts made of PE according to DIN 8074 / DIN 8075 with
must be checked in the welding area at a minimum of eight meas-
wall thicknesses > 30 mm or with diameters > 630 mm.
uring points evenly distributed around the circumference. Calibrated
The process sequences basically correspond to the procedure de- thermal contact measuring devices must be used for the meas-
scribed in the DVS 2207-1 technical code. The recommendations urement (according to the DVS 2208-1 technical code).
described below constitute additional indications.
4.2 Minimise the misalignment of the joining faces
The maximum permissible misalignment is 10 % of the wall thick-
2 General requirements ness (max. 5 mm).
The quality of the welded joints is dependent on the qualification – The misalignment must be minimised in order to avoid any
of the welders, on the suitability of the utilised machines and jigs notch effect or stress concentrations.
as well as on the compliance with the technical codes for weld- – As compensation for any fabrication-induced tolerances in the
ing. wall thickness or in the ovality, orientation to the marking is rec-
The welding work must be monitored by a welding supervisor ommended during the alignment of the pipes in order to mini-
qualified according to the DVS 2213 or DVGW GW 331 guideline. mise the misalignment. For this purpose, it is recommended to
The contracting parties must reach agreement on the type and join the pipes according to the production sequence (metering).
scope of the monitoring. The process data must be documented – Since different pipe end sagging may be a cause of impermis-
on welding record sheets or on data carriers. In this respect, pref- sible misalignment, the pipe end sagging must be checked
erence should be given to electronic data acquisition. and, if necessary, must be eliminated by shortening the pipe
ends.
Within the framework of the quality assurance, it is recommended
to manufacture and test trial welds in the given working conditions – Welds between pipes and fittings require particular attention
before commencing and during the welding work. because the fitting was manufactured from a different pipe
batch, was injection-moulded or was subjected to chip-produc-
Every welder must be trained and must possess a valid qualifica- ing machining. If the ovality of a pipe end leads to a non-tolera-
tion test certificate according to the DVS 2212-1 or GW 330 ble misalignment, this must be compensated for with suitable
guideline. The planned area of application determines the type of aids.
the qualification.
The machines and jigs used for the welding must satisfy the 4.3 Handling of the pipe trains
requirements according to the DVS 2208-1 technical code. Particular diligence is imperative when handling thick-walled
components.
3 Measures before the welding – The outer fibre strains must be minimised in order to avoid any
stress peaks on the welds. Therefore, it is recommended to
The immediate welding area must be protected from unfavoura- carefully observe the following bending radii in relation to the
ble weathering influences (e.g. wind or the action of moisture). If outside diameter (OD) in question:
suitable measures (e.g. preheating, enclosing with tents or heating)
20°C 30 x OD
ensure the existence of conditions permissible for the welding,
the work may be carried out at any outdoor temperature - provid- 10°C 52.5 x OD
ed that the dexterity of the welder is not hindered. If necessary, 0°C 75 x OD
additional proof must be provided by manufacturing trial welds in
the specified conditions. Applies to pipe series  SDR 26
416
– In order to avoid having to unnecessarily apply any force for Special applications (e.g. relining processes) demand the removal
the movement of the pipes, the friction of the pipe train to be of the external and/or internal welding bead on butt-welded piping.
moved must be reduced by taking suitable measures (e.g. With regard to the tools used for this purpose (bead removers), it
dollies). It is preferable to move the shorter pipe train. must be ensured that, during the removal of the bead, the pipe is
– Since the pipe trains consisting of thick-walled pipes naturally not damaged (notches) and the wall thickness of the pipe in the
exhibit a higher weight, it must be ensured that the utilised weld- area of the weld is not lower than the nominal wall thickness of
ing machines can produce enough force reserves in order to the pipe. This can only be guaranteed with suitable devices or with
achieve the stipulated changeover time. devices specially developed for this purpose. The indications from
the device manufacturer must be observed.
4.4 Removal of the welding bead
As a rule, it is not necessary to remove the welding bead for
reasons relating to the hydraulic flow resistance. Moreover, the
removal of the welding bead makes it more difficult to evaluate
the weld and does not improve the quality of the weld.
417
Draft March 2013
DVS – DEUTSCHER VERBAND Hot-gas string-bead welding and hot-gas
FÜR SCHWEISSEN UND welding with the torch separate from the filler Technical Code
VERWANDTE VERFAHREN E.V. rod of pipes, piping parts and panels – DVS 2207-3
Methods, requirements
Objections to be submitted by June 30th 2013

Intended as replacement for issue dated April 2005
Contents: Special applications, such as welding sealing sheets, are de-

scribed in the Guidelines DVS 2225-1 and DVS 2225-4, while
1 Scope welding of PE casing pipes is detailed in Guideline DVS 2207-5.
2 General requirements
3 Materials 2 General requirements
4 General process description
4.1 Hot-gas welding with the torch separate from the filler rod Hot gas welding is a welding process that calls for extensive
4.2 Hot-gas string-bead welding knowledge concerning the materials to be welded and handling
5 Device types
of the equipment, as well as high levels of skills in the execution.

6 Structural design, joint designs and weld structure
7 Requirements Furthermore, the quality of the welded joints is influenced by the
7.1 Requirements for the materials and their weldability suitability of the materials used, the quality of the welding equip-
7.2 Requirements for the quality of the welded joints ment and adherence to the welding guidelines.
7.3 Requirements for the welding equipment and accessories The seams can be tested using non-destructive and destructive
8 Commissioning the welding equipment and setting the methods.
welding parameters.
The welding work is to be supervised. The extent and type of the
9 Weld preparations
supervision are to be agreed between the parties to the contract.
9.1 Equipment
The process data must be documented in welding protocols (see
9.2 Protection against environmental influences
example in Appendix 2).
10 Welding
10.1 Preparing the joint surfaces and the welding consumable All welders must be trained and possess a valid Qualification
10.2 Tacking Certificate. Guideline DVS 2212-1 is applicable to hot gas weld-
10.3 Hot-gas welding with the torch separate from the filler rod ing in accordance with this guideline.
10.4 Hot-gas string-bead welding When welding materials that are not yet listed in Guideline DVS
10.5 Mechanical post-processing of the seam 2212-1 (for example FEP, PFA, MFA, E/CFTE, etc.), the require-
10.6 Thermal post-treatment ments apply analogously. The certificate of qualification must be
10.7 Welding protocol provided in the form of a proof of suitability, tailored to the appli-
11 Checking the welded joints cation in question and based on the specifications of Guideline
12 Safety guidelines DVS 2212-1.
13 References
Appendix 1: Quick guide to welding
Appendix 2: Welding protocol for hot gas welding 3 Materials
This Guideline applies to the materials named in Supplements 1

1 Scope and 3 to Guideline DVS 2207-3. For other materials and material
modifications (e.g. electrically conductive materials), the Guide-
This Guideline applies to the hot-gas welding with the torch sepa- line may be applied analogously. Additional instructions from the
rate from the filler rod and the hot-gas string-bead welding of manufacturer of the semi-finished products must be observed.
semi-finished products made from thermoplastics in container,
apparatus and pipeline construction. It describes the different
processes, highlights the limits of the processes and sets out 4 General process description
requirements pertaining to quality assurance.
In the case of hot-gas string-bead welding or hot-gas welding
Hot-gas string-bead welding and hot-gas welding with the torch
with the torch separate from the filler rod, a welding consumable
separate from the filler rod are commonly used for material thick-
(for example a round or profile rod) is used. The joint surfaces of
nesses between 1 and a maximum of 10 mm. In general, greater
the base material and welding consumable are plastified by hot
thicknesses are hot gas extrusion welded in line with Guideline
gas, generally air (see Guideline DVS 2207-3 Supplement 2),
DVS 2207-4. However, depending on the material, component
and then joined under pressure.
type and the technical possibilities, hot gas extrusion welding
may be recommended even with lower workpiece thicknesses,
4.1 Hot-gas welding with the torch separate from the filler rod
due to the higher seam quality that can be achieved (Guideline
DVS 2203-1 Supplement 2). Frequently, the tack welds for the The base material and the welding consumable are heated by a
subsequent extrusion welding are hot-gas string-bead welded or hot gas flow that is directed at the joint surfaces using a round
hot-gas welded with the torch separate from the filler rod. nozzle attached to the welding equipment, Figure 1.
418
Welding wire
Welding force
Fanning movement
Welding equipment
Round nozzle
Welding direction
Bow wave
Hot gas stream
Weld border
Weld seam
Figure 1. Hot-gas welding with the torch separate from the filler rod.
Welding consumable
Drawing nozzle
Welding force
Welding equipment
Hot gas
Welding direction
Weld seam
Weld border
Figure 2. Hot-gas string-bead welding.
The welding equipment is moved along the welding groove in a 5 Device types
continuous movement. The plastified welding wire, guided by
hand, is inserted into the welding grove while applying joining The welding devices consist of an electric lead, welding gas sup-
pressure. The main areas of application are areas that are difficult ply, blowpipe shank, heating, including regulation and/or control,
to reach, as well as the root pass of weld seams, particularly with and a replaceable nozzle. In general, the welding gas is heated
PVC. by means of electrical resistance heating. A distinction is made
between devices with an external welding gas supply and devices
4.2 Hot-gas string-bead welding with integrated fans, as well as between electronically regulated
and electronically controlled devices. Electronically regulated de-
In this process, the welding consumable is routed to the joining
vices are preferred to controlled Devices.
zone through a channel located in the nozzle. The nozzle chan-
nel must correspond to the shape and thickness of the welding – Devices with an external welding gas supply require an ad-
consumable. This may be round, flat or triangular (see Guideline ditional fan, high-pressure gas cylinders or a compressed-air
DVS 2211 on this point). connection for the gas supply. This also makes it possible to
use gases other than air (for example nitrogen in the case of
As a result of the way in which the hot gas stream is directed and
materials that are sensitive to oxidation). Due to their light-
the shape of the drawing nozzle, the welding consumable and
weight design, they are better suited to continuous use, Figure 3a.
the base material are pre-heated and plastified. The required
joining pressure is applied via a beak-shaped attachment at the – Devices with an integrated fan are overwhelmingly used for
end of the nozzle (contact piece). With correct handling, welding short-term welding operations, for example site welds, due to
is more continuous, more even and quicker than with hot-gas their higher weight, Figure 3b.
welding with the torch separate from the filler rod. The side angle
– Regulated devices have a direct welding gas temperature
of the welding equipment depends on the drawing nozzle used
measurement integrated into the device using regulation elec-
and/or on the material to be welded.
tronics. Irrespective of the environmental influences, fluctua-
Hot-gas string-bead welding is therefore to be preferred to hot- tions in the volume of air and changes in voltage, the devices
gas welding with the torch separate from the filler rod. However, it enable a high level of consistency in the welding gas tempera-
cannot always be used in places that are difficult to access. ture. This temperature is generally shown via a display with
target and actual values.
– Controlled devices do not have any internal temperature ad-
justment. The actual temperature is liable to fluctuate in line
with the amount of gas fed in and/or fluctuations in the supply
voltage.
419
Nozzle Heating element Electronics Air hose In particular, the following points must be observed:
– Crossing welds must be arranged so that they are offset. The
clearance should be approximately three times the weld open-
ing width, but at least 30 mm.
– The clearance between parallel welds should be approximately
a) Electrical connection three times the weld opening width, but at least 30 mm.
– In the case of butt welds, connecting ends of differing thick-
Heating element Fan Electronics nesses must be levelled out in the workpiece thickness (Guide-
line DVS 2205).
– If possible, weld seams should always be back-welded or exe-
cuted as double-V butt welds, double fillet welds or double
bevel butt welds.
– If the spot is only accessible from one side, the weld seam
shape selected should guarantee that the cross-section of the
Nozzle Electrical connection thinner joining part in each case can be fully connected (for
b)
example using a single-bevel butt weld in the case of a T-joint).
Figure 3. Hot gas welding devices;
a) Devices with external welding gas supply, – It must be ensured that the joining surfaces are freely accessi-
b) Devices with internal welding gas supply. ble with the welding equipment.
The most important weld shapes are shown in Figures 4 and 5
with their weld seam shape and execution.
6 Structural design, joint designs and weld structure
Round and profile rods are used as welding consumables in ac-
The Guidelines DVS 2205 et seq. apply to the structure. cordance with Guideline DVS 2211. Round rods are generally
welded in multiple layers, depending on the weld cross-section.
Guideline DVS 2205-3 is applicable to the structural design and Profile rods are usually worked in a single-layer. In addition, it is
dimensioning of the weld seams. DIN EN 22553 applies to the necessary to adapt the welding groove geometry to the section –
designation, depiction in drawings and symbolic depiction of the in line with the information provided by the welding consumable
weld seams. manufacturer.
Figure 4. Welding groove preparation and weld seams in the case of butt joints.
a) Double fillet weld b) Single-bevel butt weld c) Double-bevel butt weld d) Single-bevel butt weld with backing run
Figure 5. Welding groove preparation and weld seams in the case of T joints.
420
Table 1. Examples for the weld run sequence, depending on the 7 Requirements
material thicknesses, with a weld preparation angle of 60° at
single-V and double-V butt welds.
7.1 Requirements for the materials and their weldability
Weld shape Base Filler rod (round) The semi-finished product and welding consumables must be
material Number x diameter suitable for hot gas welding. For welded joints that are to comply
thickness with the requirements pursuant to Guideline DVS 2203, the use
[mm] [mm] of a welding consumable that is of equivalent type to the base
Single-V butt weld 2 1x4 material, or is at least similar, is a prerequisite.
3 3x3 For semi-crystalline materials such as PE, PP and PVDF, the

melt flow rate is used as a characteristic value for weldability. If
4 1x3+2x4 the melt flow rate values (MFR values) of the items to be welded
5 6 x 3 oder 1 x 3 + 3 x 4 together lie within the permitted melt index ranges set out in
Guidelines DVS 2207-1, -11 and -15, one can generally assume
if possible weldability. If two semi-finished products in different MFR groups
plus one sealing run from this range are to be welded to one another, it is necessary to
in each case (7) select a welding consumable where the MFR value lies between
Double-V butt weld 4 per side: 1 x 4 the values for the combination of semi-finished products. For PE,
PP and PVDF, the instructions in the "Scope" section of Guide-
5 per side: 3 x 3
lines DVS 2207-1, -11 and -15 must be observed. If the melt flow
6 per side: 3 x 3 rate lies outside the ranges permitted in the above guidelines, the
8 per side: 1 x 3 + 2 x 4 welding documentation in accordance with Guideline DVS 2203-4
must be provided following a tensile creep test.
10 per side: 6 x 3 oder
per side: 1 x 3 + 3 x 4 In the case of PVC, only identical moulding compound types (e.g.
PVC-U/ PVC-U or PVC-C/PVC-C) may be welded together.
The semi-finished products and welding consumables must be
labelled appropriately and so that they cannot be confused (on
the packaging in the case of welding consumables).
Only semi-finished products with defined quality requirements
should be welded (for example test certificate in line with DIN EN
10204).
The welding consumables must comply with the requirements
pursuant to Guideline DVS 2211 and/or DIN EN 12943 . Profiled
welding consumables (triangular or triplet form) may only be used
if the quality of the joint is proven in line with the relevant require-
ments, e.g. by a procedure test.
The base material and welding consumables must be in perfect
processing condition, clean and dry.
a) If there are any doubts as to whether the semi-finished product
and/or the welding consumable are of the same type, for exam-
ple through lack of labelling, or if changes in the material are
feared due to
– incorrect storage,
– low joining part temperatures,
– contamination,
– ageing,
– operating influences (media, temperatures),
the weldability must be determined by means of tests carried out
on trial welds.
The type and scope of the tests must be agreed. The Guidelines
DVS 2203-1 and DVS 2201-2 provide information on this point.
7.2 Requirements for the quality of the welded joints

b)
With correct execution of the welds in accordance with this guide-
Figure 6. Run sequence for a single-butt V weld (without backing run); line, the minimum requirements concerning quality of welds (weld
a) full penetration root pass, strength reduction factors, angle of bend/path of bend) set out in
b) finished weld. Guideline DVS 2203-1 are certain to be attained.
In general, the layers are built up in line with Table 1 and Figure With regard to the application in question, any statutory require-
6. With other weld preparation angles or weld geometries, the ments (German Water Resources Act, Pressure Equipment
layer structure must be adapted accordingly. When using profile Directive, etc.) and the required dimensions, the client and manu-
rods or welding strips, the weld geometry and the welding nozzle facturer should agree on the corresponding requirements for the
must be adapted to the geometry of the welding consumable. component and the necessary minimum quality of the welded
joints, and specify these points. The Guideline DVS 2202-1 contains
The weld must be complete and free from cavities, and must information and criteria for this.
have a reinforcement in accordance with Figure 4 and/or Guide-
line DVS 2202-1. The numbering of the individual wires in Table 1 Where appropriate, evidence of the required quality must be pro-
reflects the recommended welding sequence. vided by means of trial welds. This applies particularly to all ma-
terials that are not named in this guideline (see also Supplement 3
of this guideline).
421
7.3 Requirements for the welding equipment and – Personal protective equipment
accessories – Fume extraction and fresh air supply where necessary
The welding equipment must be CE-compliant, operational and – Dust protection for welding consumable
suitable for the welding assignment. This also applies to acces- – Adequate lighting
sories such as nozzles, thermoelectric sensors, etc. – Weather protection where necessary
– Special cleaning agent (non-welling, non-dissolving and not
Special requirements for the equipment and welding nozzles are containing fat), lint-free cloths
detailed in Supplement 2 to this Guideline.
– Table of welding parameters in line with Supplement 1 to this
Guideline and/or information from the semi-finished product
manufacturer
8 Commissioning the welding equipment and setting
– Welding protocol in line with Appendix 2.
the welding parameters.
Commissioning and setting takes place in line with the manual 9.2 Protection against environmental influences
from the welding equipment manufacturer, in conjunction with the The environmental conditions may have a significant effect on
welding parameter recommendations specified in Supplement 1 the welding operation and therefore the quality of the joint. For
to this Guideline and, where appropriate, the information from the this reason, the following points must be observed:
manufacturer of the raw material or semi-finished product. Prior to
use, when changing the welding consumable and, where appro- – The weld area must be protected from adverse weather condi-
priate, with interruptions to welding, the drawing nozzles on the tions (e.g. moisture, wind, draughts and temperatures below
contact piece and the air channel must be cleaned, for example 5°C).
using a brass brush. The nozzle surfaces must not be damaged. – Provided that suitable measures have been implemented (for
Before starting welding, the hot gas temperature is checked on example preheating, tenting, heating) to ensure that a semi-
the welding equipment. The measurement is carried out with a finished product temperature suitable for welding can be main-
suitable fast-acting thermometer (with a thermocouple between tained, then welding may be carried out regardless of the am-
approx. 1 and 1.5 mm in diameter), around 5 mm inside the nozzle bient temperature – assuming this does not impair the welder's
- in the middle of the nozzle for round nozzles and in the main ability to carry out the work. If necessary, trial welds should be
nozzle opening for drawing nozzles. Measurement of the air produced under the prevailing conditions as additional evi-
quantity prior to entry into the welding equipment is carried out dence.
with a flow meter (see Supplement 2 of this Guideline). – In the case of joining parts at different temperatures, for exam-
The welding equipment must be in operation for at least 15 min- ple due to one-sided exposure to sunlight or different storage
utes before the start of welding and the check on the parameters. conditions, the temperatures must be equalised prior to welding.
Repeated checks are recommended for longer welding assign-

ments or following interruptions to the work. 10 Welding
Welding operators must accustom themselves to the speed of
travel and welding force through practice and must check these 10.1 Preparing the joint surfaces and the welding
regularly. For example, the required welding force can be consumable
checked by carrying out trial welds on a table-top balance. The joint surfaces must not be damaged, oxidised or contaminated.
All measurements must be carried out with calibrated measuring They and the surrounding edge areas must therefore be ma-
equipment that has been checked at regular intervals, in accord- chined with suitable tools prior to welding.
ance with Supplement 2 of this Guideline, and must be docu-
In the case of PVC-U, PVC-C, PP and PE, this is also necessary
mented (Appendix 2). The thermometers used must have a max-
for the welding consumable.
imum deviation of ± 3 K in the operating range.
Machining tools such as scrapers, draw blades, milling cutters
and saws are suitable. Grinding tools are only permitted if con-
9 Weld preparations tamination caused by the introduction of abrasives and overheating
of the surface can be ruled out.
The welding grooves of the joint surfaces are prepared in line Particularly in the case of joining parts that are exposed to UV or
with Section 6. It must be ensured that the joint surfaces are suf- the influence of media for a relatively long period of time, the
ficiently accessible with the welding equipment. Out-of-position damaged layer may be so deep that, after processing, a check on
welding should be avoided or minimised, due to the necessary the residual wall thickness is necessary, with consideration of the
welding force that the welding operator must apply. Steps must structural requirements.
be taken to ensure that, during welding, the welding operator is
not impeded by the necessary adjustment of the connecting Where required, special, non-fatty cleaning agents must be used
cables and hoses, and of the welding consumable. The welding to clean the joint surfaces.1)
zone must be adequately lit. Additional lights that are attached
directly to the welding equipment and provide secure illumination 10.2 Tacking
of the welding zone are recommended.
Tacking is used to fix the joining parts in their intended position
with regard to one another, in order to exclude the possibility of
9.1 Equipment
the joining parts shifting position during welding. Tacking is usu-
For correct execution of the welded joint, the following minimum ally carried out by surface-fusing the joint surfaces using a spe-
equipment is necessary: cial tacking nozzle or an appropriate nozzle attachment.
– Hot gas device, in accordance with this Guideline and Supple-
ment 2 1) The cleaning fluid or any cloths that are delivered from the factory pre-
– Hot gas nozzle, in line with the welding assignment moistened must be made from a 100% evaporable solvent, e.g. con-
– Flow meter for welding gas sisting of 99 parts ethanol with a degree of purity of 99.8% and 1 part
– Quick-acting, digital thermometer MEK (methyl ethyl ketone, denaturing). Material tested according to
– Suitable measuring equipment for checking misalignment / di- DVGW VP 603 conforms to this specification. The use of white spirit
ameter / thickness can result in a degradation in quality due to the fact that it contains
– Suitable tool rest water.
– Scraper, draw blade, nozzle brush, diagonal pliers, flat broach, The paper used for cleaning purposes must be clean, previously
gouge and bevel-edge chisel, and similar unused, absorbent, lint-free and non-staining.
422
10.3 Hot-gas welding with the torch separate from the filler rod welding equipment is moved into the welding groove with even
application of the joining pressure.
In the case of hot-gas welding with the torch separate from the
filler rod, the joining pressure is applied by hand via the welding In order to prevent stretching of the welding consumable due to
consumable. Here the welding consumable should be stretched, friction in the nozzle, the welding consumable is fed in by hand
compressed or twisted as little as possible, in order to minimise where appropriate. The drawing movement along the welding
the generation of residual welding stresses. groove is carried out while observing the bow wave that is created,
the weld border (double bead) and the surface of the welding
At the start of a weld layer, it is recommended to slightly chamfer
consumable introduced. Notches in the base material due to in-
the welding consumable at the tip (Figure 7).
correct guiding of the drawing nozzle (contact piece) are to be
The nozzle orifice should be aligned at an angle of approximately avoided.
45° to the base material in the weld zone. The base material and
Prior to the following weld bead, the weld border and the adjacent
the welding consumable are plastified on the joint surfaces with a
base material that has been affected by the heat must be finished
triangular fanning movement in the direction of welding. Follow-
with a suitable scraper until they are smooth, as in hot-gas welding
ing this, the chamfered welding consumable is pressed onto the
with the torch separate from the filler rod.
relevant spot and the fanning movement is continued in the direc-
tion of welding.
10.5 Mechanical post-processing of the seam
The joining pressure is applied to the welding consumable by
In general, post-processing of the weld seam is not required. If
hand, so that this then forms a weld bead.
mechanical post-processing is carried out on the seam, checks
During welding, a bow wave of plastified material running in front must be carried out to ensure it is free from grooves. Post-pro-
of the welding consumable and a weld border in the form of an cessing may only take place after the seam has cooled down suf-
even double bulge on both sides of the weld bead should be ficiently.
apparent.
10.6 Thermal post-treatment
The welding parameters of joining pressure and temperature and
the heating time resulting from the rate of travel must be adjusted Residual welding stresses can be reduced by cooling the weld
to one another in an appropriate manner, based on the material seam slowly (e.g. by covering it immediately after welding) or by
thickness and the material (see Supplement 1 to this Guideline subsequent tempering of the component. The tempering conditions
for the welding parameters). depend on the material and the component. The instructions from
the manufacturer of the semi-finished products must be followed
When starting at a weld bead that has already been laid down or
here.
for circumferential welds, the process shown in Figure 7 must be
followed. At the end of a welding operation, the welding wire With PVC-C, the base material and welding consumable must be
should not be twisted or torn off, but instead cut off, for example tempered before welding where appropriate, and after welding in
using a knife or diagonal pliers. After every weld layer, the weld all cases.
border and the adjacent base material that has been affected by
the heat must be finished with a suitable scraper until they are 10.7 Welding protocol
smooth so that the next weld bead can be connected securely. The welding protocol documents the welding conditions and
welding parameters, among other things. It forms the basis for
Welding rod assessment of the weld quality by the welding supervisor (sam-
ple protocol in Appendix 2).
60° 11 Checking the welded joints
A distinction is made between non-destructive and destructive

test methods. These methods are listed in Table 2 "Possible test
Starting point at the beginning of the weld seam procedures".
The visual inspection is carried out in accordance with Guideline
DVS 2202-1 and focuses particularly on the form of the weld, sur-
faces and edge areas that are free from grooves, optimal weld
filling, complete fusion on the root side and offset of the joining
parts.
chamfered
By testing with ultrasound and X-rays (see Guideline DVS 2206),
defects inside the welds can be determined in a non-destructive
manner. However, these alone do not provide sufficient information
on the quality of the welded joint. In addition, the possible uses of
Starting point within the weld seam
these test methods are limited with regard to the weld geometry
Figure 7. Guiding welding rod.
and the thickness of the weld.
The prerequisite for the leakage test with high voltage is the pres-
10.4 Hot-gas string-bead welding ence of a conductive substrate as a reciprocal pole. In general,
In hot-gas string-bead welding, the welding consumable is pressed the high voltage test is carried out after the first pass and during
into the joining zone through the contact piece located in the nozzle. the final inspection. It does not provide any information on the
With weld undercuts and ends, the same process as for hot-gas quality of the welded joint (see Guideline DVS 2206-4 and DIN
welding with the torch separate from the filler rod should be followed, EN 14879-4, prEN 13100-4 on this point). The test voltage must
Figure 2. be determined on the basis of the material and the material thick-
ness. A test voltage of approximately 5 kV per mm of material
Pre-heating of the base material takes place at the start of the ac- thickness is usual.
tual welding operation, using the hot gas stream emerging from
The type and scope of the tests to be carried out in each individual
the main nozzle orifice, with a fanning movement. Then the weld-
case depend on the component in question and its application,
ing consumable is introduced into the nozzle and heated in the
and must therefore be agreed with the client.
hot gas stream . As soon as the surfaces of the items to be joined
together are plastified, the welding consumable is pressed into General material-specific tests can be found in the Guidelines
the prepared welding groove using the contact piece, and the DVS 2201-1 and DVS 2206.
423
Table 2. Possible test methods for hot gas welds.
Non-destructive testing
Visual inspection of the Visual inspection of the seam surface and seam geometry. Evaluation in line with Guideline
undamaged seam DVS 2202-1, Table 4, based on the quality level to be determined in the individual case, pursuant
(external findings) to Section 2.
Leak test with low pressure Using a suitable vacuum bell jar and foaming liquid. The test conditions must be defined for each
individual case. Usual test pressure 0.4 to 0.6 bar.
Leak test with electrical high Execution of test and equipment requirements in line with Guideline DVS 2206-4. The type of test
voltage equipment (with or without reciprocal pole) and the test voltage must be defined for each individual
case.
Pressure test Generally used with pipelines. Test conditions in accordance with the Pressure Equipment Directive.
Execution of test in accordance with Guideline DVS 2210-1 Supplement 2.
Information provided: tightness, experimental evidence of operational safety.
Destructive testing
Visual inspection of the Visual inspection of the seam cross-section after cutting open the seam. Evaluation in line with
seam cross-section Guideline DVS 2202-1, Table 4, based on the quality level determined pursuant to Section 2.
(internal findings)
Tensile test Execution in accordance with Guideline DVS 2203-2, minimum requirements in accordance with
Guideline DVS 2203-1 - Supplement 1
Tensile creep test Execution in accordance with Guideline DVS 2203-4, minimum requirements in accordance with
Technological bend test Execution in accordance with Guideline DVS 2203-5, minimum requirements in accordance with
12 Safety guidelines Guideline Testing of welded joints of thermoplastic pla-

DVS 2203-1 tes and tubes – Requirements in the tensile
When overheated beyond the thermoplastic state (decomposition Supplement 1 test – Short-term tensile weld strength reduc-
range), some materials develop dangerous products of decom- tion factor fz
position and fumes that are hazardous to health (for example Guideline Testing of welded joints of thermoplastic pla-
PVC, PVC-C, PVDF). Fluoroplastics such as ECTFE, FEP, MFA, DVS 2203-1 tes and tubes – Requirements in tensile creep
PFA, PTFE develop the above even during welding (see Supple- Supplement 2 test – Tensile creep test weld strength reduction
ment 3 to this Guideline). factor fs
For these materials, operating instructions in accordance with Article Guideline Testing of welded joints of thermoplastic pla-
14 of the German Hazardous Substances Directive (GefStoffV) DVS 2203-1 tes and tubes – Requirements in technological
must be drawn up by the semi-finished product processor, based Supplement 3 bend test – Bending angle/bending path
on the material data sheets to be provided by the raw material/
Guideline Testing of welded joints of thermoplastic pa-
semi-finished product manufacturer. These instructions must high-
DVS 2203-2 nels and pipes – Tensile test
light all the potential risks and the necessary protective measures.
Guideline Testing of welded joints of thermoplastic pla-
In areas at risk of explosion, the pertinent safety regulations must DVS 2203-4 tes and tubes – Tensile creep test
be observed with regard to the welding operations.
Guideline Testing of welded joints of thermoplastics pla-
DVS 2203-5 tes and tubes - Technological bend test
13 References Guideline Calculation of thermoplastic tanks and appa-
DVS 2205-3 ratus, welded joints
DIN EN 10204 Metallic products – Types of test certificates Guideline Non-destructive test on tanks, apparatus and
DIN EN 14879-4 Organic coating systems and linings for pro- DVS 2206-1 piping made of thermoplastics – Dimensional
tection of industrial apparatus and plants checking and visual inspection
against corrosion caused by aggressive me- Guideline Non-destructive test on tanks, apparatus and
dia – Part 4: Linings on metallic components DVS 2206-4 piping made of thermoplastics – Testing with
prEN 13100-4 Non-destructive testing of welded joints of electrical high voltage
thermoplastics semifinished products – Part Guideline Welding of thermoplastics - Heated tool wel-
4: High voltage testing DVS 2207-1 ding of pipes, pipeline components and pa-
DIN EN 22553 Welded, brazed and soldered joints – Symbo- nels made of PE-HD
lic representation on drawings Guideline Welding of thermoplastics – High-speed hot
DIN 1910-3 Welding; Welding of Plastics, Processes DVS 2207-3 gas string welding and hot-gas welding with
DVGW VP 603 Provisional testing specification for cleaning Supplement 1 the torch separate from the filler rod of pipes,
agents and their containers, for preparation of piping parts and panels - Welding parameters
welded joints on polyethylene pipes Guideline Welding of thermoplastics – Hot-gas string-
Guideline Joining of plastics – Acronyms and abbrevia- DVS 2207-3 bead welding and hot-gas welding with the
DVS 2200-1 tions – Welding processes Supplement 2 torch separate from the filler rod of pipes, pi-
Supplement 1 ping parts and panels - Requirements for wel-
ding equipment and accessories
Guideline Testing of welded semi-finished products
DVS 2201-1 made from thermoplastics; Basics, indications Guideline Welding of thermoplastics – Welding of PE
DVS 2207-5 casing pipes – Tubes and tubular components
Guideline Imperfections in thermoplastic welding joints –
DVS 2202-1 Features, descriptions, evaluation
424
Guideline Welding of thermoplastics - Heated tool wel- Guideline Welding of thermoplastics – Welding fillers –
DVS 2207-11 ding of pipes, piping parts and panels made of DVS 2211 Marking, requirements and tests
PP Guideline Qualification testing of plastics welders –
Guideline Welding of thermoplastics - Heated tool wel- DVS 2212-1 Qualification test groups I and II
DVS 2207-15 ding of pipes, piping parts and panels made of Guideline Specialist for plastics welding
PVDF DVS 2213
Guideline Industrial pipelines made of thermoplastics – Guideline Welding of sealing sheets made of polyethy-
DVS 2210-1 Planning and execution – Above-ground pipe DVS 2225-4 lene (PE) for the sealing of dumps and conta-
systems minated sites
Guideline Industrial piping made of thermoplastics – Pl-
DVS 2210-1 anning and execution – Above-ground pipe DIN standards can be obtained from Beuth Verlag, Berlin,
Supplement 2 systems – Recommendations for the internal DVS leaflets and Guidelines can be obtained from DVS Media
pressure and leak tests GmbH, Düsseldorf.
Appendix 1: Quick guide to welding
1. Putting together the welding equipment 4. Commissioning the welding equipment and setting the
(Section 8.1) parameters.
– Valid welder's certificate in accordance with Guideline DVS (Section 7)
2212-1 – Check supply lines (current, air) for anything that could ob-
– Hot gas welding device with operating instructions struct the welding operation
– Welding nozzles appropriate for the welding assignment – Connect welding equipment in line with operating instructions
and the welding consumable and switch on
– Flow meter for welding gas – Select and mount hot gas nozzle; set and check hot gas
quantity and hot gas temperature (Supplement 1)
– Thermometer with sensors to measure the temperature of
the hot gas and the semi-finished product 5. Preparing the weld seams and joint surfaces
– Suitable measuring equipment for checking misalignment, (Section 5.8)
diameter, thickness – Check weld geometry and weld shape, where necessary
– Tool rest determine and create these
– Scraper, drawing blade – Remove oxide layer on the joint surfaces by machining directly
before welding
– Personal protective equipment
– Dust protection for welding consumable 6. Tacking the joining parts
– Cleaning agent (Section 9.2)
– Supplement 1 – Welding parameters – Partial or continuous tacking using tacking nozzle

– Appendix 2 – Welding protocol 7. Welding
– Special welding instructions where necessary (Sections 9.3 and 9.4)
– Check speed of travel and monitor evenness
2. Check working conditions and arrange measures
(Section 8.2) – Check tracking of welding consumable and/or drawing noz-
zle continuously and make the necessary corrections
– Accessibility
– Bevel seam ends before new starts
– Adequate lighting
– Remove weld border after each bead
– Protective tent
– Heating – Protect welding consumable from contamination
– Measure the temperature of the semi-finished product and 8. Post-processing of the weld seams
initiate appropriate measures if necessary (Section 9.7)
– Adequate ventilation / fume extraction – Allow welded parts to cool sufficiently before unclamping
– Special protective equipment them and subjecting them to loads
– Mechanical dressing of weld seam notches and weld border
3. Check weldability at weld flanks
(Section 6.1)
– Check the manufacturer's information regarding the semi- 9. Draw up welding protocol
finished products and welding consumables to ensure a (Section 9.6)
match – Complete welding protocol (Appendix 2) and carry out visual
– Check the identity, condition and cleanness of the items to inspection in line with Guideline DVS 2202-1
be joined, clean if necessary
– Where necessary, check the weldability of the items to be
joined by surface welding in accordance with Guideline
DVS 2201-2 or by trial welds.
425
426
Appendix 2: Welding protocol for hot gas welding
Hot gas welding of panels and pipes Company logo

Welding protocol
Project name: Project no.: Safety
Weather precautions
Drawing no.: Base material (manufacturer, type, batch, date) details:
1 = Sunny 1 = None
Welder: Filler material (manufacturer, type, batch, date) details: 2 = Dry 2 = Screen
Welder's certificate no.: /valid until, issued by: Welding equipment make, type: 3 = Precipita-
3 = Tent
tion
Welding supervisor2): Nozzle(s)
4 = Wind 4 = Heating
Design Seam Joining part Shape of Process Air supply Hot gas Semi-finished Safety
Date weld Ambient product Weather precautions Visual
detail no. thickness (symbol) WF, WZ rate temperature1) temperature (code no.) evaluation
temperature (code no.)
[mm] [l/min] [°C] [°C] [°C]
1) Measured in the centre of the nozzle outlet opening, 5 mm in the nozzle Remarks, e.g. aggravating conditions:
2) e. g. Specialist for plastics welding according to guideline DVS 2213
Date / signature of the welder Date / signature of the welding supervisor


File-Name: D:\Eigene Dateien\Kunden\DVS\Ri+Me\2207\englisch\e2207-3.fm
September 2007

FÜR SCHWEISSEN UND
Hot-gas string-bead welding and hot-gas welding
with torch separate from filler rod of pipes, pipe Technical Code
VERWANDTE VERFAHREN E.V. components and sheets – Methods, requirements DVS 2207-3
Translation of the German version from April 2005
Contents: welding of semi-finished thermoplastic products in tank, process

equipment and pipeline manufacture. It describes the various
1 Applicability methods, shows the method limitations and defines the quality
2 Materials assurance requirements.
3 General description of the method
3.1 Hot-gas welding with torch separate from filler rod (WF) Hot gas welding is mainly used for welding material thicknesses
3.2 Hot-gas string-bead welding (WZ) between 2 and 10 mm. Larger thicknesses are generally hot-gas
4 Device types extrusion welded according to DVS 2207-4. Special applications,
5 Constructional design, weld shapes and weld structure such as welding of waterproof sheeting, are described in
6 Requirements DVS 2225-1 and 2225-4; welding of PE pipe jackets is described
6.1 Requirements for the materials and their weldability in DVS 2207-5.
6.2 Quality requirements for welding joints
6.3 Requirements for welding tools and accessories
6.4 Requirements for welders 2 Materials

7 Commissioning welding equipment and setting the welding
parameters
8 Preparation for welding This technical code applies for the materials stated in DVS 2207-3
8.1 Equipment Supplement 1. The technical code can be applied in principle to
8.2 Protection against environmental influences other materials and material modifications (e.g. electrically
9 Welding conducting). Supplementary notes from the semi-finished
9.1 Preparing the joining surfaces and the welding filler products manufacturer are to be observed.
9.2 Tacking
9.3 Hot-gas welding with torch separate from filler rod (WF)
9.4 Hot-gas string-bead welding (WZ) 3 General description of the method
9.5 Mechanical reworking of the weld
9.6 Thermal reworking A welding filler (for example round or section rod) is used in hot-
9.7 Welding record sheet gas string-bead welding and hot-gas welding with torch separate
10 Testing the welded joints from filler rod. The joining surfaces of the base material and the
11 Safety instructions welding filler are plasticized with hot gas, usually air (require-
12 Other applicable standards and technical codes ments – see DVS 2207-3 Supplement 2), and joined under
Appendix 1: Brief instructions for welding pressure.
Appendix 2: Welding record sheet
3.1 Hot-gas welding with torch separate from filler rod (WF)
1 Applicability
The base material and the welding filler are heated with a stream
This technical code applies for hot-gas welding with torch of hot gas directed to the joining surfaces by means of the round
separate from filler rod (WF) and hot-gas string-bead (WZ) nozzle fitted on the welding tool, Figure 1.
Figure 1. Hot-gas welding with torch separate from filler rod.
427
Figure 2. Hot-gas string-bead (rod) welding.
The welding tool is passed along the welding joint in continuous

motion. The plasticized welding rod, positioned by hand is placed
in the welding joint with the application of joining pressure. The
main areas of application are hard to access places, as well as
the weld root, especially in the case of PVC.
a)
3.2 Hot-gas string-bead welding (WZ)
In this method, the welding filler is fed through a channel located
in the nozzle into the joining zone. The nozzle channel must
match the shape of the welding filler.
The welding filler and the base material are evenly pre-heated
and plasticized by directing the stream of hot gas and as a result b)
of the shape of the draw nozzle. The required joining pressure is
applied via a beak shaped tip on the end of the nozzle (nozzle Figure 3. Hot gas welding torch;
shoe). When handled correctly, welding is more continuous, even a) Torch with external gas supply,
and faster than with hot-gas welding with torch separate from b) Torch with internal blower.
filler rod.
Hot-gas string-bead welding is therefore preferable to hot-gas 5 Constructional design, weld shapes and weld structure
welding with torch separate from filler rod. However, it is not
always practicable in inaccessible places. DVS 2205 applies to the construction of the components.
The constructional design and dimensioning of the welds is
subject to DVS 2205-3. The terminology, drawing and symbolic
4 Device types representation of the welds is subject to DIN EN 22553.
Welding tools (torches) consist of an electrical lead, welding gas Special attention should be paid that:
supply, handle, heating element including regulator or controller, – Crossing welds must be avoided.
as well as replaceable nozzle. The welding gas is usually heated
with an electrical resistance heater. Torches are distinguished – The separation of welds must be approx. 3x the width of the
between those with an external welding gas supply and those covering layer, however at least 30 mm.
with an integrated blower, as well as between electronically – The different thicknesses of the connection ends for butt joints
regulated and electronically controlled torches. must be matched with the thickness of the workpiece (DVS
2205).
– Torches with an external welding gas supply require an additio-
nal blower, compressed gas bottles or a compressed air con- – In the case of accessibility from only one side only, a weld
nection for their gas supply. This also enables the use of gases shape should be chosen which ensures that the cross-section
other than air (for example nitrogen in the case of oxidation- of the respective thinner joining part can be completely con-
sensitive materials). They are better suited for prolonged use nected (for example for a T-butt with single-bevel weld).
on account of their lightweight construction, Fig. 3 a. – It must be ensured that the joining surfaces allow for proper
– As a result of their high weight, torches with integrated blowers handling of the welding torch.
are mostly used for brief welding jobs, for example on-site wel- The most important seam geometries are V butt, double-V butt,
ding, Fig. 3 b. single-bevel, double-bevel weld.
– Regulated torches include incorporated welding gas tempera- Welding fillers can be round or profile rods according to DVS
ture measurement with regulating electronics integrated into 2211. Round rods are usually multi-layer welded depending on
the tool. The tools allow a highly consistent welding gas tem- the weld cross-section. Profile rods are usually processed in a
perature irrespective of environmental influences, fluctuation in single layer. This requires adaptation of the seam geometry to
air flow rates and changes in voltage. This is normally indica- the section in accordance with the welding filler manufacturer’s
ted on a display with target and actual values. specifications.
– Controlled torches do not include internal temperature com- Table 1 shows the common materials and seam opening angles
pensation. The actual temperature is subject to fluctuations of for V and double-V welds. The angles 45° and 90° are common
the air flow applied and of the supply voltage. for fillet welds, Fig. 4.
428
0 – 2 mm
0 – 2 mm
a) V-weld on butt joint – b) V-weld on butt joint – c) Double V-weld

without backing with backing at a butt joint
0 – 2 mm
d) Single-bevel weld with e) Double-bevel weld at T-joint f) Double fillet weld

fillet weld at T-Joint
Figure 4. Common welding geometries.
Table 1. Materials and seam opening angles for V and double-V welds .
Material Weld opening angle α
PE- HD(1), PP(2), PVC, PVC- C, PVDF, E/CTFE 60°-70°
MFA, FEP, PFA 0°-30° (dependent on material thickness)
(1) PE 63, PE 80, PE 100 ; (2) PP- H, PP- B, PP- R
Table 2. Examples for the weld structure dependent upon the material thickness with an opening angle of 60°.
Base material thickness Welding rod (round)

in mm Number x diameter [mm]
V-weld 2 1x4
3 3x3
4 1x3+2x4
5 6x3
if possible, additionally with
backing (7) in each case
4 per side: 1 x 4
5 per side: 3 x 3
6 per side: 3 x 3
8 per side: 1 x 3 + 2 x 4
10 per side: 6 x 3 or
per side: 1 x 3 + 3 x 4
429
The nature and scope of testing are to be agreed upon. Relevant
references are given in technical codes DVS 2203-1 and 2201-2.
6.2 Quality requirements for welding joints

If the welds are produced according to this technical code, the
minimum weld quality requirements specified in DVS 2203-1
(welding factors, bending angle/distance) should be safely
achieved.
The contractor and manufacturer should agree upon and define
the specifications for the component and the welding joints in
respect of the statutory requirements for the respective
welded root finished weld application (Federal Water Management Act (WHG), European
Pressure Equipment Directive) and the required dimensioning.
Figure 5. Weld structure with a V-weld (without backing).
References and criteria for the definition of quality are included in
The layer structure is usually produced according to Table 2 and DVS 2202-1.
Fig. 5. The layer structure is to be adapted for other opening The required quality should be verified on test welds if necessary.
angles and weld geometries. If section rods or welding tapes are This particularly applies for materials for which no specifications
used, the seam geometry and welding nozzles must be adapted are stated in the aforementioned technical codes (for example
to the geometry of the welding filler. PFA, FEP, MFA, PVC-C etc.).
The weld must be filled completely and free of occlusions and
must show a weld protrusion according to DVS 2202-1. The 6.3 Requirements for welding torches and accessories
numbering of the individual rods in the table shows the Welding torches must be CE compliant, safe, functional and
recommended welding sequence. suitable for the welding task. This also applies for accessories,
such as nozzles, temperature probes etc.
6 Requirements Special requirements for the equipment are described in
Supplement 2 of this technical code.
6.1 Requirements for the materials and their weldability
6.4 Requirements for welders
Semi-finished products and welding fillers must be suitable for
hot gas welding. For welding joints to be compliant with DVS Hot gas welding is a welding technique demanding extensive
2203, a welding filler should be used which is the same as the knowledge of the materials to be welded and the operation of
base material, or at least of the same type. equipment, as well as a high level of workmanship skills.
The melt index is used as a characteristic parameter for The welder must have passed an examination corresponding to
weldability in the case of partially crystalline materials, such as DVS 2212-1 and be in possession of a valid examination
PE, PP, and PVDF. If the melt index values (MFR values) of the certificate.
welding components lie within the permissible meld index range Welding of special materials (for instance FEP, PFA, MFA, E/
of DVS 2207-1, -11, -15, weldability can generally be assumed. If CTFE...) is subject to requirements equivalent to or proof of
two semi-finished products of different MFR groups from this suitability along the technical codes of DVS 2212.
range are to be welded together, a welding filler is to be selected
whose MFR value lies between those of the semi-finished
products combination. In the case of PE-HD, PP and PVDF, the 7 Set-up of welding equipment and setting the welding
instructions from the applicable technical codes DVS 2207-1, parameters
2207-11 and 2207-15 are to be observed. If the melt index lies
outside the permissible range in the stated technical codes,
Set-up and setting takes place according to the operating in-
weldability is to be ascertained with tensile creep testing
structions of the equipment manufacturer in association with the
according to DVS 2203-4.
welding parameter recommendations specified in Supplement 1
For amorphous materials (such as PVC): Only semi-finished and possibly with the specifications from the raw material or
products of the same moulding compound are weldable. semi-finished products manufacturer. On the draw nozzles, the
nozzle shoe and the air- and material channels are to be cleaned,
The semi-finished products and welding fillers must be labelled
for example with a brass brush prior to use or when the welding
accordingly and unambiguously (on the packaging for welding
filler is changed and possibly when welding is interrupted. The
fillers).
nozzle surfaces must not be damaged.
Only semi-finished products with defined quality specifications
The temperature of the hot gas is to be checked before starting
should be welded (for example, test report in accordance with EN
welding. The measurement is made with a suitable quick display
10204).
temperature meter (with a thermo-element of 1 – 1.5 mm diame-
The welding fillers must comply with the specifications of DVS ter) approx. 5 mm inside the nozzle, in the centre for round
2211 as well as EN 12943. nozzles, at the main nozzle aperture for draw nozzles. Air flow
The base and filling materials must be in perfect condition for measurement is performed at the point of entry into the welding
processing, dry and clean. equipment using a flow meter (see Supplement 2).
If there is any doubt as to the homogeneity of the semi-finished The welding torch should be in operation at least 15 min. prior to
products and/or the welding filler, for example, the absence of commencing welding and checking the parameters.
labelling or if material changes are of a concern as a result of Repeated checks are recommended in the case of prolonged
– improper storage, welding jobs or after interruption of work.
– low joining component temperatures, The welder must establish the appropriate welding speed and
– soiling pressure with practice, and carry out regular checks. The welding
– aging, pressure required can, for example, be checked by test welding
– operational influences (media, temperatures) on a platform balance.
the welding compatibility is to be ascertained with testing on All measurements must be carried out regularly with calibrated
sample welds. and tested measuring equipment according to Supplement 2 and
430
must be documented (Appendix 2). The temperature meters Especially in the case of joining parts subject to prolonged
used should have a maximum deviation in their working range of exposure to UV or media, the damaged layer can be so deep that
± 3 K. it is necessary, after mechanical processing, to check the
residual wall thickness taking into account the static
requirements.
8 Preparation for welding
For the materials PVC, PP, PE and PVDF, the welding filler must
be mechanically treated (scraped) with suitable tools prior to
The weld edges of the joining surfaces are prepared according to welding.
Section 5. It must be ensured that adequate accessibility to the
welding equipment to the joining surfaces is achieved. Problems Should the joining surfaces need to be cleaned, non-fat cleaners
experienced by the welder as a result of the welding force applied should be used.
by the welder should be avoided or minimised. The welder
should not be hindered in the necessary advancement of the 9.2 Tacking
connection cables, hoses, and the welding filler. Tacking serves to fix the joining parts together in their intended
position to avoid displacement of the joining parts during welding.
8.1 Equipment Tacking is often carried out by melting the joining surfaces with a
The following equipment represents the minimum requirement for special tacking nozzle or an equivalent nozzle attachment.
carrying out professional welding:
– Hot gas device in accordance with this technical code and 9.3 Hot-gas welding with torch separate from filler rod (WF)
Supplement 2 In hot-gas welding with torch separate from filler rod, the joining
– Flowmeter for welding gas pressure is applied by hand via the welding filler. The welding
filler should be stretched, compressed or twisted as little as
– Fast display, digital temperature meter possible in this process to minimize the occurrence of residual
– Suitable measuring equipment to check displacement / diame- stress in the weld.
ter / thickness At the beginning of a welding pass, it is recommended to slightly
– Suitable equipment storage facilities bevel the tip of the welding filler.
– Scraper, retractable blade, nozzle brush, wire cutting pliers or The nozzle aperture should be directed into the welding zone at
similar an angle of approx. 45° to the base material. The base material
and the welding filler are plasticized with triangular fanning
– Table of welding parameter acc. to Supplement 1 and/or in- motion in the direction of welding. The bevelled welding filler is
structions from the semi-finished products manufacturer then pressed onto the desired point and the fanning motion
– Welding record sheet acc. to Appendix 2 continued in the welding direction.
– Personal protective equipment The joining pressure is applied by hand on the welding filler such
that it then forms a welding string.
– Dust protection for welding filler
During welding, a bow wave of plasticized material spreading in
– Adequate illumination front of the welding filler must be observed, as well as a welding
– Protection against weather as required seam in the form of a uniform double bead on both sides of the
weld string-bead.
– Special cleaner as required (non-swelling, dissolving or contai-
ning fat), lint-free cloths The welding parameters – joining pressure, temperature and the
heat penetration time resulting from the welding speed and the
8.2 Protection against environmental influences material thickness – are to be balanced against each other
(welding parameters – see Supplement 1).
The environmental conditions can have a significant effect on the
welding process and therefore the quality of the joint. The When commencing on a welding string already made or in the
following points should therefore be observed: case of round welds, proceed according to the representation in
Fig. 6. At the end of welding, the welding rod should not be
– The welding area should be protected against the weather twisted off or torn off, but, for example, removed with a knife or
conditions (e.g. moisture, wind, draughts and temperatures be- cutting pliers. After each welding pass the weld should be
low + 5 °C). reworked without scoring using a suitable scraper.
– If the appropriate measures (for example preheating, enclos-
ure in a tent, heating) ensure that an adequate temperature of
the semi-finished products can be maintained for welding, wel-
ding can be carried out at any outside temperature provided
the welder’s manual skill is not impaired. It may be required to
produce test welds under the prevailing conditions as additio- Commencing at the beginning
nal verification. of a weld
– If the joining parts are of an uneven temperature, for example

due to sunshine incident on one side, different storage conditi-
ons etc., the temperature must be equilibrated prior to welding.
9 Welding
9.1 Preparing the joining surfaces and the welding filler

The joining surfaces must not be damaged, oxidized or soiled.
They and the adjacent edges must therefore be mechanically
treated prior to welding.
Mechanical cutting tools, such as scrapers, retractable blades,
mills and drills are suitable for removal. Grinding tools are only Commencing within the weld
permissible if soiling, through the use of grinding equipment and
overheating of the surface, can be avoided. Figure 6. Welding rod positioning.
431
9.4 Hot-gas string-bead welding (WZ) 9.6 Thermal reworking
Residual stress within the weld can be reduced by tempering.
In hot-gas string-bead welding, the welding filler is pressed via The temperature conditions depend on the material and
the nozzle shoe at the end of the draw nozzle into the joining component. The specifications from the semi-finished products
zone. At the start and finish of welds, the same procedure is to be manufacturer are to be observed.
followed as in WF welding, Fig. 2.
9.7 Welding record sheet
The base material is preheated at the beginning of the actual
welding process with the stream of air from main nozzle aperture The welding record sheet also documents the welding conditions
in a fanning motion. The welding filler is then fed into the nozzle and the welding parameters. It forms the basis for the
and is also preheated. As soon as the surfaces of the joining assessment of the weld quality by the welding inspector (cf. DVS
parts are plasticized, the filler is pressed into the prepared 2213 and the sample record sheet in Appendix 2).
welding joint with the tacking tip and the welding machine is
passed along the welding joint under uniform application of
joining pressure. 10 Testing the welded joints
To avoid stretching of the welding filler through friction in the Destructive and non-destructive tests are distinguished. They are
nozzle, it may be necessary to feed the welding filler by hand. shown in Table 3 “Possible test procedures”
The drawing motion along the welding joint takes place while Visual inspection takes place according to DVS 2202-1 and
observing the emerging bow wave, the welding seam (double particularly concerns the weld shape, score-free surfaces and
bead) and the surface of the welding filler introduced. Scoring of edges, optimal weld filling, continuous welding of the root and
the base material arising from improper handling of the draw displacement of the joining parts.
nozzle (tacking tip) should be avoided.
Defects inside the welds can be determined non-destructively
with ultrasound and x-ray testing (see DVS 2206). These
After each welding pass, the weld should be reworked without techniques alone cannot however provide an adequate indication
scoring using a suitable scraper, as with hot-gas welding with of the quality of the welded joint. The possibilities of applying
torch separate from filler rod. these test methods is also limited in regard to the weld geometry
and thickness.
9.5 Mechanical reworking of the weld The nature and scope of the tests to be undertaken in the
individual case are to be defined.
It is normally not necessary to rework the weld. If the weld is
mechanically reworked, care should be taken to avoid scoring. General material specific tests can be found in DVS 2201-1 and
Reworking may only take place once the weld has cooled DVS 2206.
sufficiently.
Table 3. Possible testing methods for hot-gas welds.
Non-destructive testing
Visual inspection of the intact weld Visual inspection according to DVS 2202-1 and 2206
(external findings) The evaluation group is to be defined on a case-by-case basis
Seal test with vacuum Using a vacuum bell jar and foaming liquid; the test conditions are to be defined on a
case-by-case basis. Usual testing pressure -0.4 to -0.5 bar.
Seal test with high voltage The type of test equipment (with or without counter pole) and test voltage are to be
defined on a case-by-case basis. Testing methods according to DVS 2206, para.
3.3.1.4
Radiation transmission testing Applicability: Evidence with the number, position, shape and size of pores, shrink
holes and similar defects possible. Testing method according to DVS 2206, Section
3.5
Ultrasound testing Applicable with PE-HD, restricted with PP (evidence of hollow sites, not of quality)
Testing method according to DVS 2206, Section 3.4
Pressure testing Typical application for pipelines; Testing conditions according to the German
Pressure Tank Ordinance / Pressure Equipment Directive. Test performed according
to DVS 2219-1 Supplement 2 and DIN 4279
Evidence: Sealing quality, experimental evidence for operational safety
Destructive testing
Visual inspection of the weld cross-section Form of the weld cross-section (weld geometry), inner findings according to DVS
2202-1 Tab. 4 and 5. Fracture surface of the weld destroyed by tensile testing or
technological bending trials.
Tensile testing Execution according to DVS 2203-2. Rapid tension-weld factor; DVS 2203-4 tensile
creep weld factor; Minimum requirements according to DVS 2203-1
Testing not applicable for fillet and bevel welds.
Technological bending test Minimum requirements (bending angle/distance) according to DVS 2203-1
Testing not applicable for fillet and bevel welds.
432
11 Safety instructions DVS 2205 Calculation of thermoplastic tanks and

apparatus
Some materials develop hazardous decomposition products and Part 3 Welded joints
poisonous vapours if overheated (for example PVC, PVDF and Part 4 Flanged joints
E-CTFE), others even when welded (for example FEP, MFA,
PFA, PTFE). In accordance with Article 20 of the German Part 5 Rectangular tanks
Hazardous Substances Ordinance (GefStoffV) or according DVS 2206 Testing of components and constructions
national regulations, the company owner must produce operating made of thermoplastic materials
instructions based on the manufacturer’s safety datasheets, DVS 2207-1 Welding of thermoplastics – electro fusion
which show all potential hazards and protective measures welding of pipes made of PE-X with
required. Other specific protective measures are to be defined on pipeline components and sheets made of
a case-by-case basis. PE-HD
The applicable safety regulations pertaining to welding in EX DVS 2207-3 Hot-gas welding of thermoplastics – hot-
protected areas are to be observed and the necessary measures Supplement 1 gas welding with torch separate from filler
are to be agreed with the safety office responsible; see the and string-bead welding of pipes, pipeline
German Workplace Safety Ordinance (BetrSichV) or according components and sheets – welding
national regulations in this regard. parameters
DVS 2207-3 Hot-gas welding of thermoplastics – hot-
Supplement 2 gas welding with torch separate from filler
and string-bead welding of pipes, pipeline
12 Other applicable standards and technical codes components and sheets – welding
equipment requirements
DIN 1910-3 Welding of plastics, processes
DVS 2207-3 Hot-gas welding of thermoplastics – hotgas
DIN 4279 Testing of pressure pipelines for water by Supplement 3 welding with torch separate from filler and
internal pressure – Low density PE-LD (in preparation) string-bead welding of pipes, pipeline
polyethylene pressure pipelines, high components and sheets – welding of fluor
density PE-HD (PE 80 and PE 100) plastics
polyethylene pressure pipelines, Cross-
linked PE-X polyethylene pressure DVS 2207-4 Welding of thermoplastics; extrusion
pipelines, unplasticized polyvinyl chloride welding of pipes, pipe components and
PVC-U pressure pipelines. sheets – Welding processes, requirements
DIN 16960-1 Welding of thermoplastics – principles DVS 2207-5 Welding of thermoplastics; Welding of PE-
pipe jacktets – pipes and pipe components
DIN 32502 Imperfections in plastic welded joints;
classification, terminology, Explanations DVS 2207-11 Welding of thermoplastics – heated tool
welding of pipes, pipeline components and
DIN EN 10204 Metallic products – Types of inspection sheets made of PP
documents
DVS 2207-15 Welding of thermoplastics – heated tool
DIN EN 12943 Filler materials for thermoplastics welding of pipes, pipeline components and
DIN EN 22553 Welded, brazed and soldered joints – sheets made of PVDF
Symbolic representation on drawings DVS 2210-1 Industrial pipelines made of thermoplastics
DIN EN ISO 1043-1 Plastics – symbols and abbreviated terms – planning and execution – above-ground
DVS 2201-2 Testing of semi-finished products of pipe systems
thermoplastics, weldability, test methods – DVS 2211 Filler Materials for thermoplastics – scope,
requirements designation, requirements and tests
DVS 2202-1 Imperfections in thermoplastic welding DVS 2212-1 Examination of plastic welders: Examina-
joints; tion groups I and II
Features, descriptions, evaluation DVS 2213 Plastic welding specialist – Examination
DVS 2203 Testing of welded joints of thermoplastics DVS 2225 Joining of lining membranes made of
Part 1 Test methods – requirements polymer materials in geotechnical and
hydraulic engineering
Part 2 Tensile test
Part 4 Tensile creep test DIN standards may be obtained from Beuth Verlag, Berlin, DVS
technical codes from Verlag für Schweißen und verwandte
Part 5 Technological bending test Verfahren DVS-Verlag GmbH, Düsseldorf.
433
Appendix 1: Brief instructions for welding 4. Commissioning welding equipment and setting parameters
(Section 7)
1. Compile welding equipment (Section 8.1) – Check supply lines (electricity, air) for any possible interrup-
– Valid welding certificate in accordance with DVS 2212-1 tion of the welding process.
– Hot-gas welding equipment with operating instructions – Connect and switch on the welding equipment according to
the operating instructions
– Welding nozzles suitable for the welding job and the wel-
ding filler – Select and fit hot-gas nozzle; set hot-gas flow rate and tem-
perature and check (Supplement 1)
– Flowmeter for welding gas
– Temperature meter with probe to measure the hot-gas and 5. Prepare the weld and joining surfaces (Section 5.8)
the semi-finished product temperature.
– Check weld geometry and shape, define and produce as re-
– Suitable measuring equipment to check displacement, dia- quired
meter, thickness
– Mechanically remove the oxide layer from the joining sur-
– Equipment storage facilities faces with abrasion immediately prior to welding
– Scraper, retractable blade
– Personal protective equipment 6. Tacking the joining surfaces (Section 9.2)
– Dust protection for welding filler – Partial or continuous tacking with tack nozzle
– Cleaning agent
7. Welding (Sections 9.3, 9.4)
– Supplement 1 Welding parameters
– Monitor the welding speed and check uniformity
– Appendix 2 Welding record sheet
– Continuously check the handling of the welding filler and
– Special welding instructions, as required
the draw nozzle and perform necessary corrections
2. Check working conditions and plan measures – Bevel the weld end before commencing afresh
(Section 8.2) – Scrape the weld seam of each weld zone before applying
– Accessibility further weld
– Adequate illumination – Protect the welding filler from soiling
– Protective tent
8. Reworking the welds (Section 9.7)
– Heating
– Allow the welded parts to cool down sufficiently before un-
– Measurement of the semi-finished product temperature and clamping and loading
introduce measures, as required
– Mechanically process weld scoring and the welding seam
on the weld flanks
3. Check welding suitability (Section 6.1)
– Check the manufacturer’s specifications on the semi-fin- 9. Complete the welding record sheet (Section 9.6)
ished products and welding filler for compatibility
– Complete the welding record sheet (Appendix 2) and carry
– Check the identity, condition and cleanliness of the joining
out visual inspection according to DVS 2202- 1
parts and clean as required
– Check the weldability of the joining parts with contract weld-
ing according to DVS 2201- 2 or test welding
434
Appendix 2: Welding record sheet
Hot-gas welding of sheets and pipes Company logo

Welding record sheet
Project name: Project no.: Weather Protective
measures
Drawing no.: Base material (manufacturer, type, batch, date) form: 1 = sunny 1 = none
Welder: Welding filler (manufacturer, type, batch, date): 2 = dry 2 = screen
Welding certificate no.: / valid until, issued by: Welding equipment (make, type): 3 = precipi- 3 = tent
3 = tation
Welding inspector (2): Nozzle(s): 4 = wind 4 = heating
Date Construction Weld Joining Weld Process Air flow (1) Hot-gas Ambient Semi-finished Weather Protective Visual
detail no. part shape WF, WZ l/min temperature temperature product temp. (code no.) measures assessment
thickness (symbol) °C °C °C (code no.)
mm
(1) Measured in the middle of the nozzle exit aperture, 5 mm inside

the nozzle Remarks, e.g. adverse conditions
(2) e.g. plastic welding specialist as defined in DVS 2213
Date / welder signature Date / welding inspector signature

435
Draft March 2013
DVS – DEUTSCHER VERBAND Hot gas string-bead
FÜR SCHWEISSEN UND and fan welding of pipes Technical Code
VERWANDTE VERFAHREN E.V. piping parts and panels – DVS 2207-3
Welding parameters Supplement 1
Objections by June 30, 2013

Replaces draft dated May 2009
Planned as the replacement for the April 2005 edition
This supplement to the DVS 2207-3 technical code includes guide values for the welding parameters for hot gas string-bead and fan
welding. They apply to manual welding with the devices described in the DVS 2207-3 technical code, Supplement 2 and with the
materials listed in the table.
In addition, before the application of the parameters, attention must also be paid to the information from the manufacturers of the semi-
finished products.
By coordinating the hot gas temperature, gas volume and welding speed parameters, it must be guaranteed that the joining parts are
plastified down to a depth of min. 0.3 mm at the joint.
Hot gas Hot gas Welding Welding force [N]

Welding temperature1) volume flow2) speedt3) with wire 
Material Abbreviation
process
[°C] [Nl/min] [mm/min] 3 mm 4 mm
High-density polyethylene PE-HD4) 300–320 70–90
PP-H, PP-B and 8–10
Hot gas fan
Polypropylene, Types 1, 2 and 3 305–315 60–85

welding
PP-R 20–25
(WF)
40–50
Unplasticised polyvinyl chloride PVC-U 330–350 110–170 8–10
Chlorinated polyvinyl chloride PVC-C 340–360 55–85
15–20
Polyvinylidene fluoride PVDF 350–370 45–50 25–30
High-density polyethylene PE-HD 300–340
Hot gas string-bead
PP-H, PP-B and

Polypropylene, Types 1, 2 and 3 300–340 250–350 15–20 25–35
PP-R
welding
(WZ)
Unplasticised polyvinyl chloride PVC-U 350–370 45–55
Chlorinated polyvinyl chloride PVC-C 370–390 180–220

20–25 30–35
Polyvinylidene fluoride PVDF 365–385 200–250
1) Measured 5 mm in the nozzle, in the centre of the main nozzle opening

2) Drawn-in cold air volume at the ambient pressure
3) Depending on the welding filler material diameter and the welding groove geometry
4) PE 63, PE 80 and PE 100
436
April 2005
DVS – DEUTSCHER VERBAND Welding of thermoplastics –

FÜR SCHWEISSEN UND
Hot gas string-bead and fan welding of pipes, Technical Code
piping parts and panels – DVS 2207-3
Replacement for DVS 2207-3, supplement, April 1986 edition
This supplement to the DVS 2207-3 technical code includes In addition, before the application of the parameters, attention
guide values for the parameters for hot gas string-bead and fan must also be paid to the information from the manufacturers of
welding. They apply to manual welding with the devices de- the semi-finished products.
scribed in the DVS 2207-3 technical code, Supplement 2 and By coordinating the hot air temperature, air volume and welding
with the materials listed in the table. speed parameters, it must be guaranteed that the joining parts
are plastified down to a depth of min. 0.3 mm at the joint.
Hot gas Hot gas Welding Welding force (N)

Welding temperature1) volume flow 2) speed3) with stick diameter
Material Abbreviation
process oC Nl/min mm/min 3 mm 4 mm
High-density polyethylene PE-HD4) 300 ... 320 70 ... 90

Hot gas fan welding
PP-H; PP-B; 8 ... 10

Polypropylene, Types 1, 2 and 3 305 ... 315 60 ... 85
PP-R 20 ... 25
(WF)
40 ... 50
Unplasticised polyvinyl chloride PVC-U 330 ... 350 110 ... 170 8 ... 10
Chlorinated polyvinyl chloride PVC-C 340 ... 360 55 ... 85
15 ... 20
Polyvinylidene fluoride PVDF 350 ... 370 45 ... 50 25 ... 30
High-density polyethylene PE-HD 300 ... 340
PP-H; PP-B;
Polypropylene, Types 1, 2 and 3 300 ... 340 250 ... 350 15 ... 20 25 ... 35
PP-R
Hot gas string-bead welding
45 ... 55
Unplasticised polyvinyl chloride PVC-U 350 ... 370
Chlorinated polyvinyl chloride PVC-C 370 ... 390 180 ... 220
20 ... 25 30 ... 35
Polyvinylidene fluoride PVDF 365 ... 385 200 ... 250
WZ
50 ... 60
Ethylene / chlorotrifluoroethylene E/CTFE 350 ... 380 Hot gas 220 ... 250
Nitrogen
Tetrafluoroethylene perfluorovinyl
FEP 380 ... 390 10 ... 15 No data
ether copolymer
60 ... 80
Tetrafluoroethylene 50 ... 60
MFA 395 ... 405
perfluoromethyl vinyl ether
Perfluoroalcoxy copolymer PFA 400 ... 410 70
1) Measured 5 mm in the nozzle in the centre of the main nozzle opening
3) Depending on the welding filler material diameter and the welding groove geometry
4) PE 63, PE 80 and PE 100
437
Draft March 2013
DVS – DEUTSCHER VERBAND Hot-gas string-bead welding and hot-gas welding
FÜR SCHWEISSEN UND with torch separate from filler rod of pipes, Technical Code
VERWANDTE VERFAHREN E.V. pipe components and sheets – DVS 2207-3
Requirements for welding equipment and accessories Supplement 2
Objections to be submitted by 30 June 2013
Intended as replacement for issue dated April 2005
This draft is being published for the purposes of inspection and comment. Suggestions for additions or modifications should be submitted
to DVS e.V., Postfach 10 19 65, 40010 Düsseldorf.
Contents: – all functional components can be easily accessed in accord-

ance with the intended usage as well as for cleaning and main-
1 Scope tenance purposes, wearing parts can be easily replaced
2 Requirements
– supply hoses and cables are flexible and cause no great exer-
2.1 General requirements
tion for the welder, neither do they kink or twist during proper
2.2 Safety requirements
usage
2.3 Marking and documentation
2.4 Hot-gas supply – they can be safely stowed away after the welding operation
2.5 Nozzles has been completed or during stoppages

2.6 Flow meters
3 References – the nozzles used can be easily replaced and safely fixed in
position, even when hot
– a constant welding gas temperature is achieved after max.
1 Scope 15 minutes
This supplement to Guideline DVS 2207-3 describes the general, – the control elements are protected against accidental manipu-
qualitative and safety-relevant requirements on equipment and lation
the necessary accessories to perform hot-gas string-bead welding The equipment must comply with the applicable European direc-
and hot-gas welding with torch separate from filler rod (WZ, WF) tives, see section 3.
on thermoplastic materials.
The manufacturer or his authorised representative established in
It applies to the equipment types specified in Guideline DVS the Community is responsible for issuing the EU Declaration of
2207-3 with and without a dedicated hot-gas supply as well as Conformity and the CE mark. The market surveillance authorities
controlled or regulated equipment. It seeks to ensure that the must on request be presented with all relevant measuring and
required seam quality is achieved from the proper handling and testing documentation that verifies conformity with the directives.
usage of the equipment.
Specific equipment for special applications are not covered by 2.2 Safety requirements
this supplement. The equipment must afford the user protection against injuries of
all kinds during the proper usage of the equipment. In particular:
2 Requirements – Parts in proximity to the user must not exceed an operational
temperature of + 40°C, even during periods of extended use.
2.1 General requirements – Equipment surfaces that pose a risk of burns must be kept as
The equipment must ensure that small as possible or isolated and indicated accordingly where
necessary.
– safe and reliable operation is guaranteed within the tempera-
ture range (10 to + 50°C) and a max. air humidity of 60% – An overtemperature protection device must be fitted to prevent
– storage within a temperature range of (20 to + 60°C) does overheating or destruction of the equipment or individual com-
not cause any damage ponents (e.g. due to lack of air).
– the mechanical loads incurred during proper transport and op- – Sharp edges on the machine and accessories must be avoided.
eration do not cause any faults or damage
– sufficient protection against corrosion from externally-acting
humidity is present The following must be permanently affixed to all equipment:
– the equipment tools are ergonomically designed in accordance – Manufacturer's details and equipment type
with their purpose and handling, are of the lowest weight possi- – Power supply, power consumption and frequency details
ble and can be used easily and safely
– ID number
– the handle together with the leads are bi-directional, the nozzle
can be fixed in any position – CE mark and protection class
438
Operating and maintenance manuals must be provided for all – The guide surfaces for the filler material must be polished.
equipment, which contain at the very least:
– Functional description with operating instructions – The nozzle material must be low-scaling and slow-corroding.
– Application area – The contact piece must be designed in such a way that the
– Maintenance plan with test cycle details required electrode pressure can be safely applied to the filler
material (e.g. even during the root pass of a single-V butt weld)
– Service addresses and that the edges of the contact piece do not leave any
A compilation of possible operating errors including possible notches in the base material during welding.
causes and solutions is recommended.
2.6 Flow meters
2.4 Hot-gas supply
Regardless of the equipment design, the welding gas supply Flow meters for measuring and setting the hot-gas flow must not
must ensure that exceed a maximum deviation of 3.0% from the full scale value. In
general situations, the design should permit a flow of 100 l/min in
– the welding gas is free of dust, water and oil standard conditions at 20°C and with an average delivery pres-
– the volume of gas remains constant throughout the welding sure to the downstream equipment. Rotameters or orifice flow-
operation and a supply of air adjusted to the particular welding meters with a pre-pressure display calibrated in standard litres
task as per Guideline DVS 2207-3 Supplement 1 is also pro- have proven to be suitable in this respect.
vided if, for example, several welding systems are in continuous
operation
– the temperature fluctuations at the nozzle do not exceed ± 5 K, 3 References
regardless of the fluctuations in voltage or gas flow, nozzle
shapes and differing ambient temperatures DIN EN 55014-1 Electromagnetic compatibility. Requirements
for household appliances, electric tools and
– the welding gas temperature can be set easily and precisely
similar apparatus. Part 1: Emission
and cannot be changed accidentally
DIN EN 55014-2 Electromagnetic compatibility. Requirements
– the emerging gas volume deviates by no more than  5% from for household appliances, electric tools and
the set value regardless of any back pressure fluctuations similar apparatus. Part 2: Immunity. Product
caused by the task at hand (e.g. unfavourable nozzle position) family standard
For welding equipment with a built-in air supply, it must be en- DIN EN 60335-1 Household and similar electrical appliances.
sured that Safety. Part 1: General requirements
– the intake-air openings are designed such that a sufficient in- DIN EN Household and similar electrical appliances.
take of air is guaranteed at all times during proper usage of the 60335-2-45 Safety. Part 2-45: Particular requirements
equipment (e.g. cannot be covered by the hand) for portable heating tools and similar appli-
– the filter element is easy to change ances
DIN EN 61000-3-2 Electromagnetic compatibility (EMC). Part 3-2:
If welding gas is being supplied from an external source, the gas Limits. Limits for harmonic current emissions
temperature from the central supply must not exceed 50°C. (equipment input current  16 A per phase)
2.5 Nozzles DIN EN 61000-3-3 Electromagnetic compatibility (EMC). Part 3-3:
Limits. Limitation of voltage changes, voltage
The following criteria apply to welding nozzles for hot-gas string fluctuations and flicker in public low-voltage
bead welding: supply systems, for equipment with rated
– The welding nozzles must be suitable for the material to be current  16 A per phase and not subject to
welded (Figure 1). conditional connection
DIN EN 61000-6-2 Electromagnetic compatibility (EMC). Part 6-2:
– The nozzles must be suitable for the filler material cross-sec-
Generic standards. Immunity for industrial
tion to be welded and permit easy guidance of the filler mate-
environments
rial even when its volume expands.
Flat high-speed welding Steep high-speed welding nozzle, Wide slot nozzle, suitable
nozzle, suitable for PE, PP, suitable for FEP, PFA, etc. for capping strips (Capstrip)
PVC, PVDF, ECTFE, etc. e.g. with FEP, PFA
Figure 1. Hot-gas string bead welding nozzles.
439
DIN EN 62233 Measurement methods for electromagnetic

fields of household appliances and similar
apparatus with regard to human exposure
Leaflet Volume measurement of industrial gases for
DVS 0801 welding, cutting and allied working methods
Guideline Welding of thermoplastics – Hot-gas string-
DVS 2207-3 bead welding and hot-gas welding with torch
separate from filler rod of pipes, pipe com-
ponents and sheets – Methods, requirements
Guideline Welding of thermoplastics – High-speed hot
DVS 2207-3 gas string welding and hot-gas welding with
Supplement 1 the torch separate from the filler rod of
pipes, piping parts and panels – Welding
parameters
440
File-Name:
D:\Eigene Dateien\Kunden\DVS\Ri+Me\2207\englisch\e2207-3-Bb2.fm
September 2007
Welding of thermoplastics
DVS – DEUTSCHER VERBAND Hot-gas string-bead welding and hot-gas welding
FÜR SCHWEISSEN UND with torch separate from filler rod of pipes, pipe Technical Code
VERWANDTE VERFAHREN E.V. components and sheets – Requirements for DVS 2207-3
welding equipment and accessories Supplement 2
Translation of the German version from April 2005
Contents: – the nozzles used are also easy to remove and fit in the heated
state,
1 Applicability
– a constant welding temperature is achieved after a maximum
2 Requirements
of 15 minutes,
2.3 Labeling and documentation – the operating controls are protected against inadvertent
2.4 Hot-gas supply displacement.
2.5 Nozzles
2.6 Flowmeters 2.2 Safety requirements
3 Other applicable standards and technical codes
The equipment used in a proper manner must afford the user
protection against injuries of any nature. The applicable statutory
regulations governing the use of equipment must, in particular,
1 Applicability
be observed. (Also see Section 3)
This supplement to technical code DVS 2207- 3 describes, in Additionally applicable:
general terms, qualitative and safety-relevant requirements for
welding equipment and the necessary accessories for hot-gas – Parts in close proximity to hands must not exceed + 40°C
string-bead and hot-gas welding with torch separate from filler under operating condition even after prolonged usage.
rod (WZ, WF) of thermoplastics. – Equipment surfaces presenting a burn hazard are to be kept
It applies to the types of equipment described in technical code as small as possible, or isolated and labelled as required.
2207-3, with and without built-in hot-gas supply, as well as – Over-temperature protection must be fitted to avoid overheat-
controlled or regulated, and serves to ensure that the required ing or destruction of the equipment or individual elements (for
weld quality is achieved provided the equipment is operated and example due to a shortage of air).
handled correctly.
– Sharp edges on equipment and accessories are to be avoided.
Special devices for special applications are not covered within
the scope of this supplement. 2.3 Labelling and documentation
All equipment must display at all times:
2 Requirements – specifications of manufacturer and model,
2.1 General requirements – specifications on power supply, power consumption and fre-
quency,
The equipment must ensure that
– identification number,
– safe functionality is ensured within the intended temperature
application range (- 5 to + 60 °C), – CE mark and protection class.
– storage within a temperature range of - 5 to + 60°C causes no All equipment must include operating and maintenance instruc-
damage, tions, which contain at least:
– no faults or damage arise as a result of the mechanical strain – functional description and operating instructions,
arising during proper transportation and operation,
– specifications on areas of application,
– there is adequate corrosion protection against moisture
entering from the outside, – maintenance schedule specifying service intervals,
– the equipment elements are ergonomically designed according – service addresses.

to their intended use and are as light as possible and may be A compilation of potential functional faults is recommended,
operated easily and safely, including possible causes and information on rectification.
– the handle has no preferred direction in relation to the supply
lines and that the nozzle can be fixed in any position, 2.4 Hot-gas supply
– the functional elements are easily accessible for proper Irrespective of the equipment construction, the welding gas
operation and for the necessary cleaning and maintenance supply must ensure that
and that expendable parts are easy to replace, – the welding gas is free of dust, water and oil,
– feed hoses and cables can be extended by the welder with the
– the gas volume remains constant during welding and an air
minimum of effort and do not kink or twist in proper operation,
flow matched to the welding job according to DVS 2207-3
– they can be stored safely when welding work is finished or Supplement 1 is provided even if several welding tools are in
during interruptions, continuous operation,
441
– the required air flow rate is adjustable for each welding tool 3 Other applicable standards and technical codes
and is displayed with an accuracy of ± 5 l/min,
EN 55014-1 EMC testing: emission
– the temperature fluctuations at the nozzle do not exceed ± 5 K
independent of voltage or air flow fluctuations, nozzle EN 55014-2 EMC testing: immission
geometry and differences in ambient temperatures, DIN EN Electrical equipment of industrial machines
– setting of the welding temperature is easy and sensitive and 60204- 1
cannot be inadvertently displaced, EN 61000-3-2 Electromagnetic compatibility (EMC) Part 3-2:
– the output gas volumes fluctuate in a maximum range of ± 5% Limit values – limit values for harmonic current
from the set value, independent of process-related counter- emissions (equipment input currents 16 A per
pressure fluctuations (for example unfavourable nozzle phase)
position). EN 61000-3-3 Electromagnetic compatibility (EMC) Part 3-3:
Limits: Limitation of voltage changes, voltage
For welding torches with integrated air supply it must be ensured
fluctuations and flicker in public low-voltage
that
supply systems, for equipment with rated cur-
– the air suction openings are fitted such that they allow rent 16 A per phase and not subject to condi-
sufficient entry of air at all times for proper use of the tional connection.
equipment (for example no covering with hands), EN 60335-1 Safety for household and similar electrical
– the filter element is easy to change. appliances – Part 1: General requirements
In the case of an external welding gas supply, the temperature of EN 60335-2.45 Safety for household and similar electrical
the gas from the central supply must not exceed 50°C appliances – Part 2-45: Special requirements
VDE 0875 Radio interference suppression of electrical
2.5 Nozzles devices and systems for rated frequencies of 0
For nozzles in hot-gas string-bead welding: to 10 kHz
– The nozzles must match the cross-section of the welding filler DVS 0801 Flow measurement of technical gases for weld-
to be used and must also allow the smooth passage of welding ing, cutting and related procedures
filler taking into account its volume expansion. DVS 2207-3 Hot-gas welding of thermoplastics – hot-gas
string-bead and hot-gas welding with torch
– The leading surface of the nozzle shoe must be polished.
separate from filler rod of pipes, pipeline com-
– The nozzle material must be resistant to oxidation and ponents and sheets – methods, requirements
corrosion. DVS 2207-3 Hot-gas welding of thermoplastics – Hot-gas
– The nozzle shoe must be formed such that its edges do not Supl. 1 welding with torch separate from filler and
score the base material. string-bead welding of pipes, pipeline compo-
nents and sheets – welding parameters
The aforementioned statements apply in principle as well to
pressure rollers for welding soft materials (e.g. soft PVC).
2.6 Flowmeters
Flowmeters to measure and regulate the flow of hot gas must not
exceed a maximum deviation of 3.0% of the maximum scale
value. They should normally be designed for 100 l/min under
normal conditions at 20°C and average working pressure of the
equipment connected. Suspended body flowmeters or orifice
flowmeters calibrated with pre-pressure display in standard litres
have proven effective.
442
Draft March 2013

FÜR SCHWEISSEN UND
Hot gas string-bead and fan welding of pipes, Technical Code
Welding of fluoroplastics Supplement 3
Replaces draft edition dated May 2009
Contents: The welding work must be monitored. The contracting parties

must reach agreement about the type and scope of the monitoring,
1 Scope of application see Section 7.
3 Materials All the welders must be trained and possess valid proof of their
4 Structural configuration, weld shapes and weld build-up qualifications. The hot gas welding according to this technical
5 Requirements on the materials and their weldability code is governed by the DVS 2212-1 guideline.
6 Welding parameters The requirements apply analogously to the welding of materials
7 Requirements on the quality of the welded joints which have not yet been specified in the DVS 2212-1 guideline
8 Requirements on the welding devices and the welding (e.g. FEP, PFA, MFA, ECTFE ...). The proof of qualification must be
nozzles provided in the form of proof of suitability, adjusted to the applica-
9 Requirements on the welders tion in question and with reference to the guideline.
10 Welding
10.1 Welding preparations and equipment
10.2 Fixing of the joining parts 3 Materials
10.3 Execution of the welding
10.4 Post-machining of the welds
11 Welding record sheet The supplement applies to the materials listed below. The weld-
12 Testing and inspection of the welded joints ing is primarily carried out on sheets, panels and pipes with material
13 Safety instructions thicknesses of 1 - 4 mm.
14 Literature ECTFE Ethylene chlorotrifluoroethylene
FEP Tetrafluoroethylene perfluorovinyl ether copolymer
1 Scope of application PFA Perfluoroalkoxy copolymer
PTFE-m Modified polytetrafluoroethylene
This supplement to the DVS 2207-3 technical code applies to the
hot gas string-bead welding of thermoplastic fluoroplastics. It
supplements the technical code and describes, in particular, de- 4 Structural configuration, weld shapes and weld build-up
viating and special procedures and requirements during the weld-
ing of the materials in apparatus, tank and pipeline construction. The components are designed in relation to the geometrical and
Because of their high chemical resistances with comparatively mechanical requirements on the load-bearing material (substrate).
low mechanical strengths, the fluoroplastics are predominantly However, in this respect already, attention should also always be
utilised for the lining of steel and GFRP components. For this pur- paid to the structural and welding technology possibilities of the
pose, the films are mostly provided with an adhesion-promoting fluoropolymers (cf. DIN EN 14879-4), to the instructions from the
lamination on one side in order to guarantee the bond to the sub- manufacturers of the semi-finished products as well as to any
strate material. The usual welding process is hot gas string-bead safety data sheets which are also applicable.
welding. Hot gas fan welding is not taken into consideration below. Usual weld shapes are indicated on Figs. 1 to 4. In principle, sin-
gle-V and double-V welds are manufactured with welding groove
preparation angles of 50 - 70° with ECTFE and PTFE-m and
2 General requirements 20 - 40° with FEP and PFA. Round sections which have diame-
ters of 3 - 4 mm and are welded in one pass in most cases be-
For the welding of the fluoroplastics, the welders must have spe- cause of the low material thicknesses are utilised as the welding
cial knowledge and skills, in addition to the criteria specified in filler material. Double-V welds, welds with cap passes and double
the DVS 2207-3 technical code. These can be acquired in DVS fillet welds are recommendable in order to avoid any notches in
course centres and at manufacturers of semi-finished products. the weld root (Figs. 2a and 4b).
Furthermore, the quality of the welded joints is influenced by the
In the case of lined GFRP components, it is recommended to
suitability of the utilised materials, the quality of the welding de-
execute an additional cover pass (cap strip), also provided with
vices as well as the compliance with the technical codes for weld-
an adhesion-promoting coating (e.g. fabric layer), over the ma-
ing.
chined-off weld (Fig. 2). This serves to ensure the full-area bond-
The welds can be tested and inspected using non-destructive ing of the GFRP material to the lining and decreases any possi-
and destructive procedures. ble tensile or compressive stresses in the weld (Fig. 2b).
443
Lap welds (Fig. 3) are frequently applied for so-called loose-shirt 5 Requirements on the materials and their weldability
linings but, in the case of execution from one side, need particu-
lar attention with regard to the quality of the execution. The base materials and welding filler materials to be welded must
be of the same kind and type. However, PFA welding filler mate-
rial is used with the PTFE-m base material as a rule. In addition
to the material certificates to be agreed upon (e.g. works certifi-
cate with reference to DIN EN 10204), it is imperative to identify
the materials of the semi-finished products and the welding filler
materials in an unmistakable way. In the case of welding filler
materials, the identification is located on the packaging and there
a) may be suitable stamping directly on the welding filler material in
addition.
Appropriate measures must be taken in order to exclude any
mixing-up of the materials during the processing.
It must also be ensured that the welding filler materials and the
base material are protected from contaminations and moisture in
a suitable way.
b) The welding filler materials must satisfy the requirements accord-
ing to the DVS 2211 technical code.
Figure 1. Weld geometry of a single-V weld for fluoroplastics;
a) weld and weld geometry of a single-V weld in the case of
ECTFE
b) weld and weld geometry of a single-V weld in the case of 6 Welding parameters
FEP and PFA
By coordinating the hot gas temperature, hot gas volume, joining
pressure and welding speed parameters, it must be guaranteed
that the joining parts are plastified sufficiently at the joint. Those
guide values for the joining parameters which were established
using practical investigations are listed in Table 1. Deviating in-
a) formation from manufacturers is possible. If this is used, attention
must be paid to the measuring points, e.g. for temperature meas-
urement.
7 Requirements on the quality of the welded joints
High-quality welds are achieved reliably if the welds are executed

b) properly, according to this technical code. Generally binding
technical codes for testing and inspection as well as minimum
Figure 2. Double-V weld and single-V weld with an additionally welded-
requirements on the weld quality are under preparation.
on cap strip
a) double-V weld It is recommended that the contracting parties should reach
b) single-V weld with a welded-on cap strip agreement about the necessary minimum quality of the welds de-
pending on the requirements on the component. Instructions
about this are given in Section 12 and in the DVS 2202-1 techni-
cal code.
The proof that the demanded quality has been achieved must be
provided on trial welds and documented.
a)
8 Requirements on the welding devices and the welding
nozzles
Because of the more precise temperature control, exclusively

b) electronically regulated devices are recommended for the welding
Figure 3. Lap welds of fluoroplastics, see the DVS 2207-3 technical code, Section 5.
a) one-sided lap weld
b) double-sided lap weld With regard to their preheating zones, the welding nozzles must
correspond to the melting behaviour of the materials and to the
different plastification phenomena of the welding filler material
a) b) and the base material, e.g. during the welding of PTFE-m / PFA.
Requirements on the shape of the nozzles and on the materials
are described in the DVS 2207-3 technical code, Supplement 2.
9 Requirements on the welders
Because of the slow welding operation (see Table 1), the welders
are mostly exposed to high continuous physical burdens. Moreo-
ver, the protective equipment to be worn during the welding (see
Section 12 – with the exception of ECTFE) sets additional re-
quirements on the welders. In order to guarantee a uniformly high
Figure 4. Fillet welds weld quality, this must be taken into consideration in a suitable
a) single-bevel butt weld with a fillet weld form. Jigs for partially mechanised welding are recommended for
b) double fillet weld longer welding work.
444
Table 1. Guide values for the welding parameters for hot gas string-bead welding
Hot gas tem- Hot gas Welding Welding force with

Welding
process
Material Abbreviation perature1) volume flow2) speed 3) wire 

[°C] [Nl/min] [mm/min] 3 mm 4 mm
400 … 420 50 … 60 220 … 250 20 … 25
Ethylene chlorotrifluoroethylene ECTFE 4) Hot gas,
400 … 420 N2 or air6) 180 … 220 25 … 30
Hot gas string-bead welding
Tetrafluoroethylene perfluorovinyl 440 … 470 60 … 80 15 … 20

FEP4)
ether copolymer 440 … 470 40 … 60 20 … 30
Tetrafluoroethylene perfluoromethyl 450 … 480 60 … 80 15 … 20

MFA4) 10 … 15
vinyl ether copolymer 450 … 480 40 … 60 20 … 30
50 … 60
450 … 480 60 … 80 15 … 20
Perfluoroalkoxy copolymer PFA4)
450 … 480 40 … 60 20 … 30
Polytetrafluoroethylene 490 … 510 50 … 70 15 … 20

PTFE-m4) 5)
(with PFA addition) 540 … 560 40 … 60 30 … 40
1) Measured 5 mm in the nozzle, in the centre of the main nozzle opening.
2) Drawn-in cold air volume at the ambient pressure.
3) Depending on the welding filler material diameter and the welding groove geometry.
4) The second value in each case applies to the welding of cap strips (approx. 6 - 12 mm wide). The welding force in question is dependent on the cap
strip width.
5) During the heating-up of the joining members, approx. 80 % of the hot air must be guided on to the base material (PTFE-m) and approx. 20 % on to the
welding filler material (PFA). Use special nozzles.
6) According to the current state of the art, both gases can be utilised as heat carriers.
10 Welding chip-producing process as in Section 10.1. On no account may

the weld be removed by means of grinding. In the case of multi-
10.1 Welding preparations and equipment pass welding, the lateral welding border of the preceding pass
must be removed before the subsequent pass is welded.
The stipulations made in Sections 9 and 9.2 in the DVS 2207-3
technical code are applicable. In addition to the equipment parts
specified in Section 9.1, it is necessary to provide any jigs
required for the extraction of the welding gases as well as for res- 11 Welding record sheet
piratory protection independent of circulating air, see Section 13.
In particular, V-shaped firmer chisels and flat mortise chisels are A welding record sheet must be filled in according to the
suitable for preparing the welding groove and removing the weld- DVS 2207-3 technical code, Section 10.7.
ing bead.
The joining faces must be clean, dry and grease-free. The weld-
12 Testing and inspection of the welded joints
ing filler wire is cleaned with a special grease-free detergent and
a non-fraying cloth.1)
10.2 Fixing of the joining parts testing and inspection procedures. These are listed in Table 2:
"Possible testing and inspection procedures for hot gas welds in
Since the fluoroplastics have a strong inclination to extreme dis- the case of fluoroplastics".
tortion when subjected to the action of heat, the joining members
must be fixed for the welding in a suitable way as close as possi- The requirements in the DVS 2202-1 technical code, Table 4,
ble to the joining point. Tacking without welding filler material is Assessment Group I analogously apply to the visual evaluation of
not possible. the weld quality. In this respect, attention must be paid, in partic-
ular, to undercuts, root defects, insufficient peripheral zone weld-
10.3 Execution of the welding ing and the misalignment of the joining faces.
The welding is executed according to the stipulations in the The weld quality cannot be established by means of destructive
DVS 2207-3 technical code, Section 10.4 and paying attention to tests on the welds either in the short-time tensile test according to
the welding parameters specified in Table 1. the DVS 2203-2 technical code because of the high elongations
at break of the materials or in the technological bending test
10.4 Post-machining of the welds according to the DVS 2203-5 technical code because of the low
elastic moduli.
As a rule, welds executed with a round profile are not post-ma-
chined. However, if (for example) a cap strip is to be welded in The weld quality can be evaluated by means of a short-time ten-
addition according to Fig. 2b, the weld must be removed in a sile test in which the stress-dependent elongation is considered
in relation to the base material. Assured, material-dependent
1)
requirement values are not yet available at the time of printing.
The cleaning fluid or any cloths which have already been moistened
with it in the factory must be made of a 100 % evaporating solvent, e.g. The leak tightness of the welds can be tested with high voltage.
99 parts of ethanol with a degree of purity of 99.8 % and one part of The execution of the test and the utilised testing devices are de-
MEKP (methyl ethyl ketone, denatured). Agents tested according to scribed in DIN EN 14879-4, prEN 13100-4 and the DVS 2206-4
DVGW VP 603 comply with this stipulation. The use of spirit may lead technical code. It is also possible to prove the leak tightness of a
to a deteroriation in quality due to the water contained in it.
weld by means of tests using suction bell jars subjected to a par-
The paper used for the cleaning must be clean, unused and absorbent tial vacuum. No statements about the strengths of the welded
and must not fray or be dyed.
joints can be made with either method.
445
Table 2. Possible testing and inspection procedures for hot gas welds in the case of fluoroplastics.
Non-destructive tests and inspections

Visual inspection of the undes-
Visual inspection, according to the DVS 2202-1 technical code, Table 4, Assessment Group I
troyed weld (external findings)
Leak test with a partial vacuum Using suitable vacuum bell jars and a foaming liquid; the testing conditions must be stipulated in
each individual case; usual testing pressure: - 0.4 bar to - 0.6 bar
Leak test with electric high The type of testing device (with or without an antipole) and the testing voltage must be stipulated in
voltage each individual case; testing voltages of 5 kV/mm of material thickness are usual; testing technique
according to the DVS 2206-4 technical code, DIN EN 14879-4 and prEN 13100-4
Destructive tests
Tensile test Execution with reference to the DVS 2203-2 technical code, short-time tensile test at a testing
speed of 50 mm/min and assessment of the elongation behaviour of the weld in comparison with
the unwelded specimen.
13 Safety instructions
14 Literature
The heating of the materials up to the welding temperature in
DIN EN 10204 Metallic products – Types of inspection docu-
question may lead to significant quantities of gases harmful to
ments
health. Inhalation causes influenza-like symptoms with a high fever
(polymer chills). The symptoms generally arise a few hours after prEN 13100-4 Non-destructive testing of welded joints of
the effect. In this case, it is imperative to consult a doctor. thermoplastics – Part 4: High-voltage testing
Therefore, stringent safety regulations must be complied with DIN EN 14879-4 Organic coating systems and linings for protec-
during the welding: tion of industrial apparatus and plants against
corrosion caused by aggressive media – Part 4:
– The welder must use EN-tested breathing apparatus, corre- Linings on metallic components
sponding to the recommendation in the technical bulletins con-
cerning respiratory protection (ZH-1/701 and ZH-6/606) and in Rules 190 of the Use of breathing apparatus
the DIN testing regulations. employers'
liability insurance
– A full respiratory protection mask independent of circulating air association
or a full respiratory protection mask. It is necessary to provide
DVGW VP 603 Provisional testing basis for detergents and
proof of a suitability examination on the welder (G 26/2 and
their containers for the preparation of welded
G 26/3 in Rules 190 of the employers' liability insurance asso-
joints on polyethylene pipes
ciation).
Technical code: Defects in welded joints between thermoplas-
– The mask must also guarantee the protection of the welder's DVS 2202-1 tics – Characteristics, description and assess-
eyes. ment
– At the welding workplaces, it is necessary to ensure sufficient Technical code: Testing of welded joints between thermoplas-
ventilation and venting, e.g. using local extraction hoods. DVS 2203-2 tics, tensile test
– Ideally, welding work should be carried out in a working area Technical code: Welding of thermoplastics – Welding of PE
screened off from other work or in a separate room. casing pipes – Pipes and piping parts
DVS 2203-5
– Smoking is prohibited at the workplaces and welding stations. Non-destructive tests and inspections on tanks,
Technical code:
The welders must not carry any tobacco products on them in apparatus and piping made of thermoplastics
DVS 2206-4
order to avoid any contamination by polymer dusts and chips – Testing with electric high voltage
and the health hazards connected with these due to inhalation
of the thermal decomposition products. Technical code: Welding of thermoplastics – Hot gas string-
DVS 2207-3 bead and fan welding of pipes, piping parts
– No food may be consumed in the direct working area. and panels – Processes and requirements
– The entrainment of fluoropolymer dust and chips out of the Technical code; Welding of thermoplastics – Hot gas string-
working area must be excluded by suitable working sequences DVS 2207-3, bead and fan welding of pipes, piping parts
as well as by personal hygiene, e.g. changing the working Supplement 2 and panels – Requirements on the welding
clothes and keeping them separate. devices and the accessories
– It must be ensured that waste and material residues cannot Technical code: Welding of thermoplastics – Welding filler
burn. Material-related or thermal recycling is possible in suita- DVS 2211 materials – Identification, requirements, tests
ble devices or in special installations. and inspections
– When disposing of fluoropolymer waste, it is necessary to com- Guideline: Qualification testing of plastics welders –
ply with the applicable statutory provisions and ordinances. DVS 2212-1 Qualification Test Groups I and II
Further instructions about the safe handling of fluoropolymers are Technical reports published by the PlasticsEurope Association
included in the EC safety data sheets from the suppliers of the of Plastics Manufacturers: "Guide for the safe handling of
raw materials or the semi-finished products as well as in the bro- fluoroplastic resins"
chure published by the PlasticsEurope Association of Plastics
Manufacturers: "Guide for the safe handling of fluoropolymer resins".
446
Draft March 2013

FÜR SCHWEISSEN UND
Extrusion welding of pipes,
piping parts and panels – Technical Code
Processes and requirements DVS 2207-4
Contents: earthwork construction and water engineering are included in the

DVS 2225-1 and DVS 2225-4 technical codes. Instructions for
1 Scope of application the extrusion welding of casing pipes are included in the
2 General requirements DVS 2207-5 technical code.
3 Materials
4.1 Continuous welding process 2 General requirements
4.2 Discontinuous welding process
5 Machine variants Hot gas extrusion welding is a welding process for which not only
5.1 Machine Variant I comprehensive knowledge with regard to the materials to be
5.2 Machine Variant II welded and to the handling of the machines and the devices but
5.3 Machine Variant III also great skills in the execution are prerequisites.
6 Structural configuration, weld shapes and weld build-up
Furthermore, the quality of the welded joints is influenced by the
7 Requirements
suitability of the utilised materials, the quality of the welding de-
7.1 Requirements on the welding machines and devices
vices and machines as well as the compliance with the technical
7.2 Requirements on the welding shoes
codes for welding.
7.3 Requirements on the preheating
7.4 Requirements on the materials and their weldability The welds can be tested and inspected using non-destructive
7.5 Requirements on the quality of the welded joints and destructive procedures.
8 Start-up of the welding machines and setting of the welding The welding work must be monitored. The contracting parties
parameters must reach agreement about the type and scope of the monitor-
9 Welding preparation ing. It is recommended to document the process data on welding
9.1 Equipment record sheets (for a specimen, see Appendix 2).
9.2 Protective measures against environmental influences
10 Welding All the welders must be trained and possess valid proof of their
10.1 Preparation of the joining faces qualifications. The hot gas extrusion welding according to this
10.2 Tacking technical code is governed by the DVS 2212-1 guideline, Sub-
10.3 Execution of the welding groups II-1.1 to II-4.2.
10.4 Post-machining of the welds The requirements apply analogously to the welding of materials
10.5 Thermal post-treatment of the welds which have not yet been specified in the DVS 2212-1 guideline
10.6 Welding record sheet (e.g. PVC-U, PVC-C, PVDF, ECTFE ...). The proof of qualifica-
11 Testing and inspection of the welded joints tion must be provided in the form of proof of suitability, adjusted
12 Safety instructions to the application in question and with reference to the stipula-
13 Literature tions in the DVS 2212-1 guideline.
Appendix 1: Brief instructions for welding
Appendix 2: Welding record sheet for extrusion welding
3 Materials
1 Scope of application This technical code applies to the materials specified in the
DVS 2207-4 technical code, Supplement 1.
This technical code applies to the hot gas extrusion welding (WE)
(hereinafter called extrusion welding) of pipes and panels in tank, The technical code can be analogously applied to other materials
apparatus and pipeline construction as well as during the manu- and material modifications (e.g. electrically conductive). It is nec-
facture of self-supporting collecting pans and of seals on concrete essary to pay attention to supplementary instructions from the
structures with thermoplastics. It describes the different processes, manufacturers of the semi-finished products.
indicates the process limits and stipulates requirements for the
quality assurance.
Hot gas extrusion welding is usually deployed for components
with material thicknesses from approx. 6 mm to 50 mm but can
Extrusion welding is a manual or partially mechanised welding
also be utilised for both thinner and thicker components; thicker
process. The work is performed with a welding filler material
components by means of multipass welding if necessary.
which consists of wire or granulate and is melted completely and
Special instructions for the extrusion welding of sealing sheets in plastified in a plastifying system (extruder). A welding shoe shaped
447
according to the weld geometry serves to press the welding filler This process is predominantly utilised wherever confined space-
material into the base material welding groove which is plastified related conditions or certain structural details exclude continuous
by hot air as a rule. Other heat sources/carriers may be, for ex- welding.
ample, a light beam or inert gases. The material output capacities
of the machines or devices determine the maximum weld dimen-
sions and influence the welding speed. The required joining pres- 5 Machine variants
sure is generated by the emerging material and the counterforce
of the welder. The machines/devices consist of:
A distinction is made between the following processes: – the plastifying system (extruder) for the plastification of the input
– continuous welding process welding filler material
– discontinuous welding process – the preheating system for the heating of the joining faces (as a
rule, hot air)
4.1 Continuous welding process
– the welding head in order to accommodate the welding shoe
The plastified welding filler material emerging from the manually and the preheating system (alternative to the quiver in the case
or mechanically guided device or from the machine is continu- of the discontinuous process)
ously pressed into the also plastified welding groove by a welding
shoe (Figs. 1, 3 and 4). – the welding shoe in order to input the extrudate into the welding
groove and to shape the surface (alternative to the pressing-on
In the case of manual welding, the advance speed results from the tool in the case of discontinuous welding)
volume of the emerging material flow and the weld cross section
to be filled. In the case of welding with an advance system, the
5.1 Machine Variant I
welding speed must be adjusted to the material output.
Machine or device type in which all the device components form
The welding zone is preheated by a hot gas fan attached to the
one unit. As a rule, the welding filler material is supplied to the
welding head.
device as round wire or, in the case of larger devices, also as
granulate (Fig. 1).
Granulate hopper Drive
5.2 Machine Variant II
The extruder and the welding head are structurally separate in
Air supply the case of this machine type. For continuous welding, both ma-
chine parts are connected with each other by a heated hose for
the welding filler material (Fig. 3). For discontinuous welding, the
extrudate is extracted directly from the extruder using replacea-
Welding wire spool ble material nozzles (Fig. 2).
Extruder screw Hot gas device

Heated hose
Extruder
Preheating of the
welding groove
Welding shoe
Welding direction Air hose
Welding Air supply

Figure 1. Diagram for continuous welding with Machine Variant I. head
4.2 Discontinuous welding process

For the welding, the plastified welding filler material is extracted
from the extruder section by section with a corresponding quiver,
is inserted into welding groove plastified with a hot gas device
and is pressed in, shaped and smoothed with a pressing-on tool
(Fig. 2). Figure 3. Diagram for continuous welding with Machine Variant II.
Extruder
Welding groove preheating
Quiver Pressing-on tool
Insertion and
pressing-on
of the extruder
Figure 2. Diagram for discontinuous welding with Machine Variant II.
448
The machines of this type have high output capacities but are 6 Structural configuration, weld shapes and weld build-up
principally used in stationary operation due to their size. The
welding filler material is usually supplied to the device in granulate The structures of the components are governed by the DVS 2205 ff.
form. technical codes and the configurations of the welds by the
DVS 2205-3 technical code as well as the supplements to the
5.3 Machine Variant III respective technical codes. In particular, attention must be paid
to the following:
The machines/devices consist of the welding wire intake station,
the plastifying unit and the preheating system. The welding filler – Crossing welds must be in a staggered arrangement. The clear
material in wire form is transported into the heating chamber by distance should be about three times the width of the cover
the wire feed unit which inputs the plastified welding filler material pass but min. 50 mm.
into the joining zone via the welding shoe (Fig. 4). As a rule, the – The clear distance between parallel welds should be about
devices are smaller and easier to handle than Machine Variants I three times the width of the cover pass but min. 50 mm.
and II but also have a lower output capacities.
– In the case of butt joints, it is necessary to match the material
thicknesses of connecting ends with different thicknesses
(DVS 2205 technical code).
Handle – In order to reduce the weld volume and because of the more
Wire feed unit uniform distribution of the residual welding stresses, the welds
should, if at all possible, be executed on both sides or with cap
passes (double-V butt weld, double fillet weld and double-
bevel butt weld).
– A weld shape which guarantees that the cross section of the
Hot gas unit thinner joining part in each case can be connected completely
(e.g. T-joint with a single-bevel butt weld) should be chosen in
Air supply the case of accessibility from one side only.
– In the case of single-V and single-bevel butt welds, the resid-
Plastifying unit
ual root opening should be max. 1 mm in order to ensure full-
penetration welding.
– The material input into the welding grooves should be mini-
mised because of the shrinkage stresses arising during the
cooling of the welds. It is therefore recommendable to change
the weld preparation angle according to the joining part thick-
nesses (Fig. 7).
Figure 4. Diagram for continuous welding with Machine Variant III.
– As a rule, the welds are manufactured in a single pass. In the
case of great workpiece thicknesses (> 30 mm in the case of
single-V and single-bevel butt welds and fillet welds), multi-
pass welding serves to minimise shrinkage stresses and the
formation of vacuoles.
The most important weld shapes and their execution are por-
trayed on Figs. 5 and 6.
The designations of the welds and their drawing-related and sym-
bolic representation are governed by DIN EN 22553.
a) Single-V butt weld without a cap pass b) Double-V butt weld

Figure 5. Welding groove preparation and welds in the case of butt joints.
449
a) Single-bevel butt weld b) Double-bevel butt weld c) Double fillet weld
Figure 6. Welding groove preparation and welds in the case of T-joints.
The root gap should not exceed 2 mm in the continuous welding 7 Requirements
process and 4 mm in the discontinuous welding process. If the
root gap width cannot be complied with for structural or design- 7.1 Requirements on the welding machines and devices
related reasons, appropriate measures must be taken (e.g. using
The welding devices must conform with the CE specifications and
a backing strip).
must be in a functioning condition and suitable for the welding
For materials other than those listed in Appendix 1, it may be task. That also applies to the accessories such as nozzles, welding
necessary to choose different weld shapes and weld preparation shoes, temperature detectors etc.
angles. Their condition and good working order must be checked regularly
(e.g. by means of monitoring by the manufacturers).
Single-V and
The output quantity and the preheating capacity must be adjusted
Weld depth s [mm]
double-V buttwelds
to the welding task.
Single-bevel butt welds
Special requirements on the welding machines and the welding
devices are described in Supplement 2 to this technical code.

The joining pressure necessary for the welding is applied to the
joining faces with the welding shoe via the welding filler material.
At the same time, the welding shoe shapes and smooths the weld
surface
Weld preparation angle [°] Therefore, the welding shoes must correspond to the welding
Continuous welding task, must be structurally adjusted to the respective weld shapes
and thicknesses (Fig. 8), must have smooth, anti-adhesive sur-
faces and must be sufficiently temperature-resistant.
As a rule, they are made of polytetrafluoroethylene (PTFE). This
Weld depth s [mm]
Single-bevel Single-V and material possesses the specified properties and is easy to ma-
butt welds double-V butt welds chine.
The lengths of the pressing-on zone and the smoothing surface
should not be less than the minimum lengths specified on Fig. 9
and in Table 1. This ensures that the joining pressure acts during
a minimum time and that the necessary bond can thus be pro-
duced in the entire joining area (particularly the weld root and the
weld sidewalls). For design-related reasons or in the case of fillet
welds, it may be necessary to use welding shoes with shorter
pressing-on lengths if the prescribed weld geometry and the re-
Weld preparation angle [°] quirements on the weld quality are complied with (corresponding
proof must be provided if necessary).
Discontinuous welding
The weld overlap in the case of single-V and double-V butt welds
Figure 7. Recommended weld preparation angles for PE-HD and PP for b should be greater than or equal to 0.2 times the joining part
single-V and single-bevel butt welds depending on the weld
depth and the welding process (for other materials, it may be
thickness but should be min. 3 mm.
necessary to choose different weld preparation angles). The weld reinforcement s should be 0.1 to 0.2 times the joining
part thickness.
The "nose" machined out of the front part prevents the material
from running ahead, is a prerequisite for generating the required
450
joining pressure and supports the forward movement of the weld- For the semi-crystalline materials (e.g. PE, PP and PVDF), refer-
ing device. It must correspond to the welding groove shape but ence is made to the melt flow index as a characteristic parameter
must not touch the welding groove surfaces during the welding. for the weldability. If the melt flow index (MFR) values of the
The gap between the nose and the weld sidewalls should be welding members are within the permissible melt flow index rang-
1 - 3 mm depending on the weld thickness. es in the DVS 2207-1, DVS 2207-11 and DVS 2207-15 technical
codes, weldability may be assumed in general. If two semi-finished
The undercut on the contact surfaces prevents completely products in different MFR groups from these ranges are to be
molten base material from being pushed away. welded with each other, it is necessary to choose a welding filler
When pressing-on tools are used for discontinuous welding, the material whose MFR value is between those of the combination
above stipulations apply analogously. of semi-finished products. For PE-HD, PP and PVDF, attention
must be paid to the instructions in the scope of application of the
Pressing-on zone / sliding surface Contact surface DVS 2207-1, DVS 2207-11 and DVS 2207-15 technical codes. If the
Undercut melt flow index is outside the authorised ranges in the specified
technical codes, the welding proof according to the DVS 2203-4
technical code must be provided in the tensile creep test.
The following applies to amorphous materials such as PVC: In
principle, only semi-finished products of the same moulding material
type are weldable.
Pressing-on zone / The semi-finished products and the welding filler materials must
Contact surface Nose sliding surface Nose be marked correspondingly and unmistakably (in the case of
Welding shoe for single-V butt welds Welding shoe for fillet welds welding filler materials, on the packaging).
Figure 8. Perspective representations of welding shoe designs. Only semi-finished products with stipulated quality requirements
should be welded (e.g. works certificate according to DIN EN
10204).
The welding filler materials must satisfy the requirements according
to the DVS 2211 technical code and DIN EN 12943.
The base and filler materials must be available in a flawless pro-
cessing condition and must be dry and clean.
If there are any doubts that the semi-finished products and/or the
welding filler material are of similar types (e.g. due to a lack of
marking) or if any material changes are to be feared due to:
– improper storage
– low joining part temperatures
Approx. 0.5 mm
– soiling
– ageing
– operating influences (media or temperatures)
it is necessary to establish the weldability by means of tests on
trial welds. Agreement must be reached with regard to the type
and scope of the tests. Instructions about this are given in the
DVS 2203-1 and DVS 2201-2 technical codes.
7.5 Requirements on the quality of the welded joints

If the welds are executed properly according to this technical
Figure 9. Pressing-on length and geometry of a welding shoe for single-V code, those minimum requirements on the quality of the welds
butt welds. which are specified in the DVS 2203-1 technical code, Supple-
ments 1, 2 and 3 (welding factors and bending angles) are sure
Table 1. Guide values for welding shoe dimensions.
to be satisfied. With regard to the application in question, to stat-
utory stipulations if needed (Water Resources Management Act,
Weld depth s of Pressing-on length LA Pressure Device Directive etc.) and to the necessary dimensioning,
single-V butt welds the customer and the manufacturer should agree on the corre-
sponding requirements on the component and on the necessary
[mm] [mm] minimum quality of the welded joints and should stipulate these.
Up to 15 35 Instructions and criteria for this purpose are included in the
>15 bis 20 45 DVS 2202-1 technical code. The inclusion of the weld quality in
>20 bis 30 55 the component calculation is described in the DVS 2205-1 to
DVS 2205-5 technical codes.
7.3 Requirements on the preheating If necessary, the proof of the demanded quality may be provided
within the framework of establishing the suitability on trial welds,
The preheating must guarantee that the joining faces and the ar-
with reference to DVS 2212-1. This applies particularly to materi-
eas of the weld overlap (Fig. 8) are sufficiently plastified even
als for which no requirements have yet been stipulated in the
when the welding groove geometry changes. The welding shoes
specified technical codes (e.g. PVC-C, PVDF and ECTFE).
and the preheating (nozzle geometry, air volume and hot gas
temperature) must be coordinated.
8 Start-up of the welding machines and setting of the
7.4 Requirements on the materials and their weldability welding parameters
Semi-finished products and welding filler materials (wire and
granulate) must be suitable for extrusion welding. One prerequisite The start-up is carried out according to the operating instructions
for welded joints which should satisfy the requirements according from the machine manufacturer.
to the DVS 2203-1 technical code, Supplements 1, 2 and 3 is the Extrudate residues in the extruder, at the outlet opening as well
use of a welding filler material of the same type as the base as, if applicable, in the transport hose must be melted completely
material but at least of a similar type. before the extrusion drive is switched on.
451
In order to avoid using any welding filler material with prior thermal – protective measures against weathering influences (see Sec-
damage, the reheated melt should be extruded out completely tion 9.2)
before the beginning of the welding. This also applies to longer – special detergent (non-swelling, non-dissolving or not containing
interruptions in the work. The maximum dwell times are dependent any grease) and non-fraying cloths
on the material in question (in the case of PE-HD and PP, approx.
5 min). In the case of thermally sensitive materials such as PVC – welding parameters according to the DVS 2207-4 technical
and PVDF, the material output of the extruder should not be inter- code, Supplement 1 and/or instructions from the manufacturers
rupted during the interruption in the welding. of the semi-finished products
If the material is changed, it must be ensured, by means of clean- – welding record sheet according to Appendix 2
ing or extruding-out, that all the material in the welding extruder is
replaced. If necessary, the nozzles must be changed. In the case 9.2 Protective measures against environmental influences
of Machine Variant II, the hose must always be changed as well. The ambient conditions may exert a fundamental influence on the
In practice, it is recommended not to use the same extruder for welding operation and thus on the quality of the joint. Therefore,
different materials. attention must be paid to the following:
The welding filler material must be dry. If necessary, it must be – The welding area must be protected from unfavourable weath-
dried before use (e.g. several hours in an exhaust air oven at ering influences such as moisture, the formation of condensa-
temperatures from approx. 60°C to 80°C). Attention must be paid tion water, wind, draughts and temperatures below 5°C.
to the information from the manufacturer of the welding filler ma-
terial. – If suitable measures (e.g. preheating, enclosing with tents or
heating) ensure that a semi-finished product temperature suffi-
While the machine is running, the required material temperature cient for the welding can be complied with, the welding may be
is checked directly at the material outlet in the middle of the carried out at any outdoor temperature – provided that the dex-
strand using the insert sensor of a quick-display temperature gauge. terity of the welder is not hindered. If necessary, additional
The control measurement of the hot air temperature is taken in proof must be provided by manufacturing, testing and inspecting
the hot air nozzle between the nozzle outlet plane and a depth of trial welds in the existing conditions.
5 mm using a precision probe with a diameter of approx. 1 mm – If the joining parts are tempered non-uniformly (e.g. due to solar
(see the instructions in the DVS 2207-4 technical code, Supple- radiation on one side, in the case of different storage conditions
ment 2). etc.), the temperatures must be equalised before the welding.
The prescribed air volume must be checked in the case of devices
with an external air supply. It is necessary to ensure the flawless
function of devices with an internal air supply. 10 Welding
The material and hot gas temperatures must be checked immedi-
10.1 Preparation of the joining faces
ately before the beginning of the welding. Repeat checks are rec-
ommendable in the case of a welding task lasting a longer time or The joining faces must not be damaged, oxidised or contaminat-
after interruptions in the work. ed. Therefore, they and the adjacent weld overlap areas must be
subjected to chip-producing machining immediately before the
All the measurements must be taken with regularly checked
welding.
measuring instruments (according to DVS 2207-4, Supplement
2) and must be documented (Appendix 2). Chip-producing tools, e.g. scrapers, scraper blades, milling cut-
ters and saws, are suitable. Grinding tools are only permissible if
it is possible to exclude the contamination caused by incorporat-
9 Welding preparation ing abrasives and the overheating of the surfaces.
Particularly in the case of joining parts which have been exposed
The welding grooves of the joining parts are prepared according
to the effect of UV or media for a long time, the damaged layer
to Section 6.
may be so deep that the residual wall thickness, including the
It must be guaranteed that the welding head of the machine or static requirements, must be checked after the machining-off.
the device has sufficient accessibility to the joining faces. Weld-
If the joining faces must be cleaned, it is necessary to use special
ing out of position should be avoided or minimised because of the
detergents which do not contain any grease.1)
required counterpressure to be applied by the welder. It must be
ensured that the welder is not hindered during the welding as a
10.2 Tacking
result of the necessary readjustment of the connecting cables
and hoses as well as of the welding filler material. Tacking serves to fix the joining parts in their planned positions in
relation to each other in order to exclude any changes in the posi-
9.1 Equipment tions of the joining parts during the welding. Tacking is usually
carried out by means of the partial or continuous hot gas string-
The following equipment constitutes the minimum requirements
bead welding of a root pass with a welding filler wire.
for the proper execution of the welded joints:
– hot gas extrusion welding device, according to the welding task 10.3 Execution of the welding
and this technical code
Before the beginning of the welding operation, the welding shoe
– welding shoes, according to the welding task must be heated up (e.g. using a baffle plate) since welding with a
– flow meter for welding gas cold welding shoe results in a rough and uneven weld surface.
This also applies to pressing-on tools in the case of discontinuous
– temperature gauge, according to the DVS 2207-4 technical
welding.
code, Supplement 2
– suitable measuring instruments for checking the misalignment,
the diameter and the thickness 1) The cleaning fluid or any cloths which have already been moistened
– suitable storage space for the devices with it in the factory must be made of a 100 % evaporating solvent, e.g.
99 parts of ethanol with a degree of purity of 99.8 % and one part of
– scraper and scraper blade MEKP (methyl ethyl ketone, denatured). Agents tested according to
– personal protective equipment DVGW VP 603 comply with this stipulation. The use of spirit may lead
to a deteroriation in quality due to the water contained in it.
– dust protection for the welding wire The paper used for the cleaning must be clean, unused and absorbent
– sufficient lighting and must not fray or be dyed.
452
The start of the weld is preheated and completely melted with hot In the case of semi-automatic and fully automatic systems and
air. Immediately before the welding shoe is placed on the welding facilities for extrusion welding, the welding parameters (the material
groove, the welding filler material which has already emerged is output, the preheating and the welding speed) must be coordinated
removed from the welding shoe opening. After the filling of the and must be set correspondingly.
groove, the material pressure builds up due to the counterpres- It is recommended to manufacture trial welds.
sure generated by the welder and the forward movement of the
welding shoe begins. In the case of discontinuous welding, the welding filler material is
extracted from the extruder with the quiver and is inserted into
In the case of manual welding, the welding speed is determined the plastified welding groove section by section. The joining pres-
by the material output of the extruder and the size of the weld sure is applied with the pressing-on tool across all the cross-sec-
cross section. tional areas of the weld (central and edge areas) in several oper-
The preheating of the joining parts must be adjusted to the weld- ations and the weld surface is shaped at the same time.
ing speed in such a way that the base material is plastified down
to a depth of 0.5 - 1 mm. 10.4 Post-machining of the welds
Subject to corresponding welding shoe formation and machine
The plastifying zone must be wider than the weld width (guide
guidance during the welding, the post-machining of the welds is
value: weld width + 2 x (0.2 x joining part thickness s), see Fig. 10.
not required (in this respect, also see the DVS 2202-1 technical
code, Table 5).
Weld reinforcement
Weld width It is imperative to remove the lateral flow which may be pressed
through under the contact surfaces of the welding shoe. Rein-
Joining width
forced weld beads and reinforced weld roots must be machined
s off correspondingly without any notches.
Weld overlap b
The weld may only be machined off after sufficient cooling.
Weld edge
10.5 Thermal post-treatment of the welds
Residual welding stresses can be decreased by means of tem-
pering. The tempering conditions depend on the material and the
component. Attention must be paid to the information from the
manufacturers of the semi-finished products.
Weld root Plastifying zone 10.6 Welding record sheet
Joining planes
The completely filled-in welding record sheet documents the
welding conditions and the welding parameters, amongst other
Figure 10. Example of a single-V butt weld with representation of the details. It is the foundation for the evaluation of the weld quality
complete melting zones and the weld overlap. by the welding supervisor (DVS 2213 guideline, specimen record
sheet in Appendix 2).
The complete melting depth is checked directly in front of the
welding shoe. This can be carried out with a thin, blunt tool.
11 Testing and inspection of the welded joints
The welder must ensure that the completely molten base material
at the weld sidewalls is not pushed off by the welding shoe nose. A distinction is made between non-destructive and destructive
Before any restarts and at the end of circular welds, it is neces- testing and inspection procedures. For the main weld shapes,
sary to diagonally machine off the already executed ends of the these are listed in Table 2: "Usual testing and inspection proce-
weld. dures for extrusion welds, applicability and requirements".
If multipass welds are required, the cooled weld sidewalls and The visual inspection according to the DVS 2202-1 technical
surfaces of the already welded passes must be subjected to chip- code is oriented, in particular, to the weld shape, the notch-free
producing machining. surfaces and peripheral zones, the optimum weld filling, the full-
penetration welding on the root side and the misalignment of the
In order to avoid the excessively quick cooling of the weld surface joining parts. General dimensional and visual inspections on
and the resulting formation of shrinkage cavities, it is recom- components are governed by the DVS 2206-1 technical code.
mended to cover the extrusion weld immediately after the welding
With ultrasound (see the DVS 2206-3 technical code), flaws can
particularly in the case of large-volume welds.
be detected in the interior of the welds without any destruction.
Design-induced modifications to the weld geometry in the weld However, on their own, they do not provide a sufficient indication
path (e.g. in the case of segment bends and branches) demand of the quality of the welded joint. Moreover, the utilisation possi-
particularly careful guidance of the welding shoe. If necessary, bilities of these testing procedures are limited with regard to the
the welding shoe must be changed. weld geometry and the weld thickness.
Table 1. Usual testing and inspection procedures for extrusion welds, applicability and requirements.
Non-destructive tests and inspections

Visual inspection of the undestroyed Visual inspection of the weld surface and the weld geometry; assessment according to the
weld (external findings) DVS 2202-1 technical code, Table 5, on the basis of the assessment group according to
Section 2 to be stipulated in each individual case
Leak test with a partial vacuum Using suitable vacuum bell jars and a foaming liquid; the testing conditions must be stipulated
in each individual case; usual testing pressure: - 0.4 bar to - 0.6 bar
Leak test with electric high voltage Test execution and device requirements according to the DVS 2206-4 technical code; the
type of testing device (with or without an antipole) and the testing voltage must be stipulated
in each individual case
Pressure test Application usually for pipelines; testing conditions according to the Pressure Device Directive;
test execution according to the DVS 2210-1 technical code, Supplement 2; meaningfulness:
leak tightness and experimental proof of the operating safety
453
Destructive tests and inspections

Visual inspection of the weld cross Visual inspection of the weld cross section after the weld has been cut open; assessment
section (internal findings) according to the DVS 2202-1 technical code, Table 5, on the basis of the stipulated assess-
ment group according to Section 2
Tensile test Execution according to the DVS 2203-2 technical code, minimum requirements according to
the DVS 2203-1 technical code, Supplement 1
Tensile creep test Execution according to the DVS 2203-4 technical code, minimum requirements according to
Technological bending test Execution according to the DVS 2203-5 technical code, minimum requirements according to
It is necessary to stipulate the type and scope of the tests and Technical code: Testing of welded joints between panels and
inspections to be performed in each individual case. DVS 2203-1, pipes made of thermoplastics – Requirements
Supplement 3 in the technological bending test – Bending
Material-specific tests and inspections are indicated in the DVS
angle / bending path
2201-1 technical code.
Technical code: Testing of welded joints between panels and
DVS 2203-2 pipes made of thermoplastics – Tensile test
Technical code: Testing of welded joints between panels and
Hazardous decomposition products and health-endangering DVS 2203-4 pipes made of thermoplastics – Tensile creep
fumes develop as a result of the overheating of some materials test
beyond the thermoplastic condition (decomposition range), e.g. Technical code: Testing of welded joints between panels and
PVC, PVC-C and PVDF. Others such as ECTFE, FEP and PFA DVS 2203-5 pipes made of thermoplastics – Technological
already develop these during the welding. bending test
Therefore, stringent safety regulations must be complied with Technical code: Calculation of tanks and apparatus made of
during the welding of these materials. Instructions about these DVS 2205-1 thermoplastics – Characteristic values
are given in the DVS 2207-3 technical code, Supplement 3 and Technical code: Calculation of tanks and apparatus made of
by the manufacturers of the respective semi-finished products. DVS 2205-2 thermoplastics – Vertical round, non-pressur-
On the basis of the safety data sheets to be submitted by the ised tanks
manufacturer, the contractor must elaborate operating instruc- Technical code: Calculation of tanks and apparatus made of
tions which comply with Section 14 of the Hazardous Substances DVS 2205-3 thermoplastics, welded joints
Ordinance (GefStoffV) and indicate all the hazard potentials and
Technical code: Calculation of tanks and apparatus made of
required protective measures. It may be necessary to take further
DVS 2205-4 thermoplastics – Flanged joints
specific protective measures in each individual case.
Technical code: Calculation of tanks and apparatus made of
In explosion-protected areas, the valid safety regulations must be DVS 2205-5 thermoplastics, rectangular tanks
observed with regard to the welding work and any measures
which may be required must be agreed upon with the safety offic- Technical code: Non-destructive tests and inspections on tanks,
er responsible; on this subject, see the Operational Safety Ordi- DVS 2206-1 apparatus and piping made of thermoplastics –
nance (BetrSichV). Dimensional and visual inspections
Technical code: Non-destructive tests and inspections on tanks,
DVS 2206-4 apparatus and piping made of thermoplastics –
13 Literature Testing with electric high voltage
Technical code: Welding of thermoplastics – Heated tool weld-
DIN EN 10204 Metallic products – Types of inspection docu-
DVS 2207-1 ing of pipes, piping parts and panels made of
ments
PE-HD
DIN EN 12943 Filler materials for thermoplastics – Scope,
Technical code: Welding of thermoplastics – Hot gas string-
designation, requirements, tests
DVS 2207-3, bead and fan welding of pipes, piping parts and
DIN EN 22553 Welded and brazed seams – Symbolic repre- Supplement 1 panels – Welding parameters
sentation on drawings
Technical code: Welding of thermoplastics – Hot gas string-
DIN 1910-3 Welding; welding of plastics, processes DVS 2207-3, bead and fan welding of pipes, piping parts and
Technical code: Joining of plastics – Codes and abbreviations – Supplement 2 panels – Requirements on the welding devices
DVS 2200-1, Welding processes and the accessories
Supplement 1 Technical code: Welding of thermoplastics – Extrusion welding
Technical code: Testing of semi-finished products made of ther- DVS 2207-4, of pipes, piping parts and panels – Welding pa-
DVS 2201-2 moplastics – Weldability – Testing procedures Supplement 1 rameters
– Requirements Technical code: Welding of thermoplastics – Extrusion welding
Technical code: Defects in welded joints between thermoplas- DVS 2207-4, of pipes, piping parts and panels – Require-
DVS 2202-1 tics – Characteristics, description and assess- Supplement 2 ments on the welding machines and the weld-
ment ing devices
Technical code: Testing of welded joints between panels and Technical code: Welding of thermoplastics – Welding of PE
DVS 2203-1, pipes made of thermoplastics – Requirements DVS 2207-5 casing pipes – Pipes and piping parts
Supplement 1 in the tensile test – Short-time tensile welding Technical code: Welding of thermoplastics – Heated tool weld-
factor fz DVS 2207-11 ing of pipes, piping parts and panels made of PP
Technical code: Testing of welded joints between panels and Technical code: Welding of thermoplastics – Heated tool weld-
DVS 2203-1, pipes made of thermoplastics – Requirements DVS 2207-15 ing of pipes, piping parts and panels made of
Supplement 2 in the tensile creep test – Tensile creep weld- PVDF
ing factor fs
454
Technical code: Industrial piping made of thermoplastics – De-

DVS 2210-1 signing and execution – Above-ground pipe
systems
Technical code: Industrial piping made of thermoplastics – De-
DVS 2210-1, signing and execution – Above-ground pipe
Supplement 2 systems – Recommendations for the internal
pressure and leak tests
Technical code: Welding of thermoplastics – Welding filler ma-
DVS 2211 terials – Marking, requirements and tests
Guideline: Qualification testing of plastics welders – Qual-
DVS 2212-1 ification Test Groups I and II
Guideline: Specialist for plastics welding
DVS 2213
DIN standards can be obtained from Beuth Verlag, Berlin and

DVS technical bulletins, technical codes and guidelines from
DVS Media GmbH, Düsseldorf.
455
Appendix 1: Brief instructions for welding 5. Tack the joining parts

(Section 10.2)
1. Put together the welding equipment
– execute a partial or continuous root pass with a hot gas
(Section 9.1)
welding device
– valid welder's certificate
6. Start up and prepare the welding extruder
– hot gas extrusion welding device corresponding to the
(Section 8)
welding task, including the operating instructions
– check the supply lines (electricity and air) for any possible
– possibly hot gas welding device for tacking the joining parts
hindrances to the welding operation
– welding shoes, corresponding to the weld shape
– connect and start the extruder according to the operating in-
– flow meter for welding gas structions
– temperature gauge with sensors for measuring the hot gas – select, adjust and assemble the welding shoe and the hot
and the extrudate as well as the temperature of the semi- gas nozzle according to the weld geometry and the weld
finished product shape
– suitable measuring instruments for checking the misalign- – extrude the reheated welding filler material out of the cylinder
ment / the diameter / the thickness
– set and check the parameters (Appendix 1)
– storage space for the devices
– preheat the welding shoe
– scraper and scraper blade
– personal protective equipment 7. Welding
(Section 10.3)
– dust protection for the welding wire
– check that the base material is sufficiently plastified (e.g. by
– detergent pricking it with a blunt tool)
– Supplement 1: Materials and welding parameters – check the welding speed and monitor the uniformity
– Appendix 2: Welding record sheet – continuously check the guidance of the welding extruder
– special welding procedure specification and make any corrections needed
– if necessary, prevent any excessively quick cooling of the
2. Check the working conditions and plan the measures weld surface by covering it
(Section 9.2)
– bevel the ends of the welds before restarts
– accessibility
– protect the welding filler material from contaminations
– sufficient lighting
– protective tent 8. Remachine the weld
(Section 10.4)
– heating
– let welded parts cool down sufficiently before unclamping
– sufficient ventilation/extraction them and subjecting them to loads
– special protective equipment – machine off the lateral flow of the weld and the weld rein-
forcements
3. Check the weldability
(Section 7.4) 9. Compile the welding record sheet
– check that the information from the manufacturers on the (Section 10.6)
semi-finished products and the welding filler materials is – fill in the welding record sheet (Appendix 2) and carry out
correct the visual inspection according to the DVS 2202-1 technical
– check the condition and cleanness of the joining members code
and possibly clean them
– if necessary, check the weldability of the joining members
by means of surface welding according to the DVS 2201-2
technical code or trial welds
4. Prepare the welds and the joining faces

(Section 10.1)
– check, stipulate and manufacture the weld geometry and
the weld shape
– remove the oxide layer from the joining faces by means of
chip-producing machining
456
Appendix 2: Welding record sheet for extrusion welding
Extrusion welding of panels and pipes Company logo

Welding record sheet
Project: Project no.: Protective
Weathering measures
Drawing no.: Base material (manufacturer, type, batch and date):
1 = Sunny 1 = None
Welder: Welding filler material (manufacturer, type, batch and date):

2 = Dry 2 = Screen
Welding certificate no.: / valid until: Welding machine (make and type):
3 = Precipitation 3 = Tent
Welding supervisor3): Year of construction / last machine examination: Process variant according to the DVS 2207-4 technical code:
Joining part Weld shape Welding shoe Material Hot gas Welding Ambient Semi-finished Weathering Protective Visual
Date Weld no. thickness Air volume product measures
(symbol) no. temperature1) temperature2) speed temperature temperature (code no.) (code no.) evaluation
[mm] [l/min] [°C] [°C] [cm/min] [°C] [°C]
1) Measured with an insert thermometer at the extruder outlet Remarks, e.g. more difficult conditions:
of the welding machine / of the welding device
2) Measured in the centre of the nozzle outlet opening, 5 mm in the nozzle
3) e.g. specialist for plastics welding according to the DVS 2213 guideline
457
File: D:\Eigene Dateien\Kunden\DVS\Ri+Me\2207\2207-4\englisch\Jan_08\e2207-4.fm
Erstellt am:
18.01.2005
29.01.2008
March 2008
DVS – DEUTSCHER VERBAND Welding of thermoplastics Extrusion

FÜR SCHWEISSEN UND welding of pipes, piping parts and panels Technical Code
VERWANDTE VERFAHREN E.V. Processes and requirements DVS 2207-4
Translation of the German version from april 2005
Contents: The technical code can be correspondingly applied to other

materials and material modifications (e.g. electrically conductive).
1 Scope of application It is necessary to pay attention to supplementary instructions
2 Materials from the manufacturers of the semi-finished products.
3.1 Continuous welding process
3.2 Discontinuous welding process 3 General process description
4 Machine variants
4.1 Machine Variant I Extrusion welding is a manual or semi-automatic welding proc-
4.2 Machine Variant II ess. It is performed with a welding filler which consists of wire or
4.3 Machine Variant III granules and is melted and plastified in a plastifying system (ex-
5 Structural design, weld shapes and weld structure truder). A welding shoe shaped according to the weld geometry
6 Requirements serves to press the welding filler into the base material welding
6.1 Requirements on the welding machines and devices groove which is plastified with hot air as a rule. Other heat sourc-
es or carriers may be, for example, a light ray or inert gases. The
6.3 Requirements on the preheating material output capacity of the machines or devices determines
6.4 Requirements on the materials and their weldability the maximum weld dimensions and influences the welding
6.5 Requirements on the welders speed. The necessary joining pressure is generated by the
6.6 Requirements on the quality of the welded joints emerging material and the counterforce of the welder.
7 Start-up of the welding machines and setting of the welding
parameters A distinction is made between the following processes:
8 Welding preparation – continuous welding process
8.1 Equipment
– discontinuous welding process
8.2 Protective measures against environmental influences
9 Welding
9.1 Preparation of the joining faces 3.1 Continuous welding process
9.2 Tacking The plastified welding filler emerging from the manually or
9.3 Execution of a weld mechanically guided device or machine is continuously pressed
9.4 Finish machining of the welds into the also plastified welding groove by a welding shoe, Figs. 1,
9.5 Thermal after-treatment of the welds 3 and 4.
9.6 Welding record sheet
10 Testing of the welded joints
12 Standards and technical codes which are also applicable
Appendix 1: Brief instructions for the welding
Appendix 2: Welding record sheet for the extrusion welding
This technical code applies to the hot gas extrusion welding

(hereinafter called extrusion welding) of pipes and panels in tank,
apparatus and pipeline construction as well as during the
manufacture of self-supporting collecting pans and of seals on
concrete structures with thermoplastics. It describes the different
processes, indicates the process limits and stipulates
requirements for the quality assurance.
Special instructions for the extrusion welding of sealing sheets in
earthwork construction and water engineering are included in the
DVS 2225-1 and DVS 2225-4 technical codes. Instructions for
the extrusion welding of casing pipes can be found in the
DVS 2207-5 technical code.
2 Materials
This technical code applies to the materials specified in the

DVS 2207-4 technical code, Supplement 1. Figure 1. Diagram for continuous welding with Machine Variant I.
458
In the case of manual welding, the feed speed results from the This process is predominantly used where confined space-
volume of the emerging material flow and from the weld cross- related conditions or certain structural details exclude continuous
section to be filled. In the case of welding with a feed system, the welding.
welding speed must be adjusted to the material output.
The welding zone is preheated by a hot gas fan attached to the
welding head. 4 Machine variants
3.2 Discontinuous welding process The machines or devices consist of:

For the welding, the plastified welding filler is extracted from the – the plastifying system (extruder) for the plastification of the
extruder section by section with a corresponding quiver, is input welding filler
inserted into welding groove plastified with a hot gas device and – the preheating system for the heating of the joining faces (as a
is pressed in, shaped and smoothed with a press-on tool (Fig. 2). rule, hot air)
– the welding head in order to accommodate the welding shoe
and the preheating system
– the welding shoe in order to input the extrudate into the
welding groove and to shape the surface (alternative to the
quiver and the press-on tool in the case of discontinuous
welding)
4.1 Machine Variant I

Machine or device type in which all the device components form
one unit. As a rule, the welding filler is supplied to the device as
round wire or, in the case of larger devices, also as granules, Fig. 1.
4.2 Machine Variant II

The extruder and the welding head are structurally separate in
the case of this machine type. For continuous welding, both
machine parts are connected with each other by a heated hose
for the welding filler, Fig. 3. For discontinuous welding, the
extrudate is extracted directly from the extruder using
replaceable material nozzles, Fig. 2.
The machines of this type have a high output capacity but are
primarily used in stationary operation due to their size. The
welding filler is usually supplied to the device in granule form.
4.3 Machine Variant III

The machines or devices consist of the welding wire intake
station, the plastifying unit and the preheating system. The
welding filler in wire form is transported into the heating chamber
by the wire feed unit which inputs the plastified welding filler into
the joining zone via the welding shoe, Fig. 4. As a rule, the
devices are smaller and easier to handle than Machine Variants I
Figure 2. Diagram for discontinuous welding with Machine Variant II. and II but also have a lower output capacity.
Figure 3.
Diagram for continuous welding
with Machine Variant II.
459
For materials others than those listed in Appendix 1, it may be

necessary to choose different weld shapes and weld preparation
angles.
Desination Sheme Symbol

V- seam
V-seam
V
Double-V-seam
Double-V-seam
(X-seam)
(X-seam)
X
Double-HV-
Double-HV-seam
seam
(K-butt) (K-
butt)
K
Fillet
Fillet
Figure 4. Diagram for continuous welding with Machine Variant III.
5 Structural design, weld shapes and weld structure
The DVS 2205 ff. technical codes apply to the structure of the
components and the DVS 2205-3 technical code to the design of
the welds (the supplements to the respective technical codes are Figure 5. Examples of weld shapes and weld symbols.
also applicable). In particular, attention must be paid to the
following:
Depth of seams s (mm)
– Crossing welds must be in a staggered arrangement. V- and double V-seams

– The distance between the welds should be about three times HV-seams
the width of the top layer but min. 50 mm.
– In the case of butt joints, it is necessary to match the work-
piece thicknesses of connecting ends with different thick-
nesses (DVS 2205).
– A weld shape which guarantees that the cross-section of the
thinner joining part in each case can be connected completely
(e.g. T-joint with a single-bevel butt weld) should be chosen in Angle of seam opering (’’)
the case of accessibility from one side only.
a) Continuous welding
DIN EN 22553 applies to the designation and graphical and
symbolic representation of the welds.
Depth of seams s (mm)
The most important weld shapes are single-V, double-V, single-

bevel and double-bevel butt welds as well as fillet welds.
HV-seam V- and double V-seams
Examples of the execution of welds as well as their symbolic
representation on fabrication drawings are shown on Fig. 5.
As a rule, the welds are manufactured in a single layer or, in
special cases, in multiple layers.
In order to reduce the weld volume and because of the more
uniform distribution of the residual welding stresses, the welds
should, if at all possible, be executed on both sides or with a Angle of seam (’’)
backing layer (double-V butt weld, fillet weld and double-bevel
butt weld). b) Descontinuous welding
The material input into the welding grooves should be minimised
because of the shrinkage stresses arising during the cooling of Figure 6. Recommended weld preparation angles for PE-HD and PP in
the case of single-V and single-bevel butt welds depending on
the welds. It is therefore recommendable to change the weld
the weld depth and the welding process (for other materials, it
preparation angle according to the joining part thickness, Fig. 6. may be necessary to choose different weld preparation angles).
The residual root opening should be max. 1 mm and full-
penetration welding must be ensured.
6 Requirements
The root gap should not exceed 2 mm in the continuous welding
process and 4 mm in the discontinuous welding process. If the 6.1 Requirements on the welding machines and devices
root gap width cannot be complied with for structural or design-
related reasons, appropriate measures must be taken (e.g. using The welding machines and the welding devices must be in a
a backing strip). functioning condition. Their condition and good working order
460
must be checked regularly (e.g. by means of monitoring by the The weld overlap ∆b should be more than or equal to 0.2 times
manufacturers). the joining part thickness but it should be min. 3 mm.
The output quantity and the preheating capacity must be The weld reinforcement ∆s should be 0.1 - 0.2 times the joining
adjusted to the welding job. part thickness.
Special requirements on the welding machines and the welding The "nose" located on the front part prevents the material from
devices are described in Supplement 2 to this technical code. flowing ahead, is a prerequisite for the generation of the
necessary joining pressure and supports the forward movement
6.2 Requirements on the welding shoes of the welding device. It must correspond to the welding groove
The joining pressure necessary for the welding is applied to the shape but must not touch the welding groove faces during the
joining faces with the welding shoe via the welding filler. At the welding.
same time, the welding shoe shapes and smooths the weld The gap between the nose and the weld sidewalls should be
surface. 1 - 3 mm depending on the weld thickness.
Therefore, the welding shoes must correspond to the welding job, The undercut on the contact surfaces prevents molten base
must be structurally adjusted to the respective weld shapes and material from being pushed away.
thicknesses (Fig. 7), must have smooth, anti-adhesive surfaces
and must be sufficiently temperature-resistant. When press-on tools are used for discontinuous welding, the
above stipulations are applicable correspondingly.
Table 1. Guide values for welding shoe dimensions.
a) Welding shoe for

single-V welds
Seam depth s for V-seams s Pressing length LA

(mm) (mm)
to 15 35
> 15 to 20 45
> 20 to 30 55
6.3 Requirements on the preheating

b) Welding shoe for The preheating must guarantee that the joining faces and the
fillet welds areas of the weld overlap, Fig. 8, are sufficiently plastified even
when the welding groove geometry changes. The welding shoes
and the preheating (nozzle geometry, air volume and hot gas
temperature) must be coordinated.
6.4 Requirements on the materials and their weldability

Semi-finished products and welding fillers (wire and granules)
must be suitable for extrusion welding. One prerequisite for
welded joints which should meet the requirements according to
DVS 2203 is the use of a welding filler of the same type as the
base material but at least of a similar type.
For the semi-crystalline materials (such as PE, PP and PVDF),
reference is made to the melt index as a characteristic parameter
for the weldability. If the melt index (MFR) values of the welding
partners are within the permissible melt index ranges in
DVS 2207-1, -11 and -15, weldability may be assumed in
general. If two semi-finished products in different MFR groups
from these ranges are to be welded with each other, it is
Figure 7. Representations of welding shoe designs. necessary to choose a welding filler whose MFR value is
between that of the combination of semi-finished products. For
As a rule, they are made of polytetrafluoroethylene (PTFE). This PE-HD, PP and PVDF, attention must be paid to the instructions
material possesses the specified properties and is easy to in the scope of application of the DVS 2207-1, 2207-11 and
machine. 2207-15 technical codes. If the melt index is outside the
authorised ranges in the specified technical codes, the welding
The lengths of the press-on zone and the smoothing surface
evidence according to DVS 2203-4 must be provided in the
should not be less than the minimum lengths specified in Table 1.
tensile creep test.
This ensures that the joining pressure acts during a minimum
time and that the necessary bond can thus be produced The following applies to amorphous materials such as PVC:
throughout the joining area (especially the weld root and the weld "Only semi-finished products of the same moulding material type
sidewalls). are weldable."
461
The semi-finished products and the welding fillers must be If the material is changed, it must be ensured, by means of
marked correspondingly and unmistakably (in the case of cleaning or extruding-out, that all the material in the welding
welding fillers, on the packaging). extruder is replaced. If necessary, the nozzles must be changed.
In the case of Machine Variant II, the hose must always be
Only semi-finished products with stipulated quality requirements
changed as well. It is recommended not to use the same extruder
should be welded (e.g. works certificate according to DIN EN
for different materials in practice.
10204).
The welding filler must be dry. If necessary, it must be dried
The welding fillers must meet the requirements according to the
before use (e.g. several hours in an exhaust air oven at
DVS 2211 technical code and DIN EN 12943.
temperatures of approx. 60 - 80°C). Attention must be paid to the
The base and filler materials must be available in a flawless information from the welding filler manufacturer.
processing condition and must be dry and clean.
While the machine is running, the required material temperature
If there are any doubts that the semi-finished products and/or the is checked directly at the material outlet in the middle of the
welding filler are similar (e.g. due to a lack of labelling) or if any strand using the prick sensor of a quick-display temperature
material changes are to be feared due to: gauge.
– improper storage The control measurement of the hot air temperature is taken in
– low joining part temperatures the hot air nozzle between the nozzle outlet plane and a depth of
- soiling 5 mm using a precision probe with a diameter of approx. 1 mm
– ageing (see the instructions in DVS 2207-4, Supplement 2).
– operating influences (media or temperatures) The stipulated air volume must be checked in the case of devices
it is necessary to establish the weldability by means of tests on with an external air supply. It is necessary to ensure the flawless
trial welds. Agreement must be reached with regard to the type function of devices with an internal air supply.
and scope of the tests. Instructions about this are given in the The material and hot gas temperatures must be checked
DVS 2203-1 and 2201-2 technical codes. immediately before the beginning of the welding. Repeat checks
are recommendable in the case of a welding job lasting a longer
6.5 Requirements on the welders time or after interruptions in the work.
Hot gas extrusion welding is a welding process for which not only All the measurements must be taken with regularly checked
comprehensive knowledge with regard to the materials to be measuring instruments (according to DVS 2207-4, Supplement
welded and to the handling of the machines and devices but also 2) and must be documented (Appendix 2).
high skills in the execution are prerequisites.
The welder must have passed a qualification test according to
the DVS 2212-1 technical code, Qualification Test Group II, and 8 Welding preparation
must possess a valid test certificate.
The welding grooves of the joining parts are prepared according
6.6 Requirements on the quality of the welded joints to Section 5.
If the welds are executed properly according to this technical It must be guaranteed that the welding head of the machine or
code, those minimum requirements on the quality of the welds device has sufficient accessibility to the joining faces. Welding
which are specified in the DVS 2203-1 technical code (welding out of position should be avoided or minimised because of the
factors and bending angles) are sure to be met. With regard to required counterpressure to be applied by the welder. It must be
the application in question, to statutory stipulations if needed ensured that the welder is not hindered during the welding as a
(Water Management Act, Pressure Device Directive etc.) and to result of the necessary readjustment of the connecting cables
the necessary dimensioning, the customer and the manufacturer and hoses as well as of the welding filler.
should agree on the corresponding requirements on the
component and on the welded joints and should stipulate these. 8.1 Equipment
Instructions and criteria for stipulating the quality are described in The following equipment constitutes the minimum requirements
the DVS 2202-1 technical code. The inclusion of the weld quality for the proper execution of the welded joints:
in the component calculation is described in the DVS 2205-1 to
-5 technical codes. – hot gas extrusion welding device according to the welding job
and this technical code
If necessary, the evidence of the demanded quality may be
provided within the framework of establishing its suitability on trial – welding shoes according to the welding job
welds with reference to DVS 2212-1. This applies especially to – flow meter for welding gas
materials for which no requirements have yet been stipulated in
–- temperature gauge according to DVS 2207-4, Supplement 2
the specified technical codes (e.g. PVC-C).
– suitable measuring instruments for checking the misalignment,
the diameter and the thickness
7 Start-up of the welding machines and setting of the – suitable storage space for the devices
welding parameters
The start-up is carried out according to the operating instructions – personal protective equipment
from the machine manufacturer.
Extrudate residues in the extruder, at the outlet opening as well
as, if applicable, in the transport hose must be melted completely – sufficient lighting
before the extrusion drive is switched on. – protective measures against weathering influences (see
In order to avoid the use of thermally predamaged welding filler, Section 8.2)
the reheated melt should be extruded out completely before the – special cleaning agent (not swelling, dissolving or containing
beginning of the welding. This also applies to longer interruptions greasy) and non-fraying rags
in the work. The maximum dwell times are dependent on the
– welding parameters according to DVS 2207-4, Supplement 1
material in question (in the case of PE-HD and PP, approx.
and/or instructions from the manufacturers of the semi-finished
5 min). In the case of thermally sensitive materials such as PVC
products
and PVDF, it is to be recommended to keep the extruder running
during the interruption in the welding. – welding record sheet according to Appendix 2
462
8.2 Protective measures against environmental influences The welder must ensure that the molten base material at the weld
The ambient conditions may exert a fundamental influence on the sidewalls is not pushed off by the welding shoe nose.
welding operation and thus on the quality of the joint. Therefore, In the case of restarts and at the end of circumferential welds, it is
attention must be paid to the following: necessary to diagonally machine off the already executed ends
– The welding area must be protected from unfavourable of the weld.
weathering influences (such as moisture, formation of
condensation water, wind, draughts and temperatures below
+ 5°C).
– If it is ensured, by taking suitable measures (e.g. preheating,
tenting or heating), that a semi-finished product temperature
sufficient for the welding can be complied with, the welding
may be carried out at any outdoor temperature – provided that
the dexterity of the welder is not hindered. If necessary,
additional evidence must be provided by manufacturing and
testing trial welds in the existing conditions.
– In the case of non-uniformly tempered joining parts (e.g. due to
solar radiation on one side, in the case of different storage
conditions etc.), the temperatures must be equalised before
the welding.
9 Welding
Figure 8. Example of a single-V butt weld with representation of the mel-
9.1 Preparation of the joining faces ting zones and the weld overlap.
The joining faces must not be damaged, oxidised or soiled. In order to avoid the excessively rapid cooling of the top layer
Therefore, they and the adjacent weld overlap areas must be and the resulting formation of shrinkage cavities, it is
subjected to chip-producing machining immediately before the recommended to cover the extrusion weld immediately after the
welding. welding.
Chip-producing tools such as scrapers, scraper blades, milling If multi-layer welds are necessary, the cooled weld sidewalls and
cutters and saws are suitable. Grinding tools are only permissible surfaces of the already welded layers must be subjected to chip-
if it is possible to exclude the soiling caused by inputting producing machining.
abrasives and the overheating of the surfaces.
Design-induced modifications to the weld geometry in the weld
Especially in the case of joining parts which have been exposed path (e.g. in the case of segment bends and branches) demand
to the influence of UV or media for a long time, the damaged particularly careful guidance of the welding shoe. If necessary,
layer may be so deep that the residual wall thickness, including the welding shoe must be changed.
the static requirements, must be checked after the machining-off.
In the case of semi-automatic and fully automatic systems and
If the joining faces must be cleaned, it is necessary to use special
facilities for extrusion welding, the welding parameters (the
cleaning agents which do not contain any grease.
material output, the preheating and the welding speed) must be
coordinated and must be set correspondingly.
9.2 Tacking
It is recommended to manufacture trial welds.
Tacking serves to fix the joining parts in their planned positions in
relation to each other in order to exclude any changes in the In the case of discontinuous welding, the welding filler is
positions of the joining parts during the welding. Tacking is extracted from the extruder with the quiver and is inserted into
usually carried out by means of the partial or continuous high- the plastified welding groove section by section. The joining
speed hot gas welding of a root layer with a welding filler wire. pressure is applied with the press-on tool across all the cross-
sectional areas of the weld (central and edge areas) in several
9.3 Execution of a weld operations and the weld surface is shaped at the same time.
Before the beginning of the welding operation, the welding shoe 9.4 Finish machining of the welds
must be heated up (e.g. using a baffle plate) since welding with a
cold welding shoe results in a rough and uneven weld surface. Subject to corresponding welding shoe formation and machine
This also applies to press-on tools in the case of discontinuous guidance during the welding, finish machining of the welds is not
welding. necessary (in this respect, see also DVS 2202-1, Table 5).
The start of the weld is preheated and completely melted with hot It is imperative to remove the lateral flow which may be pressed
air. Immediately before the welding shoe is placed on the welding through under the contact surfaces of the welding shoe.
groove, the welding filler which has already emerged is removed Reinforced weld beads and reinforced weld roots must be
from the welding shoe opening. After the filling of the groove, the machined off correspondingly without any notches.
material pressure builds up due to the counterpressure generat- The weld may only be machined off after sufficient cooling.
ed by the welder and the forward movement of the welding shoe
begins. 9.5 Thermal after-treatment of the welds
In the case of manual welding, the welding speed is determined
Residual welding stresses can be reduced by means of
by the material output of the extruder and the size of the weld
tempering. The tempering conditions depend on the material and
cross-section.
the component. Attention must be paid to the information from
The preheating of the joining parts must be adjusted to the the manufacturers of the semi-finished products.
welding speed in such a way that the base material is plastified
down to a depth of 0.5 - 1 mm. 9.6 Welding record sheet
The plastification zone must be wider than the weld width. Guide The completely filled-in welding record sheet documents the
value: weld width + 2 • (0.2 • joining part thickness s) (see Fig. welding conditions and parameters amongst other details. It is
8). the foundation for the evaluation of the weld quality by the
The melting depth is checked directly in front of the welding shoe. welding supervisor (compare DVS 2213, specimen record sheet
This may be carried out with a thin, blunt tool. in Appendix 2).
463

test procedures. They are listed in Table 2 "Possible test
procedures" for the most frequent weld shapes.
Table 2. Usual test procedures for extrusion welds, applicability and requirements.
Non-destructive tests
Visual inspection of Visual inspection, according to DVS 2202-1 and 2206. The evaluation group must be stipulated in each
the undestroyed weld individual case.
(external findings)
Leak test with a partial Using suitable vacuum bell jars and a foaming liquid; the test conditions must be stipulated in each
vacuum individual case. Usual test pressure: -0.4 bar to -0.6 bar.
Leak test with electric The type of test device (with or without an antipole) and the test voltage must be stipulated in each
high voltage individual case. Test technique according to DVS 2206, Section 3.3.1.4.
Radiographic test Applicable; statement with the number, positions, shapes and sizes of pores, shrinkage cavities and
comparable defects possible. Test technique according to DVS 2206, Section 3.5.
Ultrasonic test Applicable to PE-HD, with restrictions to PP (statement about voids, not about quality). Test technique
according to DVS 2206, Section 3.4.
Pressure test Application usually for pipelines; test conditions according to the Pressure Device Directive. Test execution
according to DVS 2210-1, Supplement 2 and DIN 4279-7. Meaningfulness: leak tightness, experimental
evidence of the operational safety.
Destructive tests
Visual inspection of Formation of the executed weld cross-section (weld geometry), internal findings according to DVS 2202-1,
the weld cross-section Tables 4 and 5. Fracture pattern of the weld destroyed in the tensile test or in the technological bending
test.
Tensile test Execution according to DVS 2203-2: short-time tensile welding factor; DVS 2203-4: creep rupture welding
factor; minimum requirements according to DVS 2203-1. Test not applicable to fillet and single-bevel butt
welds.
Technological bending Execution according to DVS 2203-5, minimum requirements (bending angle) according to DVS 2203-1.
test Test not applicable to fillet and single-bevel butt welds.
The visual inspection concentrates, in particular, on the weld In explosion-protected areas, attention must be paid to the valid
shape, the notch-free surfaces and peripheral zones, the safety regulations with regard to the welding work and any
optimum weld filling, the full weld penetration on the root side and measures which may be necessary must be agreed on with the
the joining part misalignment. safety officer responsible; in this respect, see the Operational
Safety Ordinance (BetrSichV).
With ultrasonic and X-ray testing (see the DVS 2206 technical
code), flaws can be detected in the interior of the welds without
any destruction. However, on their own, they do not provide a
12 Standards and technical codes which are also
sufficient indication of the quality of the welded joint. Moreover,
applicable
the utilisation possibilities of these test procedures are limited
with regard to the weld geometry and the weld thickness. DIN 1910-3 Welding of plastics – Processes
For the designation and evaluation of defects, reference is made DIN V 4279-7 Internal pressure testing of pressure piping for
to the DVS 2202-1 technical code. (preliminary water – Pressure pipes made of low-density
standard) polyethylene PE-LD, pressure pipes made of
It is necessary to stipulate the type and scope of the tests to be
high-density polyethylene PE-HD (PE 80 and
performed in each individual case.
PE 100), pressure pipes made of cross-linked
Material-specific tests are indicated in DVS 2201-1 and general polyethylene PE-X and pressure pipes made of
tests such as dimensional accuracy or surface assessment in unplasticised polyvinyl chloride PVC-U
DVS 2206. DIN 16960-1 Welding of thermoplastics – Principles
DIN 32502 Defects in welded joints made of plastics –
Classification, designations and explanations
DIN EN 12943 Welding fillers for thermoplastics – Scope of
Hazardous decomposition products and health-endangering application, marking, requirements and testing
fumes result from the overheating of some materials (such as. DIN EN ISO Plastics – Code letters and codes – Part 1: Base
PVC, PVDF and E-CTFE) or already develop during the welding 1043-1 polymers and their particular properties
of other materials (such as FEP, MFA, PFA and PTFE). On the DVS 2201-2 Testing of semi-finished products made of
basis of the DIN safety data sheets to be submitted by the thermoplastics – Weldability – Test procedures
manufacturer, the contractor must elaborate operating – Requirements
instructions which comply with Section 20 of the Hazardous
Substances Ordinance (GefStoffV) and indicate all the potential DVS 2202-1 Defects in welded joints between thermoplastics
hazards and necessary protective measures. It may be – Characteristics, description and evaluation
necessary to take further specific protective measures in each DVS 2203 Testing of welded joints between panels and
individual case. pipes made of thermoplastics
464
-1 Test procedures – Requirements DVS 2207-4, Welding of thermoplastics – Extrusion welding

-2 Tensile test Supplement 2 of pipes, piping parts and panels –
Requirements on the welding machines and
-4 Tensile creep test welding devices
-5 Technological bending test DVS 2207-11 Welding of thermoplastics – Heated tool welding
DVS 2205 Calculation of tanks and apparatus made of of pipes, piping parts and panels made of PP
thermoplastics DVS 2207-15 Welding of thermoplastics – Heated tool welding
-3 Welded joints of pipes, piping parts and panels made of PVDF
-4 Flanged joints DVS 2210-1 Industrial piping made of thermoplastics –
-5 Rectangular tanks Planning and execution – Overground pipe
systems
DVS 2206 Testing of components and structures made of
thermoplastics DVS 2211 Welding of thermoplastics – Welding fillers –
Marking, requirements and tests
DVS 2207-1 Welding of thermoplastics – Heated tool welding
of pipes, piping parts and panels made of DVS 2212-1 Qualification testing of plastics welders –
PE-HD Qualification Test Groups I and II – Hot gas
welding with the torch separate from the filler
DVS 2207-3, Welding of thermoplastics – High-speed hot gas rod, high-speed hot gas welding, heated tool
Supplement 1 welding and hot gas welding with the torch butt welding, sleeve welding with an
separate from the filler rod of pipes, piping parts incorporated electric heating element, heated
and panels – Welding parameters tool sleeve welding and hot gas extrusion
DVS 2207-3, Welding of thermoplastics – High-speed hot gas welding
Supplement 2 welding and hot gas welding with the torch DVS 2225 Joining of sealing sheets made of polymer
separate from the filler rod of pipes, piping parts materials in earthwork construction and water
and panels – Requirements on the welding engineering
devices and accessories
DVS 2207-4, Welding of thermoplastics – Extrusion welding DIN standards can be obtained from Beuth Verlag, Berlin and
Supplement 1 of pipes, piping parts and panels – Welding DVS technical codes from Verlag für Schweißen und verwandte
parameters Verfahren DVS-Verlag GmbH, Düsseldorf.
465
Appendix 1: Brief instructions for the welding 4. Prepare the welds and the joining faces (Section 9.1)
– check, stipulate and manufacture the weld geometry and the
1. Put together the welding equipment (Section 8.1)
weld shape
– valid welder's certificate
– remove the oxide layer from the joining faces by means of
– hot gas extrusion welding device corresponding to the welding chip-producing machining
job, including the operating instructions
5. Tack the joining parts (Section 9.2)
– possibly hot gas welding device for tacking the joining parts
– execute a partial or continuous root layer with a hot gas
– welding shoes according to the weld shape welding device
– flow meter for welding gas 6. Start up and prepare the welding extruder (Section 7)
– temperature gauge with sensors for measuring the hot gas and – check the supply lines (electricity and air) for any possible
the extrudate as well as the temperature of the semi-finished hindrances to the welding operation
products
– connect and start the extruder according to the operating
– suitable measuring instruments for checking the misalignment, instructions
the diameter and the thickness
– select, adjust and assemble the welding shoe and the hot gas
– storage space for the devices
nozzle according to the weld geometry and the weld shape
– extrude the reheated welding filler out of the cylinder
– personal protective equipment
– set and check the parameters (Appendix 1)
– preheat the welding shoe
– cleaning agent
7. Welding (Section 9.3)
– Supplement 1: Welding parameters
–- check that the base material is sufficiently plastified (e.g. by
– Appendix 2: Welding record sheet pricking it with a blunt tool)
– special welding instructions – check the welding speed and monitor the uniformity
2. Check the working conditions and plan the measures
– continuously check the guidance of the welding extruder and
(Section 8.2)
make any corrections needed
– accessibility
– if necessary, prevent any excessively rapid cooling of the weld
– sufficient lighting surface by covering it
– protective tent – bevel the ends of the welds before restarts
– heating – protect the welding filler from contaminations
3. Check the weldability (Section 6.4) 8. Finish-machine the weld (Section 9.4)
– on the semi-finished products and welding fillers, check that – let welded parts cool down sufficiently before unclamping them
the information from the manufacturers is correct and subjecting them to loads
– check the condition and cleanness of the joining partners and – machine off the lateral weld flow and the weld reinforcements
possibly clean them
9. Compile the welding record sheet (Section 9.6)
– if necessary, check the weldability of the joining partners by
means of build-up welding according to DVS 2201-2 or trial –- fill in the welding record sheet (Appendix 2) and carry out the
welds visual inspection according to DVS 2202-1
466
Extrusion welding of panels and pipes Company logo
Project: Project no.: Protective

Weathering
measures
Drawing no.: Base material (manufacturer, type, batch, date):
1 = Sunny 1 = None
Welder: Welding filler (manufacturer, type, batch, date):

2 = Dry 2 = Screen
Welding certificate no.: / valid untel Welding machine, make, tpye:

3 = Precipita- 3 = Tent
tion
Welding supervisor (3): Year of construction / last machine examination: Process variant according to DVS 2207-4:
Date Weld no. Joining part Weld shape Welding Air volume Material Hot gas Welding Ambient tem- Semi-finis- Weathering Protective Visual
thickness (symbol) shoe no. temperature temperature speed perature hed product (code no.) measures evaluation
temperature (code no.)
mm l/min C (1) C (2) cm/min C C
Appendix 2: Welding record sheet for the extrusion welding
(1) Measured with a pricking thermometer at the extrudate outlet of the welding machine / welding device Remarks: e.g. less favourable conditions
(2) Measured in the middle of the nozzle outlet opening, 5 mm in the nozzle
(3) E.g. specialist for plastics welding according to DVS 2213

467
Draft March 2013
FÜR SCHWEISSEN UND
Extrusion welding of pipes, Technical Code

Replaces draft dated May 2009
Planned as the replacement for the June 2006 edition
This supplement to the DVS 2207-4 technical code includes guide values for the parameters for hot gas extrusion welding. They apply
to manual welding with the machines and devices specified in the DVS 2207-4 technical code, Supplement 1 and with the materials
listed in the table.
If necessary, other parameters may also be used for welding with automatic welding machines, see the DVS 2207-4 technical code,
Section 10.3.
The welding speed depends directly on the material output, the weld cross section and the preheating temperature. Experience has
shown that it should be 200 - 350 mm/min.

It must be guaranteed that the joining parts are plastified down to a depth of 0.5 - 1 mm at the joint and beyond the weld width, see the
DVS 2207-4 technical code, Section 10.3.
Material Abbreviation Material Hot gas Hot gas

temperature1) temperature 2) volume3)
[°C] [°C] [Nl/min]
High-density polyethylene PE4) 210–230 250–300 300
Polypropylene, Types 1, 2 and 3 PP-H, PP-B and PP-R 210–240 250–300 300
Unplasticised polyvinyl chloride PVC-U 190–200 330–360 300
Impact-resistant polyvinyl chloride PVC-HI 170–180 280–340 300
Chlorinated polyvinyl chloride PVC-C 195–205 300–350 300
Polyvinylidene fluoride PVDF 240–260 280–350 300
1) Measured with an insert thermometer at the extrudate outlet of the welding machine
2) Measured 5 mm in the nozzle, in the centre of the nozzle opening
3) Drawn-in cold air volume at the ambient pressure (in the case of devices with an output quantity  1.5 kg/h)
4) PE 63, PE 80 and PE 100
468
June 2006
Extrusion welding of Technical Code
FÜR SCHWEISSEN UND
pipes, piping parts and panels – DVS 2207-4
Replacement for the April 2005 edition
This supplement to the DVS 2207-4 technical code includes If necessary, other parameters may also be used for welding with
guide values for the parameters for hot gas extrusion welding. automatic welding machines (see DVS 2207-4, Section 9.3).
They apply to manual welding with the machines and devices
By coordinating the hot air temperature, air volume and welding
specified in the DVS 2207-4 technical code, Supplement 2 and
speed parameters, it must be guaranteed that the joining parts
with the materials listed in the table.
are plastified down to a depth of 0.5 - 1 mm at the joint and
beyond the weld width (see DVS 2207-4, Section 9.3).
Material Abbreviation Material Hot gas Hot gas

temperature1) temperature 2) volume3)
°C °C l/min
High-density polyethylene PE-HD4) 210–230 250–300 300

Polypropylene, Types 1, 2 and 3 PP-H; PP-B; PP-R 210–240 250–300 300
Unplasticised polyvinyl chloride PVC-U 170–180 300–360 300
Impact-resistant polyvinyl chloride PVC-HI 170–180 280–340 300
Chlorinated polyvinyl chloride PVC-C 195–205 300–360 300
Polyvinylidene fluoride PVDF 240–260 280–350 300
1) Measured with an insert thermometer at the extrudate outlet of the welding machine
2) Measured 5 mm in the nozzle in the centre of the nozzle opening
4) PE 63, PE 80 and PE 100
469
Draft March 2013
DVS – DEUTSCHER VERBAND Extrusion welding of pipes, piping parts
FÜR SCHWEISSEN UND and panels – Technical Code
VERWANDTE VERFAHREN E.V. Requirements on the welding machines DVS 2207-4
and welding devices Supplement 2
Contents: – the designs of the supply hoses and the cables are flexible and
force-saving for the welder and they neither kink nor twist dur-
1 Scope of application ing proper operation
2 Requirements – the preheating of cooled extrudate at the outlet of the material
2.1 General requirements nozzle is ensured by suitable devices, e.g. baffle nozzle for the
2.2 Marking and documentation hot gas flow
2.3 Safety requirements – they can be put down in a stable position at the end of the
2.4 Plastifying system welding work or during interruptions in the work

2.5 Preheating system
2.6 Welding shoes The devices must comply with the applicable European direc-
tives, also see Section 3.
2.7 Accessories for discontinuous welding
3 Bibliography The manufacturer or his authorised agent based in the Commu-
nity is responsible for the issuing of the EC declaration of con-
formity and for the CE marking. Upon request, all the relevant
1 Scope of application measuring and testing documents which confirm that the con-
formity with the directives has been complied with must be sub-
This supplement to the DVS 2207-4 technical code describes mitted to the market monitoring authority.
general, qualitative and safety-relevant requirements on
machines and devices for the extrusion welding of thermoplas-
tics. The following information must be permanently displayed on the
machines and devices:
It applies to the Machine Variants I, II and III specified in the
DVS 2207-4 technical code and should ensure that the quality of – information about the manufacturer and the type
the welds which is demanded in the technical code is achieved – information about the electricity supply, the power input and the
when the devices and machines are operated and handled prop- frequency
erly. – identification number
– CE symbol and protection class
2 Requirements All the machines and devices are provided with operating and
maintenance instructions which, at least, must include the following:
2.1 General requirements – functional description with operating instructions
The machines and devices must guarantee that: – information about the application range (power range)
– maintenance schedule with information about the testing cycles
– the functioning capacity is ensured within the intended temper-
ature utilisation range from - 5°C to + 60°C – service addresses
– the storage within a temperature range from - 20°C to + 80°C It is recommendable to compile a list of any possible malfunc-
does not cause any damage tions, including any possible causes of defects and information
about how to rectify them.
– the mechanical stresses occurring during proper transport and
operation do not lead to any disturbances or damage 2.3 Safety requirements
– the internal surfaces and the screw have sufficient corrosion The machines and devices must not involve any risk of injury
protection against humidity acting on the outside as well as whatsoever for the user when they are utilised properly.
against the planned welding filler material or its constituents In particular, the following is applicable:
– the machine and device elements are ergonomically designed – any surfaces which become hot must be kept as small as pos-
according to their intended application and their handling and sible and, wherever technically possible, insulated
can be operated easily and safely – any parts close to the welder's hands must not exceed opera-
– all the components and functional elements must be easily ac- tionally induced temperatures of 40°C, even in the case of lengthy
cessible for the intended operation as well as for the necessary utilisation
cleaning and maintenance – sharp edges on the machines, devices and accessories are
– the required joining pressure can be applied in the planned not permissible
welding positions using corresponding holding jigs and han- The machines and devices must comply with the applicable regu-
dles lations, guidelines and technical codes.
470
2.4 Plastifying system Table 1 shows an example of a nozzle geometry. The nozzle
cross sections specified in the table guarantee the reliable over-
The following requirements must be satisfied:
lapping of the different weld geometries and weld widths [1]. In
– Uniform welding filler material supply adapted to the screw the case of larger welding groove widths, the existing basic
speed in all the planned welding positions. geometry must be correspondingly enlarged to scale.
– In order to interrupt the granulate supply, a suitable barrier In the case of machines and devices which are used for discon-
must be provided in the corresponding machines or devices. tinuous welding, the nozzle must be easy to change.
– If the material temperature and, wherever integrated by means
Table 1. Examples of the welding nozzle geometry and the air outlet
of appliance engineering, the hot gas temperature move above
cross sections for weld widths up to 40 mm.
or below the stipulated tolerance limits, an automatic drive cut-
off and overtemperature protection must take effect. Nozzle standard Weld width x1) Nozzle
– The material output above 1.5 kg/h should be infinitely adjust- (air outlet opening) [mm] dimensions
able on the machine or device with the aid of the screw speed. [mm]
Constant speeds are permissible in the case of machines and a b
devices which are used exclusively for discontinuous welding.
Up to 15 8 18
– A drive cut-off must be effective for the heating-up time of the
16...20 10 23
welding filler material which has cooled in the extruder and in
the supply hose. 21...30 12 34
– The interruption switch (on/off) for the plastifying system must 31...40 15 50
be arranged in such a way that it can be operated by the
welder at any time. This also applies to the material tempera-
1)
ture controller. maximum welding groove width
– The extrudate must be plastified in a completely homogeneous 2.6 Welding shoes

form and must emerge with a constant material output at a sta-
ble temperature. The welding shoes must comply with the stipulations in the
DVS 2207-4 technical code, Section 7.2.
– The material temperature at the material outlet must be dis-
played. The safe and secure coupling and easy replacement of the weld-
ing shoe must be guaranteed (this does not apply to devices
– The temperature fluctuation of the material must not exceed which are used exclusively for discontinuous welding).
 3 K (measured in the centre of the material) in continuous
operation and at an unchanged controller setting. 2.7 Accessories for discontinuous welding
– The deviation between the temperature set on the controller The pressing-on tools used for discontinuous welding must guar-
and the actual outlet temperature must not exceed  10 K. antee the most uniform possible input and pressing-on of the
The following applies to machines and devices which are used extrudate. The radius of the pressing-on surface with a bend
exclusively for discontinuous welding: length of 120 - 130 mm is approx. 100 mm. The width of the
pressing-on surface corresponds to the weld width. The edges of
– The material nozzles must be easy to replace. the pressing-on surface must be rounded. Special pressing-on
tools may be necessary for particular weld geometries.
– The nozzle cross section must correspond to the seam volume
to be welded in each case. The quiver consists of a PTFE pipe with a handle which closes
the pipe on one side. The inside diameter of the pipe is adapted
2.5 Preheating system to the welding filler material to be accommodated.
The preheating system must guarantee that the weld sidewalls,

the weld overlap and the weld root are plastified sufficiently. This 3 Bibliography
can be achieved with various systems, e.g. using hot gas heat or
radiant heat. Because of the practical application, only the pre- Set of rules
heating by means of hot gas is dealt with below.
DIN EN ISO Safety of machines – General guiding princi-
– The hot gas temperature is infinitely adjustable, corresponding 12100 ples for design – Risk assessment and risk
to the material to be welded, and is displayed. The temperature reduction
fluctuation at an unchanged controller setting must not exceed
 10 K. The welding gas temperature must be reached after DIN EN 55014-1 Electromagnetic compatibility – Requirements
max. 15 min. on household appliances, power tools and
similar electrical appliances – Part 1: Interfer-
– The hot gas nozzles must be provided with a test borehole ence emission
which permits reproducible measurements of the temperature
DIN EN 55014-2 Electromagnetic compatibility – Requirements
according to the DVS 2207-4 technical code. The transferabil-
on household appliances, power tools and
ity of the measured temperature values with the stipulations in
similar electrical appliances – Part 2: Interfer-
the DVS 2207-4 technical code, Supplement 1 must be guar-
ence immunity – Standard for product families
anteed – if necessary, using conversion tables.
DIN EN 60204-1 Safety of machines – Electrical equipment of
– The volume flow must be min. 300 I/min (drawn-in cold air vol- machines – Part 1: General requirements
ume at the ambient pressure) and must be kept constant dur-
ing the welding operation.
DIN EN 60335-1 Safety of electrical appliances for domestic
– The heating unit is firmly installed on the welding head or on use and similar purposes – Part 1: General
the plastifying system. In the case of machines and devices requirements
which are used exclusively for discontinuous welding, the heat- DIN EN Safety of electrical appliances for domestic
ing unit is guided independently of the plastifying system. 60335-2-45 use and similar purposes – Part 2-45: Particu-
– The hot gas nozzle must guarantee the intensive and uniform lar requirements on non-stationary electrical
preheating (plastification) of the base material across the entire heating tools and similar devices
weld width – at the lowest possible hot gas temperature.
471
DIN EN Electromagnetic compatibility (EMC) – Part 3-2:

61000-3-2 Limiting values – Limiting values for harmonic
currents (appliance input current:  16 A per
conductor)
DIN EN Electromagnetic compatibility (EMC) – Part 3-3:
61000-3-3 Limiting values – Limitation of voltage changes,
voltage fluctuations and flickers in public low-
voltage supply grids for appliances which have
a rated current of  16 A per conductor and
are not subject to any special connecting con-
ditions
Technical code: Welding of thermoplastics – Extrusion welding
DVS 2207-4 of pipes, piping parts and panels – Processes
and requirements
Technical code: Welding of thermoplastics – Extrusion welding

DVS 2207-4, of pipes, piping parts and panels – Welding
Supplement 1 parameters
VBG 22 Working machines in the chemical, rubber and
plastics industries
EC Machine Directive 89/392
2nd Amendment 91/368 EEC; 3rd Amendment 93/44 EEC
Literature
[1] Gehde, M.: About the extrusion welding of polypropylene.
Dr.-Ing. dissertation, University of Erlangen-Nuremberg, 1993.
472
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Erstellt am:
17.01.2008
29.01.2008
March 2008

FÜR SCHWEISSEN UND
Extrusion welding Technical Code
VERWANDTE VERFAHREN E.V. of pipes, piping parts and panels DVS 2207-4
Requirements on the welding machines and welding devices Supplement 2
Translation of the German version from april 2005
Contents: - the preheating of cooled extrudate at the outlet of the material

nozzle is ensured by suitable devices, e.g. baffle nozzle for the
1 Scope of application hot gas flow
2 Requirements
- they can be put down in a stable position at the end of the
welding work or during interruptions in the work
2.4 Plastifying system 2.2 Marking and documentation
2.5 Preheating system The following information must be permanently displayed on the
2.6 Welding shoes machines and devices:
2.7 Accessories for discontinuous welding
3 Standards and technical codes which are also applicable – information about the manufacturer and the type
4 Literature – information about the electricity supply, the power input and
the frequency
1 Scope of application – identification number

– CE symbol and protection class
This supplement to the DVS 2207-4 technical code describes
general, qualitative and safety-relevant requirements on ma- All the machines and devices are provided with operating and
chines and devices for the extrusion welding of thermoplastics. maintenance instructions which, at least, must include the
following:
It applies to the Machine Variants I, II and III specified in the
DVS 2207-4 technical code and should ensure that the quality of – functional description with operating instructions
the welds which is demanded in the technical code is achieved – information about the application range (power range)
when the devices and machines are operated and handled
properly. – maintenance schedule with information about the test cycles
– service addresses
2 Requirements It is recommendable to compile a list of any possible malfunc-
tions, including any possible causes of defects and information
2.1 General requirements about how to rectify them.
The machines and devices must guarantee that:
– the functioning capacity is ensured within the intended temper-
ature utilisation range from - 5°C to + 60°C The machines and devices must not involve any risk of injury
whatsoever for the user when they are utilised properly.
– the storage within a temperature range from - 20°C to + 80°C
does not cause any damage In particular, the following is applicable:
– the mechanical stresses occurring during proper transport and – any surfaces which become hot must be kept as small as pos-
operation do not lead to any disturbances or damage sible and, wherever technically possible, insulated
–- the internal surfaces and the screw have sufficient corrosion – any parts close to the welder's hands must not exceed opera-
protection against externally effective humidity as well as tionally induced temperatures of 40°C, even in the case of
against the planned welding filler or its constituents lengthy utilisation
– the machine and device elements are ergonomically designed –- sharp edges on the machines, devices and accessories are
according to their intended application and handling and can not permissible
be operated easily and safely
The machines and devices must comply with the applicable
– all the components and functional elements must be easily ac- regulations and technical codes.
cessible for the intended operation as well as for the necessary
cleaning and maintenance 2.4 Plastifying system
– the required joining pressure can be applied in the planned The following requirements must be met:
welding positions using corresponding holding jigs and han-
dles Uniform welding filler supply adapted to the screw speed in all the
planned welding positions.
– the design of the supply hoses and cables is flexible and force-
saving for the welder so that it neither kinks nor twists during In order to interrupt the granule supply, a suitable barrier must be
proper operation provided in the corresponding machines or devices.
473
If the material temperature and, wherever integrated by means of Table 1. Examples of the welding nozzle geometry and the air outlet
appliance engineering, the hot gas temperature move above or cross-sections for weld widths up to 40 mm.
below the stipulated tolerance limits, an automatic drive cut-off
Shape of nozzle Seam Dimensions
and overtemperature protection must take effect.
(air outlet opening) width x1) of nozzle
The material output above 1.5 kg/h should be infinitely adjustable (mm) (mm)
on the machine or device with the aid of the screw speed.
Constant speeds are permissible in the case of machines and a b
devices which are used exclusively for discontinuous welding. Up to 15 8 18
A drive cut-off must be effective for the heating-up time of the
16 ... 20 10 23
welding filler which has cooled in the extruder and in the supply
hose. 21 ... 30 12 34
The interruption switch (on/off) for the plastifying system must be 31 ... 40 15 50
arranged in such a way that it can be operated by the welder at
any time. This also applies to the material temperature controller.
maximum welding groove width
The extrudate must be plastified in a completely homogeneous
form and must emerge with a constant material output at a stable
temperature. 2.6 Welding shoes
The material temperature at the material outlet must be dis- The welding shoes must comply with the stipulations in the
played. DVS 2207-4 technical code, Section 6.2.
The temperature fluctuation of the material must not exceed
The safe and secure coupling as well as the easy replacement of
± 3 K (measured in the centre of the material) in continuous
the welding shoe must be guaranteed (this does not apply to
operation and with an unchanged controller setting.
devices which are used exclusively for discontinuous welding).
The deviation between the temperature set on the controller and
the actual outlet temperature must not exceed ± 10 K. 2.7 Accessories for discontinuous welding
The following applies to machines and devices which are used The press-on tools used for discontinuous welding must
exclusively for discontinuous welding: guarantee the most uniform possible input and pressing-on of the
– The material nozzles must be easy to replace. extrudate. The radius of the press-on surface with a bend length
of 120 - 130 mm is approx. 100 mm. The width of the press-on
– The nozzle cross-section must correspond to the weld volume surface corresponds to the weld width. The edges of the press-
to be filled in each case.
on surface must be rounded. If necessary, special press-on tools
are necessary for particular weld geometries.
2.5 Preheating system
The preheating system must guarantee that the weld sidewalls, The quiver consists of a PTFE pipe with a handle which closes
the weld overlap and the weld root are plastified sufficiently. This the pipe on one side. The inside diameter of the pipe is adapted
may be achieved with various systems, e.g. by hot gas heat or to the welding filler to be accommodated.
radiant heat. Because of the practical application, only the
preheating by means of hot gas is dealt with below.
– The hot gas temperature is infinitely adjustable, according to
the material to be welded, and is displayed. The temperature DIN EN ISO 12100-1 Safety of machines – Basic terms and
fluctuation at an unchanged controller setting must not exceed general guiding principles for design –
± 10 K. The welding gas temperature must be reached after Part 1: Fundamental terminology and
max. 15 min. methodology
– The hot gas nozzles must be provided with a test borehole DIN EN ISO 12100-2 Safety of machines – Basic terms and
which permits reproducible measurements of the temperature general guiding principles for design –
according to DVS 2207-4. The transferability of the measured Part 2: Technical guiding principles
temperature values to the stipulations in the DVS 2207-4 tech- DIN EN 55014-1 Electromagnetic compatibility – Require-
nical code, Supplement 1 must be guaranteed – if necessary, ments on household appliances, power
by means of conversion tables. tools and similar electrical appliances –
– The volume flow must be min. 300 I/min (cold air volume in- Part 1: Interference emission
take at the ambient pressure) and must be kept constant DIN EN 55014-2 Electromagnetic compatibility – Require-
during the welding operation. ments on household appliances, power
– The heating unit is firmly installed on the welding head or on tools and similar electrical appliances –
the plastifying system. In the case of machines and devices Part 2: Interference immunity
which are used exclusively for discontinuous welding, the heat- DIN EN 60204-1 Safety of machines – Electrical equip-
ing unit is guided independently of the plastifying system. ment of machines – Part 1: General re-
– The hot gas nozzle must guarantee the intensive and uniform quirements
preheating (plastification) of the base material across the DIN EN 61000-3-2 Electromagnetic compatibility (EMC) –
entire weld width – at the lowest possible hot gas temperature. Part 3-2: Limiting values – Limiting val-
Table 1 shows an example of a nozzle geometry. The nozzle ues for harmonic currents (appliance in-
cross-sections specified in the table guarantee the reliable put current: 16 A per conductor)
overlapping of the different weld geometries and weld widths [1]. DIN EN 61000-3-3 Electromagnetic compatibility (EMC) –
In the case of larger welding groove widths, the existing basic Part 3-3: Limiting values – Limitation of
geometry must be correspondingly enlarged to scale. voltage changes, voltage fluctuations
and flickers in public low-voltage supply
In the case of machines and devices which are used for
grids for appliances which have a rated
discontinuous welding, the nozzle must be easy to change.
current of 16 A per conductor and are not
subject to any special connecting condi-
tions
474
DIN EN 60335-1 Safety of electrical appliances for domes-

tic use and similar purposes – Part 1:
General requirements
DIN EN 60335-2-45 Safety of electrical appliances for domes-
tic use and similar purposes – Part 2-45:
Particular requirements on non-station-
ary electrical heating tools and similar
devices
DVS 2207-4 Welding of thermoplastics – Extrusion
welding of pipes, piping parts and panels
– Processes and requirements
DVS 2207-4, Welding of thermoplastics – Extrusion
Supplement 1 welding of pipes, piping parts and panels
– Welding parameters
EC Machine Directive 89/392; 2nd Amendment of 91/368
EEC; 3rd Amendment of 93/44 EEC
VBG 22 Working machines in the chemical, rub-
ber and plastics industries (now only
applicable to stocks of old machines)
4 Literature
[1] Gehde, M.: About the extrusion welding of polypropylene.

Doctoral dissertation, University of Erlangen-Nuremberg, 1993.
475
File-Name: C:\DVS Merkblätter\2207\2207-05\englisch\e2207t5.fm
Directive D
DVS – DEUTSCHER VERBAND Welding of Thermoplastics –
DVS 2207-5
FÜR SCHWEISSEN UND Welding of PE Casing Pipes, V
VERWANDTE VERFAHREN E.V. Tubes and Tubular Components (Februar 1993) S 
Contents: – Permanent mechanical joint under thermal load resulting from

the temperature of the medium under simultaneous external
1 Scope and internal mechanical load.
2 General requirements imposed on welded joints
– Permanent watertight joint of the PE-HD casing in all operating
3 Material
conditions and load cases.
4 Types of execution of welded joints on PE-HD casing pipes
4.1 Casing pipe/Sleeve joints – Transition of the forces acting on the sleeve into the casing
4.2 Welds on fittings pipe, caused for example by the increased resistance of the
5 Carrying out the welding process soil pressure in the sliding region. The increased soil
5.1 Heated plate welding (HS) resistance results from the thermal expansion of the moving
5.2 Hot gas extrusion welding (WE) long distance heating piping, when the largest sleeve diameter
5.3 Electrofusion (HM) exceeds the diameter of the casing pipe.
5.4 Indirect heated tool sleeve welding (-)
5.5 Hot gas welding (W)
6 Testing the welded joints 3 Material
6.1 Tensile test

6.2 Technological bend test The material to be used for the casing pipe, for sleeves and
6.3 Manual peel test fittings and if necessary the welding filler is PE-HD DIN 8075 –
6.4 Tensile creep test with the strength properties in terms of creep behaviour
6.5 Imperviousness test corresponding to the State of the Art (as dealt with in Section 8.3
7 Requirements imposed on welded joints of this Directive). In order to ensure weldability, the parts to be
7.1 Visual examination welded and if necessary the welding filler materials used must
7.2 Mechanical-technological tests in the short-term test correspond to the melt index groups 005 and/or 0101) to DIN
16776 Part 1.
7.3 Tensile creep test
7.4 Imperviousness test
8 Quality Assurance 4 Design versions of welded joints on PE-HD casing pipes
8.1 Quality Assurance for casing pipes and fittings in the Manu-
facturer's Works Forms of application of welded joints are found as tube/sleeve
8.2 Proofs of Quality for casing pipes and fittings joints and in the manufacture of fittings. The tube/sleeve joints
8.3 Quality Assurance of the welding work are welded on site, welds on fittings are produced both on site
9 Standards, Directives and also in the works.
9.1 Standards
9.2 Directives 4.1 Tube/Sleeve joints
Annex 1 Report Form (Proposal) for electrofusion methods
Annex 2 Report Form (Proposal) for heated plate welding 4.1.1 Heated plate welding (HS)
Annex 3 Report Form (Proposal) for extrusion welding
Heated plate welding2) is used in the works for producing fittings.
Annex 4 Report Form (Proposal) for imperviousness test
For reasons of design this method is not customary for tube/
Annex 5 Test content and implementing internal and external
sleeve joints.
monitoring
Annex 6 Determination of the time factor and a fictitious joining
4.1.2 Extrusion welding (WE)
factor for a welded joint
Annex 7 Stressing of KMR welded sleeves In extrusion welding the two weld shapes V-weld and fillet weld
are produced. Extrusion welding is customary both for the
manufacture of fittings in the works and for tube/sleeve joints.
1 Scope
4.1.2.1 Butt weld with V-weld, Fig. 1.
The Directive applies to all PE-HD welds on components of
plastic casing pipe systems. These include in particular the joints The sleeve tube, which has the same outside diameter as the
of the PE casing pipes and elbows, T-pieces, reducers and casing pipe, is placed slotted in the longitudinal direction over the
special parts with sleeves. The guideline is applicable both to casing pipe. The sleeve tube is fitted with saw cuts on both sides
welds made in the works and for welds which are carried out on and the butt bevel preparation made. Then the circular seams
site. are welded and finally the longitudinal seam. The welding of the
circular seams is done by extrusion welding with a trolley which is
rotated around the tube on a special strap. Particular care must
2 General requirements imposed on welded joints be taken when making the butt region between the circular
seams and the longitudinal seam. Suitable welding shoe shapes
The following general requirements are imposed on the welded for V- welds, matched to the seam shape, must be used (see Fig.
joint: 1).
1) Melt index group 005 = MFI 190/5 = above 0.4 to 0.7 g/10 min. Melt index group 010 = MFI 190/5 = above 0.7 to 1.3 g/10 min.
2) Formerly called "Spiegelschweißen" ("mirror welding")
This publication was prepared by a group of experienced specialists working together in an honorary capacity, and it is recommended that it should be respected as
an important source of knowledge. The user must at all times check the extent to which the contents apply to his or her special case and whether the version available
to him or her is still current. Any liability on the part of the German Welding Society and of those participating in the preparation of this document is excluded.
DVS, Technischer Ausschuß, Arbeitsgruppe "Fügen von Kunststoffen"

in common with Arbeitsgruppe "Schweißen von PE-Mantelrohren" der Arbeitsgemeinschaft Fernwärme – AGFW – e.V.
bei der Vereinigung deutscher Elektrizitätswerke
476
Detail “X” accordance with the seam shape is to be used (see Fig. 5b).
V-weld, extrusion
welding with filler 4.1.3 Electrofusion
“X” In the application electrofusion is used with integrated heating

conductors.
4.1.3.1 Sleeve tube/Plate with built-in heating conductors for longi-

tudinal and circumferential welds, Fig. 3
With this method the sleeve tube is made in the works from a
sleeve tube/plate provided with heating conductors. For the
longitudinal seam a supporting element is incorporated. Then the
tube or the plate is placed around the prepared ends of the
casing pipes and secured with external clamping rings. At the
same time the clamping rings serve to apply the compressive
Figure 1. Basic design of a fitted sleeve with V-welds. forces during electrical heating, which are necessary for the
welding. Lap welds are used for the circumferential and
longitudinal seams.
Detail “X” Fillet welds, extrusion
welding with filler 4.1.3.2 Sleeve band with built-in heating conductors for longitudinal
and circumferential seams, Fig. 4
A longitudinally slit sleeve tube is fitted between the ends of the
casing pipes with the same diameter. Over the joint grooves in
the circular butt joint region and on the longitudinal butt joint a
Profile ring “X” band provided with heating conductors is placed and fitted to an
external clamping device during the heating.
Detail “X” Band with heating conductor
Spacer/pressure support
Figure 2. Basic design of a slip-on sleeve with fillet weld. “X”

4.1.2.2 Lapp joint with fillet weld, Fig. 2.
In this case the sleeve tube is not divided. There is no
longitudinal seam. The circular seams are executed as fillet
welds as described under 4.1.2.1. For fixing and centering the
sleeve and for forming a reliable root a profile ring rounded
towards the seam (for example of plywood or plastic) is inserted.
For seam shape see DVS 2209, Fig. 10, or Fig. 5b). Care must
be taken to ensure adequate overlap of the ends of the casing
pipes (make markings).
The execution of the extrusion welding takes place as described
under 4.1.2.1. A welding shoe for this fillet weld design shaped in Figure 4. Basic design of a welding sleeve with sleeve band.
Detail “X” Sleeve tube/plate
Heating conductor
Casing pipe
“X”
Figure 3. Basic design of a welding sleeve with a longitudinally slit sleeve tube or a sleeve plate.
477
4.1.3.3 Slip-on sleeve with built-in heating grids – The manufacturer's documentation must include detailed
For this variant, basically the same welding principle is used as working instructions for the welding method used and in
for the variants with heating conductors built into the sleeve tube particular indicate the welding parameters (guide value tables).
parts in the works, as described above. The essential difference – The welding area must be protected against environmental
is that the surface areas of casing pipe and sleeve must be conditions, such as moisture, wind and dust, strong solar
prepared and the heating conductor band only applied and fixed radiation and temperatures below + 5°C. The formation of frost
in the sleeve joint on site. Furthermore, the diameter difference and moisture film must be prevented.If welding work has to be
existing between the casing pipe and the sleeve must be formed carried out under unfavourable conditions, suitable protective
by hot forming before the welding process. Sleeve and butt joint measures must be taken in good time, such as for example
shape as in Fig. 3, but without longitudinal seam. covering, preheating of the pipe joints and sleeve parts,
erection of a protective tent, if necessary with heating.
4.1.4 Indirect heated tool welding
– An even temperature must be maintained in all parts to be
In this welding process the heat energy necessary for the welding welded and also around the tube circumference (∆T < 20 °C).
is supplied through the tube joint to the welding plane by
conduction from a heating band placed on the outside of the – The welding areas must be cleaned (in the case of traces of oil
sleeve joint and used as a ring clamping element. As a result the and grease with suitable solvents, for example industrially pure
diameter distance existing between the casing pipe and the spirit), and the surface oxidized by the oxygen of the air must
sleeve tube is overcome during the welding process by shaping be removed, for example by planing, scraping, milling. If wire
the sleeve on to the casing pipe when the material is in the brushes or emery cloth are used care must be taken to ensure
thermoplastic state. that even removal of the surface layer around the
circumference is achieved, no dirt particles are "rubbed in" and
4.2 Welds on fittings abraded residues are thoroughly removed (blowing, brushing
Basically the various designs of bends and T-pieces used are clean etc.). The tools used must be kept clean and free of
mainly manufactured or prepared in the works. Making fittings on grease and must be checked and if necessary cleaned before
site is to be avoided, because the conditions are less favourable. use.
– Sleeve parts with incorporated heating conductors must be
4.2.1 Bends
supplied to the welding site in their packing and before welding
4.2.1.1 Finished bends the surfaces to be welded must be cleaned, for example with
industrially pure spirit.
The PE casing pipe of the bend is manufactured from tube
segments in the manufacturer's works by heated plate welding. – The cleaning and machining of the welding planes or welding
surfaces must take place immediately before the welding. The
4.2.1.2 Assembly bends machined surfaces must be protected against further
In order to equip bends on site with the PE-casing outside the contamination and may not be picked up again. Otherwise
prefabricated angle range also, prefabricated assembly bends repeated machining is necessary.
are used. For this the PE segment bends are longitudinally split – Adequate working space must be made around the welding
on the site, so that the part can be placed around the steel piping. site, so that the particular welding process can be carried out
The longitudinal cut is welded in the site trench. For this purpose reliably.
extrusion welding should be used.
– The tube joints, fittings, sleeve parts, etc., must be supported,
4.2.2 T-pieces aligned and fixed securely in the intended position.
Branches for connecting lines from the main piping are called T- – The welding work must be carried out and monitored by
pieces. The diameter ratios D1 to D2 are usually different. qualified welders (see Section 8.3). It is recommended that
meaningful work reports be prepared concerning the welded
Both T-piece designs with "outward necking" and heated plate
joints (for report form suggestions see Annex) and the joints
butt welding and designs which are produced by extrusion
permanently marked.
welding are usual. Similarly, combined applications of these
welding processes are customary. In special cases the work also – The welded joints may only be subjected to load after cooling
takes place on site, as described under 4.2.1.2 to ambient temperature.
4.2.3 Valves The preparations and conditions specific to each welding process
and the execution of the welding processes are described below.
PE casing pipe constructions of the most varied kind are
necessary for valves to be used in the soil, such as ball valves, 5.1 Heated plate welding (HS)
slide valves, butterfly valves or compensators. These
components are made in the works. The welding methods used This welding method is used in the case of PE casing pipe
for installing them are heated plate butt welding and extrusion exclusively for manufacturing tube bends and other prefabricated
welding. fittings in the works. The preparation and execution of the
method and the requirements imposed on the welding machines
4.2.4 Special fittings used are governed by the stipulations in the Directives DVS 2207
For the PE casing pipe constructions of anchor points, reducers, Part 2 and DVS 2208 Part 1.
end caps and other parts, as far as possible components
prefabricated in the works by extrusion welding or heated plate 5.2 Hot gas extrusion welding (WE)
welding should be used. Of the process variants described in Directive DVS 2209,
Variants II and V are mostly used in modified, partially
mechanized versions.
5 Carrying out the welding process
With process variant II, using a hand instrument, longitudinal
In the PE casing pipe field of applications joints must be made seams on fitted sleeves are welded. Also in the case of repair
both by producing fittings in the works and also in the course of work, if sleeves tubes have to be installed later, i.e. they must be
the pipelaying work under site conditions – usually in trenches. In previously split longitudinally for fitting and welded in the
order to achieve high quality welded joints, in addition to the installation position by butt welding with a V-seam. Furthermore,
special preparations necessary for the individual working these manual process variants are used for auxiliary welds in
methods the following conditions must be created, independently regions near to fittings and the like which cannot or can only with
of the method: difficulty be reached by machines.
478
For welding sleeve circumferential welds as per Variant II circumferential welds in the region at the beginning of the weld)
partially mechanized equipment is used. To reduce the and after welding over with the welding unit tilted forwards the
necessary working space the welding machine is arranged in a material being welded must be held with a hand plunger.
narrow angular position with respect to the tube axis and
equipped with a suitably matched angular welding shoe – and is – Ejected accumulations must be removed down to "healthy"
carried in a manually operated trolley running on rollers in an weld (notch-free rounded shaving).
orbital frame around the tube circumference. To ensure reliable
guidance and better matching of the equipment speed of
advance to the other welding conditions, steplessly controllable
motor drives must be provided. The welding filler is fed in in wire
form, for example 4 mm diameter, from the supply unit Welding shoe
(encapsulated roll stands, if possible with preheating and drying
system). Melt channel
The heating of the welding zone is done by hot air. Adequate

plastication of the PE material beyond the side wall edges and in
the weld root region requires optimum adjustment of the hot air
nozzle to the joint to be welded (V or fillet welds, curvature of the
weld paths, joint width). The parameters, such as air volume/
temperature and welding speed, must be matched to the filler-
ejection power of the equipment.
The equipment Variant V in the version for casing pipe welding
differs only in the machine side plastication for the welding filler. a) Welding shoe for V-seam: joint opening approx. 60o
This works on the piston principle, in which the filler wire (smaller wall thickness to 80o (greater wall thickness)).
introduced – driven in the infeed region – acts as a consumable
piston to bring about the ejection of the plasticized filler in the x = 0, i. e. without gap, if welding is done without backing.
heated cylinder. All other conditions and functions are as x = 1 – 2 mm, if welding is done with backing.
described above.
In both process variants the plasticized welding filler is brought
Melt channel Welding shoe
into the joint groove by extrusion through the shaping "welding
shoe". In order to achieve adequate welding, i.e. adequate melt
pressure in the welding filler in the critical areas of the seam (root
and upper runoff edge), the welding shoe must have a front
"shoe tip" matched to the joint and adequate overlap length (Fig.
5). For the usual weld thickness in the range of applications up to
approximately 10 mm tube wall thickness an overlap/holding
length of 40mm after the runner is necessary.
The shoe shapes must be matched to the joint shapes depending
on the type of weld (overlapping butt-fillet weld) and the
curvatures to the necessary degree. The lateral sealing surfaces
together with the front "shoe tip" form the clamping for the
welding filler introduced by the extrusion and thus the condition
for the necessary pressure build-up in the weld material. These
Profile ring
sealing surfaces should be approximately 5 mm wide. All
transitions and edges must be carefully rounded, so that during
b) Welding shoe for overlapping butt fillet weld:
welding no plasticized compound is "shaved off" the joint side
The upper edge must also be bevelled with a negative angle
walls causing defects. For extrusion welding see DVS Directive
of up to 15o.
2207 Part 4.
The edges must always be rounded!
For the carrying out of the welding the following are necessary:
– A visible positioning and fixing of the parts to be welded
(casing pipe and tubular sleeve) in the intended butt weld Feed direction
shape; if necessary short tack welds in the weld root.
– Precise centering and adjustment of the orbital frame over the
course of the joint groove; therefore the machining of the joint
surfaces with tool systems must take place in the same frame Welding shoe
setting as the welding.
Melt channel
– Control and tracking systems for continuous adjustment of the
welding unit (direction and position of the welding shoe) and Tip of welding shoe
the hot air nozzle position (central in the median line of the joint
opening).
– Stepless speed adjustment of the welding carriage and control
by intensive observation of the welding point and/or the melt
delivery.
Butt weld side wall of a
– Monitoring of adequate joint heating directly in front of the V-seam in the tube joint
welding unit by penetration tests with blunt tools (thin
screwdriver). c) Welding shoe for V-seam in the middle of the seam
(lingitudinal cut)
– Correct execution of the end regions to be overlapped in the
case of circumferential welds and longitudinal welds. The Figure 5. Schematic drawings for executing weld sheos for extrusion
groove must be adequately bevelled (in the case of welding for V-seams and overlapping butt fillet welds.
479
5.3 Electrofusion *) (HM) - Starting up and monitoring the welding process.

The process variants used in practice are based on sleeves or – Removing the welding pressure only after the welding zone
sleeve plates with heating conductors with 3-sided conductor has cooled down sufficiently to approximately + 90 °C; indicati-
arrangement incorporated in the works (additionally for the ons of the time for this must be taken from the process instruc-
longitudinal seam), or use for the particular size inlaid heating tions of the manufacturer.
grids prepared in the works, which are mounted and fixed in the
lap joint on the casing pipe. 5.3.2 Slip-on sleeve with inlaid heating grid
(cf. also Section 4.1.3.3)
The requirements imposed on the welder in all process variants
essentially relate to careful execution under site conditions. As far as the equipment is concerned, basically for this process
These are in particular: variant the same principles as described under 5.3.1 apply. In the
execution basically the following process-specific jobs must also
– The preparation of the casing pipe joints, be carried out:
– The correct assembly and fixing of the welding sleeves – Determining and marking the welding regions in the joint.
including the clamping and holding systems and – Cleaning and machining both surfaces in the welding regions
– The making of the electrical connections to the welding (casing pipe and tubular sleeve).
equipment. – Adapting the heating grid strip to the tube circumference by ap-
With modern equipment the welding process itself is propriate stretching, positioning of the strip and fixing accor-
automatically controlled on the basis of previous automated ding to the manufacturer's instructions; take note of the alloca-
actual value sensing of the critical initial values (such as tion marking of the heating grid strips!
resistance as a measure of the sleeve nominal diameter, ambient – Assembling the tubular sleeves in the predetermined position.
and component temperature) and automatically controlled as it
– Adapting the slip-on sleeves to the diameter of the casing pipe
progresses on the basis of power consumption measurements.
by hot forming. The sleeve ends are heated evenly to the for-
After the equipment has been basically set the welder has only a
ming temperature over an adequate width in the region of the
supervisory function during the welding process.
heating strips and clamping elements (approx. + 100 °C).
As far as equipment is concerned, with these methods the (Take care when using naked flame; use "soft" liquefied gas
systems must be equipped with measurement value sensing and flame). The adapting of the diameter is done by fixing the clam-
digital recording systems, so that each sleeve joint can be ping members and applying the pressure without delay. The
documented with conclusive parameter and parameter change latter is used after starting the welding process for applying the
reports. joining force.
The other functions and operations are the same as in the works
5.3.1 Tubular sleeves/sleeve plates with built-in heating conductors
sequence previously described.
(cf. Sections 4.1.3.1 and 4.1.3.2)
In respect of the introduction of energy into the joint is concerned, 5.4 Indirect heated tool sleeve welding (–)
the prescribed welding parameters must be matched in particular (cf. Section 4.1.4)
to the wall thicknesses, the semi-finished product and ambient The heat input necessary for the welding of the lap joint on the
temperaures and the material melting characteristics. The sleeve connection takes place indirectly by heat conduction
process must then be controlled with the pressure generating unit through the wall of the sleeve to the welding plane. The metal
for the welding pressure in system coupling. The welder on the heating strip applied to the outside of the sleeve joint is also used
site cannot control the welding process, because with this weld through a hydraulic clamping system as an orbital clamping
shape in the lap joint and with the superstructure formed by the element for applying the joining force for the welding.
pressure generating devices he cannot look into the welding
plane and therefore any controlling influence over the welding According to the system the temperature profile across the
process is out of the question. sleeve wall on the outside of the sleeve has a higher temperature
than the welding point on the inside; the profile of the melt
For reproducible reliable production of high quality welded joints viscosity runs in the same way. Because the clamping ring
according to these process variants welding units with preset presses the sleeve joint over the entire plasticized sleeve wall the
parameters and process controls optimized for the particular heating strip is pressed into the tube wall, i. e. a "notch" is
application are necessary. For the quality of the welded joints the produced by wall thickness reduction in the welding region.
welding and supervisory personnel must correctly and carefully
create the external preconditions on the basis of the stipulations During the welding process at the same time the annular gap
of the process instructions. These are in particular the following existing between the casing pipe and the sleeve tube is closed by
steps: the clamping of the heating strip ring which causes thermoelastic/
plastic material deformation. The external step formation under
– Dimensionally correct marking of the sleeve position and/or the the heating strip position and the wall thickness reduction of the
welding regions. sleeve in the weld region are forced to increase with the size of
– Trimming of the tube joints and fitting supporting sections for the sleeve annular gap. For this reason the use of this process
the longitudinal welds. variant is limited to small casing pipe diameters (at the moment
up to maximum 400 mm).
– Machining of the tube surfaces in the weld regions, taking care
to avoid recontamination when the sleeve is subsequently as- To what extent this "notch formation" which weakens the weld
sembled (clean slip-on sleeves and casing pipes inside and start region is acceptable from a strength point of view must be
outside beforehand). demonstrated for the particular application.
The energy supply of the welding equipment must be
– Positioning and fixing of the tubular sleeves or sleeve plates -
programmed to the tube size and to the semi-finished product
in the predetermined position with rigid straps.
and ambient temperatures. As far as the application of pressure
– Setting up the pressure generating devices and clamps. is concerned, the annular clamping system must be
synchronized with the heating process. The corresponding
– Making the electrical connections, and the pressure connec-
information must be taken from the process instructions of the
tions and control connections, followed by examination to
system manufacturer.
avoid confusion, and function monitoring of the welding ma-
chine. The weld preparation and the other operations are subject to the
*) DIN 1910 Part 3: “Sleeve welding with incorporated electric heating element”
480
Joining weld Joining weld
Specimen Shape 1
(Strip specimen) Specimen Shape 2
(Shoulder specimen)
Figure 6. Specimen shapes for the tensile tests.
same basic stipulations and operational steps as described for short term strength the specimens are pulled at constant test
the process in Section 5.3. speed. For PE-HD the test speed is 50 mm/min.
5.5 Hot gas welding (W)

The force at the moment the specimen tears must be recorded. If
the specimen should neck, this yield stress is the reference
The method is described in Directive DVS 2207 Part 3. With the stress (FB). Tests during which the specimens tear in the
method of hot gas welding with filler, for example hot gas string- clamping region should be disregarded and must be repeated.
bead welding with welding wire – generally lower long-term weld
strengths are achieved than with the welding methods described 6.1.2 Evaluation
above. This is all the more so, if the welding work has to be
carried out under difficult conditions; on sites and mostly in For the welded specimens FV and the unwelded specimens
trenches in the case of circumferential welds. (reference specimens) FB the short term joining factor fz = FV/FB
is determined from the mean values of the tearing force, in the
For these reasons hot gas welding should not be used on lines case of different specimen dimensions, from the stresses
with PE-casing pipes. referred to the specimen cross-section.
If because of local circumstances this method cannot be avoided
in exceptional cases, particular care must be taken during 6.2 Technological bending test
execution. The requirements of DVS 2203 Part 1 must be For assessing the execution of the weld the technological
fulfilled. bending test in combination with other tests can be used. The
bending angle and the fracture photomicrograph give an
indication of the deformability of the joint and thus of the quality of
6 Testing the welded joints the execution.
For the testing of welded joints the test methods described in the The bending test is carried out on the basis of the Directive DVS
following can be used, taking into account the requirements 2203 Part 5 and/or DIN 50 121. The bead is machined away in
imposed and/or the conclusions required. the region where the bending punch is applied. The edges on the
tensile stressed side must be broken. Six welded specimens are
The results of the short term tests however can only be tested. The tensile stress is applied both to the root and to the
transferred to the long term behaviour of the welded fabrication to overlay of the welded joint (3 specimens each).
a limited extent. Specific demonstrations of the long term
behaviour are only possible by means of long term tests. Information about the shape and the dimensions of the
specimens and the test arrangements is contained in Table 2.
Generally the specimens must be manufactured by sawing,
milling or water jet cutting (not stamping).
Table 2. Dimensions for the test arrangement for the technological
6.1 Tensile test bending test (from DVS 2203 Part 5).
The tensile test is carried out in accordance with DIN 53 455 or Specimen Supporting Bending beam
DVS 2203 Parts and 1 and 2. The welded joints are tested in Thickness Width Length width thickness
accordance with the actual execution, i.e. with or without bead. h LS d
The joint lies in the middle of the specimen. At least 6 welded and
6 unwelded specimens (reference specimens) are tested. 3<h≤5 20 150 80 4
5 < h ≤ 10 20 200 90 8
If the strip specimens of Shape 1 to Fig.6 tear in the clamping 10 < h ≤ 15 30 200 100 12,5
region, specimens of Shape 2 must be used. The dimensions of 15 < h ≤ 20 40 250 120 16
the particular specimen shape should be taken from Table 1. 20 < h ≤ 30 50 300 160 25
Table 1. Dimensions of the specimens for the tensile test. On smaller tubes if necessary a smaller specimen diameter
In the case of lap welded joints the dimensions L and Lf must be should be chosen. However, 15 mm should be the minimum.
increased by the welded overlap length.
6.2.1 Execution
Thickness Specimen Shape 1 Specimen Shape 2
h Unless agreed otherwise, this test is carried out at room
b Lf L b Lf L be
temperature (+ 23 °C ± 2 °C). The specimens of PE-HD are bent
< 10 15 120 ≥ 170 10 115 ≥ 170 20 in the test rig at a test speed of 50m m/min until fracture/incipient
> 10 30 120 ≥ 300 30 115 ≥ 300 40 tearing. The arrangement of the bending beam should be taken
> 20 1,5 h 200 ≥ 400 1,5 h 200 ≥ 400 80 from Fig. 7 for the various design versions of the joints.
The bending angle reached on incipient tearing or fracture is
6.1.1 Execution
measured. Complete bending of the specimen, without tearing or
Unless agreed otherwise, the test is carried out to DVS 2203 Part fracture, corresponds to a bending angle of 160° and is to be
2 at room temperature (+ 23 °C ± 2 °C). For determining the evaluated as > 160°.
481
Fig. 8 until fracture or until the free ends of the specimen come
into contact with the bar.
a)
b)
Figure 8. Diagrammatic representation of the manual test.

“X”
6.3 Manual peel test
The manual peel test is a simple, indicative workshop test carried
out by hand, which can also be carried out on site. This test is
intended in particular for lap welded joints, for example
c) electrofusion-welds, which cannot be directly tested using the
technological bending test as per Section 6.2.
6.3.1 Execution
The execution can only take place after adequate cooling of the
joint to room temperature (approx. + 23 °C). 5 strip specimens of
15 to 20 mm width – taken at intervals over the weld length – are
d) tested.
Here the end of the sleeve is clamped in the vice and the non-
welded end of the plastic casing pipe projecting into the sleeve is
Detail “X” bent away from the sleeve until it can be gripped by a pair of
pliers. Then an attempt is made to peel off the joint, see Fig.9.
Groove 1 mm deep, The free leg is bent until it kinks.
4 mm wide
Sleeve
Figure 7. Diagrammatic representation of the mechanical test and the

planes of action in the technological bending test (examples):
a) V-weld, root as tension side a) b)
b) V-weld, rear of weld under tension; during the test at a
Plastic jacket pipe
bending angle of approximately 90o,
Figure 9. Illustration of the specimens for the manual peel test;
c) and d) die arrangement for the lap welded joint with fillet
a) strip specimen before the test
weld (WE). 3 specimens each with the weld root (c) and
b) joint ends bent upwards for the peel test.
the joint side wall edges (d) under tension.
6.2.2 Evaluation 6.3.2 Evaluation
The technological bending test does not supply mathematical The joining surfaces should not separate.
values for the design calculations. On the basis of the deformati-
on behaviour determined and the fracture photomicrograph the 6.4 Tensile creep test
results however allow a general qualitative assessment of the The long-term behaviour under the required forms of stress is the
joint to be made. most important proof of quality in relation to the suitability for use
For a general good/bad assessment the minimum requirements of load carrying components made of thermoplastic polymers. In
indicated in Fig. 14, Section 7, of Directive DVS 2203 Part 1 can the case of pressure loaded structures, such as pipes and
be taken as the basis. fittings, carrying out the long-term internal pressure test has been
the proven state of the art for a long time. For pipes of larger
For max. 2 specimens, which do not fulfill the requirements, 2 dimensions, however, these tests are increasingly expensive in
replacement specimens each from the same part can be tested. cost terms, so that this test is only seldom used in testing
No value should lie below the required minimum value. practice.
6.2.3 Manual test To assess the execution of the weld the long-term tensile test in
combination with other tests has proved itself. The tests are
This version of the technological bending test is a simple
carried out at + 80 °C. The applied stresses are 4 and 3 N/mm 2.
indicative workshop test. Because of the force required this
If no brittle fracture should occur during the execution of the test,
method is limited to small thickness specimens.
lower stresses must be chosen. In order to shorten the time-to-
The specimen is bent with the machined side of the weld over a failure (acceleration effect), a 2% aqueous wetting solution (for
rounded, 6 mm thick bar with powerful application of force as per example Arkopal N 100 3) ) should be used as the test medium.
3) (R) Messrs Hoechst AG. Extensive testing experience is available for this test medium, which facilitates comparison of the results and the determination
of requirements. If other products on the same basis are used, compare the number of ethylene oxide molecules in the polyglycol ether chain.
482
The required joining factors (fs) in the tensile creep test (Table 4, 6.4.2 Evaluation
Section 7) and the fracture photomicrograph give an indication of For determining the long-term joining factor4) (fs) the creep curve
the quality of the weld execution. of the welded and unwelded specimens must be determined, the
gradient of the straight lines being particularly important. The
6.4.1 Execution tensile creep joining factor – referred to a particular stress on the
The tensile creep test is carried out in accordance with DVS 2203 reference curve B – is calculated from the curve obtained for the
Part 4 or DIN 53 444 (Fig.10). The welded joints are tested in welded specimen: see examples in Fig.11.
accordance with the actual execution. Alternatively, the ong-term joining factor can be referred to one
test stress on the reference specimen. The joining factor
determined must then be identified, with indication of this test
dial gauge stress (for example σ4(B)), see Fig.12.
Simplified method for minimum proof of a required long-term
joining factor
To reduce the complexity of the test the proof can be limited to
one stress level in each case using the following method, see
Fig.13.
For example:
– Test stress for the basic material (reference specimens)
σB = 4 N/mm2
specimen – Test stress for the weld specimens with for example fs = 0.8
σS = fs ∙ σB = 0.8 ∙ 4 N/mm2 = 3.2 N/mm2.
test medium
If the weld specimens reach at least the same mean time-to-
tank test weight failure as the base material, at least the required long-term
joining factor is demonstrated (yes/no statement).
With this test no conclusion about the stress-related strength
behaviour is possible.

Figure 10. Test set-up for the tensile creep test (on the basis of DVS Normally a positive pressure test with compressed air at approx
2203 Part 4). 0.2 to 0.3 bar is carried out. After a test duration of at least 10
minutes after coating the welds with a harmless foaming aqueous
For the shapes and dimensions of the specimens the specimen solution (for example a modern biologically degradable
shapes (Fig.6) indicated in Section 6.1 "Tensile Test" with Table household detergent in the lowest concentration) no leaks must
1 are applicable. For this test the use of the same specimens is be visible (bubble formation).
recommended. The joint position lies in the middle of the
specimen, the longitudinal axis of which must lie in the direction
of the tensile force. 7 Requirements imposed on welded joints
The specimen must be made without notches and if necessary
The welded joints on PE-HD casing pipes and fittings must – just
retouched after visual examination (for example grinding in the
like the tubes – reliably withstand the stresses occurring in
longitudinal direction). In the tensile creep test the duration until
operation over the design duration of stress.
fracture of the specimen and, if necessary, the increase in
elongation with time are determined. As a rule welded joints on PE-tubes do not achieve the same
material strength as the unwelded casing pipe. The piping
The specimens are stressed at constant temperature (± 1°C) with planning and design must indicate the weld qualities achievable
uniformly steady tensile force (± 1%) and constant ambient with the welding methods used. The required weld qualities must
conditions. be guaranteed by suitable measures and test methods.
In order to ensure even concentration of the wetting agent, it Therefore corresponding requirements must be imposed on the
must be circulated continuously in the test bath. The bath welded joints.
concentration of the test medium must be monitored by control In the Directive DVS 2203 Part 1 requirements imposed on
measurements – in its spatial distribution also – (for example by plastic welded joints are described for certain moulding
residue determination by evaporation). Evaporated water must compounds and welding methods, as are applied mainly in tank,
be topped up by adding demineralized water (deionate) vessel and piping construction. In these fields of application the
continuously (level control). plane butt joint without transition is used and welded.
After reaching the bath temperature the specimens are In the case of lines with PE-casing pipes the multiple lap joint is
vigourously stressed with the test force but without impact in the also often used in special process variants, however from a test
test bath, the force being maintained constant during the test. point of view and also in respect of the requirements imposed it
The duration of loading is calculated from the moment the test cannot be immediately treated and assessed. Otherwise the
force is reached and recorded by built-in dial gauges. requirements of the Directive quoted apply.
In order to determine the gradient of the creep curve (straight
7.1 Visual test
lines in double logarithmic form), the tests are carried out under
at least 2 stresses (for example 4 and 3 N/mm2). At least 6 In the visual test the defect-free execution of the welded joint
welded and 6 unwelded specimens are tested for each stress. must be demonstrated by visual examination. In combination with
The mean value is calculated as the geometric mean of the destructive tests the weld cross-section and fracture surfaces
individual values. must also be assessed. Typical test features are:
4) On the basis of the shape and nature of the lap welded joints involved here with superimposed types of stress in the joints in the tensile test, the long-
term joining factor is defined here, as a departure from DVS 2203 Part 4.
483
– a process-specific, correct weld/weld edge formation (root and – homogeneity of the material being welded; weld surface
edge welding) – weld flash, weld shoe guidance (WE)
– presence of notches, cavities, lack of fusion, etc – bulge/double bulge formation (HS, WZ)
– the effect of heat, fusion zones, overheating, etc Defect descriptions and evaluation references are also given in
– shape and uniformity of the weld formation
Stress (N/mm2) DIN 32 502 and DVS 2202 Part 1.
S = weld specimen
B = reference specimen
Time-to-failure (h)
Figure 11. Diagramatic representation for defining the joining factor in the tensile creep test.
Stress (N/mm2)
S = weld specimen; σ4 and σ3

B = reference specimen; σ4
Time-to-failure (h)
Figure 12. Diagram for defining the joining factor in the tensile creep test in the case of only one test stress on the refrence specimen.
7.2 Mechanical-technological tests in the short-term test proposed as an alternative for these joint shapes the surfaces to
be joined must not separate.
In principle, in the short-term tests described (tensile and
technological bending tests) the requirements of DVS 2203 Part With this form of joint the technological bending test cannot be
1 must be satisfied; see Table 3 and Fig.14. carried out easily. Likewise, essentially only the weld edge
regions are covered by the test.
In the case of lap welded joints with flat welding in the joint the
result of the tensile stress is primarily determined by the weld The results of these tests have less informative value for lap
edge execution; the welding itself is covered to a lesser extent in welded joints, in particular for flat welds in the lap joint, than for
this tensile/shear test. During the manual peel test to Section 6.3 plane butt joints.
484
Stress (N/mm2)
S = weld specimen
B = reference specimen
Time-to-failure (h)
Figure 13. Simplified method for minimum proof of a required long-term joining factor.
Table 4. Requirements for the joining factor in the tensile creep test
for the reference stress σ = 4 N/mm2 (on the basis of DVS
2203 Part 1).
Welding method Tensile creep

joining factor fs
Heated plate welding 0.8
V-weld extrusion welding 0.6
Extrusion welding on the lap joint with fillet
weld 0.5*)
Bending angle
Electrofusion in the lap joint 0.5*)
*) At present values from approximately fs = 0.4 are accepted. This low

value is permitted in order to take into account the falsification of the
tensile test due to the superimposed bending stresses, increased
inherent stresses and notch effects, etc.
7.3 Tensile creep test
In the tests as per Section 6.4, for correctly executed joints on

casing pipes at least the long-term joining factors "fs" required in
Table 4 must be demonstrated.
For the tubular semi-finished products (casing pipe and tubular
sleeves), under the same test conditions as in Section 6.4 for the
test stress 4.0 N/mm2, a minimum time-to-failure of 1500 hours is
required for the geometric mean value from at least 6 individual
specimen results, see Draft Standard DIN EN 253.
Specimen thickness
This single-point requirement in the creep diagram (+ 80 °C)
HS = Heated plate welding applies subject to the condition that the tube moulding material
LE = Light beam welding by extrusion of filler material basically satisfies at least the creep requirements in the internal
WE = Hot gas welding by extrusion of filler material pressure test according to the creep diagram used as the basis
WF = Hot gas welding with torch separate from filler rod
WZ = Hot gas string-bead welding for DIN 8075.
Figure 14. Requirements for the technological bending test (from DVS In accordance with the current quality standard, here the inclined
2203 Part 1). load range of the curves is shifted in such a way along the time
axis that the test point (4.0 N/mm2 /+ 80 °C) lies at 1000 hours.
Table 3. Joining factor requirements in the shoert-term tensile test In comparative tests it has been shown that in the case of the lap
(on the basis of DVS 2203 Part 1).
welded joints the deformations in the test specimens (strips or
Welding method Short-term tensile shoulder specimens) have no influence on the test result (pairs of
joining factor fz forces).
Heated plate welding 0.9
V-weld extrusion welding 0.8
Extrusion welding on the lap joint with fillet
weld 0.8 During the imperviousness test (as per 6.5) no leaks, atypical
Electrofusion in the lap joint 0.8 deformations or other impermissible changes may occur.
485
8 Quality Assurance The welders used must demonstrate adequate training5) in the
material science of PE- HD, having passed the welder
Because the quality of plastic welded joints for specific examination6). These must be carried out and certified as per
applications can in the last analysis only be demonstrated by Directive DVS 2212 or in rational application for the particular
destructive long term tests, the quality assurance must be based method. For the methods WZ and HS DVS 2212 Part 1 and Part
on indices, identity and reproducibility proofs. 2 apply to extrusion welding.
Therefore, for the quality assurance of welding work in the case The execution of the welding work in the manufacturer's works
of joints in PE-HD casing pipe and fittings, in addition to the use (prefabrication of fittings) and – in particular – on the site under
of moulding compounds and tube products with fixed indications difficult conditions in pipe trenches, must be supervised by a
of product qualities, qualification requirements must be imposed qualified responsible welding inspector of the manufacturer's
on the skilled welding personnel and minimum requirements on works.
the equipment and workplace arrangements of the contracting The welding inspector must supervise in particular
companies.
– The use of suitable welding equipment and accessories in a
8.1 Quality assurance for casing pipes and fittings in the functionally reliable condition,
manufacturer's works – The correct arrangement and preparation of the joints
The measures for quality assurance in the manufacturer's works – The qualified execution of the welding processes in accor-
are normally divided into two. According to DIN 18 200, a dance with the particular prescribed methods (Manufacturer's
distinction is made between internal and outside supervision: instructions, DVS Directives, etc.) if necessary using suitable
– Internal supervision protective measures (protection against weather, etc),
Tests by professionals of the manufacturer's works based on – Adequate recording of the welds (for suggested report forms
established test and work instructions. see Annex) with welder identification and documentation of the
– Outside supervision joints in accordance with what is stated in the manufacturer's
These are used to permit the regular checking of the equip- specifications and DVS Directives relating to the method.
ment and operations of the internal works inspectors, their do- Finally, he carries out
cumentation and test procedures by outside supervisors. For
the application described here, as a rule the outside supervi- – The visual examination of the finished welded joints for defect-
sion is carried out and administered by suitable independent free execution and
plastics test centres and experts as per DIN 18 200. As a rule – The imperviousness test
outside supervision dates are observed and certified twice per
and prepares a test report on these.
year. The results of the supervision inspections must be docu-
mented and the test reports of the outside inspector included in The welding inspector is responsible to and reports to the
the manufacturer's documentation. Employer/the Site Management.
For the execution of the welding work done by the Employer,
8.2 Proof of quality for casing pipes and fittings
outside supervision is recommended on a random basis.
For the casing pipes and fittings used tests must be carried out in
accordance with the basic standards, moulding compound and
moulding guidelines already in existence for the products or 9 Standards, Directives
according to a product-specific test and supervision program.
The test results obtained must be specified and documented, 9.1 Standards
contrasted with the established requirements. DIN EN 253 Preinsulated bonded pipe systems for underground
The content of the test must be based on: (Draft) hot water networks – Pipe assembly of steel
service pipes, polyurethane thermal insulation and
– DIN EN 253, 448, 488 and 489 for PE-HD casing pipe materi- outer casing of high density polyethylene.
als DIN EN 448 Preinsulated bonded pipe systems for underground
– DIN 8074/75 applied rationally, in particular in respect of the (Draft) hot water networks – Fitting assemblies of steel
long-term tests. In the case of the larger tube diameters with service pipes, polyurethane thermal insulation and
smaller wall thicknesses tensile creep tests are preferable to outer casing of high density polyethylene.
the otherwise customary long-term internal pressure tests in DIN EN 488 Preinsulated bonded pipe systems for underground
this respect. For the minimum time-to-time failure rates the (Draft) hot water networks – Steel valve assembly of steel
requirements under Section 7.3 apply. service pipes, polyurethane thermal insulation and
The proofs of quality must be produced by the manufacturing outer casing of high density polyethylene.
works at least in the form of "Works Certificates" as per 2.2, DIN DIN EN 489 Preinsulated bonded pipe systems for underground
50049. For the content of the tests and the application of internal (Draft) hot water networks – Joint assembly steel service
or outside supervision, see Annex 5. pipes, polyurethane thermal insulation and outer
casing of high density polyethylene.
8.3 Quality assurance of the welding work DIN 1910 Welding, Welding of plastics, methods
Process tests must be demonstrated by the contracting Part 3
companies and skilled workers for the welding method applied DIN 8074 Tubes of high density polyethylene (PE-HD),
(proof by the manufacturing company that it is in a position, with dimensions
its skilled personnel and the physical equipment of the company,
to execute the welding work correctly and reproducibly in DIN 8075 Tubes of high density polyethylene (PE-HD),
accordance with the high requirements imposed. general quality requirements, testing
5) Training centres for PE welders:

– Süddeutsches Kunststoff-Zentrum, Frankfurter Straße 15-17, D-97082 Würzburg
– Training centres under supervision of the Institut für Kunststoffverarbeitung at Aachen
University of Technology, Pontstraße 49, D-52056 Aachen
6) Examination centres:
- the Training Centres mentioned under 5) and
- the TÜV Plastic Test Centres; for information: Association of the Technical Supervision Societies, Kurfürstenstrasse 56, D-45038 Essen.
486
DIN 16 776 Polyethylene (PE) moulding compounds DVS 2205 Design of containers ans appaartus made from
Part 1 – Classification and description thermoplastics
Part 2 – Manufacturing the test specimens and Part 1 Characteristic values
determining the properties Part 3 Welded joints
DIN 16 963 Pipe connections and piping components for high DVS 2206 Testing of components and constructions made of
Part 5 pressure pipelines of high density polyethylene thermoplastic materials
(PE-HD); general quality requirements, testing DVS 2207 Welding of thermoplastics, PE-HD (high density
DIN 18 200 Supervision (quality monitoring) of building Part 1 polyethylene) Pipes and pipeline components for
materials, components and structures, general gas and water mains
principles Part 2 Heated plate welding – pipes and pipelines for
DIN 32 502 Effects on welded joints in plastics, classification, sewerage pipes and lines
designation, explanations Part 3 with Annex Hot gas welding of thermoplastics –
DIN 50 049 Certificates for material tests sheets and pipes, welding parameters)
DIN 53 444 Testing of plastics, tensile creep test Part 4 Welding of thermoplastic polymers, panels and
DIN 53 455 Testing of plastics, tensile test pipes – extrusion welding
DIN 53 479 Testing of plastics and elastomers; determining the DVS 2208 Machines and equipment for welding of
density thermoplastics
DIN 53 735 Testing of plastics; determining the melt flow index Part 1 – heated tool welding
of thermal plastics Part 2 – hot-gas welding (not extrusion welding)
ISO Plastics; determination of the melt flow index (MFR) DVS 2209 Welding of thermoplastics – extrusion welding,
1133:1991 and the volume flow index (MVR) of thermal Part 1 methods – features
plastics DVS 2211 Filler materials of thermoplatics, scope,
ISO Plastic pipes for conveying liquids; determination of designation, requirements, tests
1167:1973 the resistance to internal pressure DVS 2212 Testing of welders for welding plastics,
ISO Plastics; methods for determining the density and Part 1 Test group I (hot gas string bead welding and
1183:1987 relative density of non-expanded plastics heated plate welding)
ISO/DIS Tubes of polyethylene (PE); Part 1: Determination Part 2 Test group II; Hot gas extrusion welding (WE)
6259-1:1985 of the properties in the tensile test
GKR- Casing pipes for the manufacture of sleeves and
ISO/TR Determination of the thermal stability of Guideline fittings of PE-HD (high density polyethylene) for
10 837:1991 polyethylene (PE) for gas piping and fittings R 9.3.17 preinsulated bonded pipe systems for underground
hot water networks with the quality symbol of the
9.2 Directives Plastic Pipes Quality Association e.V., Bonn
DVS 2201 Testing of semifinished products of thermoplastics "Building of district heating networks" – Technical Guidelines of
Part 1 – fundamentals, references the AGFW
DVS 2202 Imperfections in thermoplastic welded joints – AGFW membbers information "Plastic jacket pipes for district
Part 1 features, description, evaluation heating lines".
DVS 2203 Testing of welded joints og thermoplastics
Part 1 Test methods – requirements
Part 2 Tensile test
Part 4 Tensile creep test
Part 5 Technological bending test
487
488
Assembly Report
Order No.: Welder:
BV/Section: Welding machine No.:
Section No.: of: Power source: Mains Generator
Sleeve No. Type Section Date Ambient Weather Weather Displays Sleeve Remarks
temperature protection
(°C)
A B C
Tent
Sunny
Wind
Time
Temperature
Sleeve initial temperature (oC)
Snow
Open
Rewelds
Screen
Replacement welds
Watertight
Programme
Cloudy
Non-watertight
Rain
Annex 1: Report form (proposal) for the electrofusion method
This Annex is only for information and is not a binding part of this Directive.
Report form for heated plate welding of tubular Laid above ground Material
Laid underground Sheet of
components
Employer Contracting company Welding machine Weather conditions Protective measures
Make: 1 = sunny 1 = none

2 = dry 2 = screen
Order title Name of the welder Identy No. Type: 3 = rain or snowfall 3 = tent
4 = wind 4 = hetating
Maschine No.:
Order No. Name and company of the welding Year of manufacture: In the case of multiple designations follow the sequence of the figures as above
inspector (e. g. 34 = rain and wind)
Weld Date Input data Adjustment/measurement values1): theoretical/acutal information Ambient conditions Remarks
No.
Pipe size Movement Heating Equalizing Heating up Joining Heating Adaption Time to Cooling Ambient Weathe- Code No.
Ø dA × t pressure, element temperature up time2) time2) complete time under temperature ring of the
measured, temperature’ joining joining code No. protective
P pressure pressure2) measures
bar oC bar bar bar s s s s oC
Annex 2: Report form (proposal) for heated plate welding
Example: (10,5+10,7) (10,5+0,7) (10,5+10,7)

1 25.5.92 160Ø14,6 10,5 220 ± 5 21,2/ 11,2/ 21,2/ 130/ <10/8 ≈ 10/12 >20/20 ≈ 20 24 2 None
Signature of welder: Date and signature of the welding inspector:

1 )The settings are the sum of the movement pressure and the indications of the manufacturer of the welding machine concerning equalization and joining pressure.
489
Annex 3: Report form (proposal) for extrusion welding
Welding Report
for the extrusion welding of panels and tubes
General Information
Order No.: Drawing No.:
Contracting Company:
Welder (Name, Reference):
Process/Equipment
Process variants: Welding shoe No.:
Welding equipment (make):
Weld shape (e. g. DVS 2205):
Material
Material to be welded:
Semi-finished product shape, thickness (mm):
Welding filler:
Welding Conditions
Hot air temperature (°C): Air volume (l/min):
Cylinder heating (°C): Compound temperature (°C):
Hose heating: Welding speed (mm/min):
Remarks:
Date/signature Date/signature
Welder Welding supervisor
490
Annex 4: Report form (proposal) for imperviousness test
Imperviousness Test
Acceptance Order No.
Project:
Building section/line section No.:
Sleeve No. Positive pressure Welder Tested and accepted Date

VL RL 0.2 bar Name Signature
Remarks:
491
Annex 5: Content of test and organization of internal and outside supervision

This Annex to the Directive contains the content of the test for the – DIN 8075 (05/87)
Quality Assurance of PE casing pipe and tubular sleeves and
– DIN 16 963 Part 5 (10/89)
corresponding sleeve plates, Table A5-1. The content of the test
for the Quality Assurance of welded joints in fittings and sleeve – GKR Guideline R 9.3.17 (05/92)
joints (welding in the works and on site) is also specified; Table
A5-2. It isbased on the requirements of the official product In Tables A5-1 and A5-2 recommendations for a Quality
standards and guidelines: Assurance Certificate are given. In the list of obligations of the
– DIN EN 253 (4th draft revision; issued on 1.11.1991 in the TC contractual partners special stipulations can be imposed
107) concerning the tests to be carried out, the scope and frequency.
– DIN EN 448 (pr EN; issued on 1.11.1991 in the TC 107)
492
Table A5-1. Monitoring tests on semi-finished products (casing pipes and tubular sleeves and sleeve plates); FM = moulding compound, HZ = semi-finished product.
Serial Application Tests Execution as per Requirements as per/ Test/frequency

Item standard, Section values
No. in:
DIN EN DVS Type of tests On On suitability internal outside
253 2207-5 FM HZ test supervision supervision
1 – Technological tests
1.1 5.2.1 – Density of the tube material × DIN 53 479 DIN EN 253, Section 4.2.1.1
E.g. Method A GKR Guideline R 9.3.17
ISO 1183:1987 "A" or "D" > 0.944 g/cm3
1.2 5.2.1 – Melt index, × × DIN 653 735 DVS 2207-5, Section 3
"MFI 190/5" (g/10 minutes) ISO 1133:1981 DIN EN 253, Section 4.2.1.2
GKR Guideline R 9.3.17
Execution of the
For moulding compounds: Execution of the In general twice
tests described
tests described per year1)
a) 0.4. ... 1.3 on each delivery
a) (classes 005 and 010
a) DIN 16 776 T1)
For welded joints:
a) ∆MFI ≤ 0.5
b) MFI(HZ) ≤ MFI (FM) + 0.22)
1.3 4.2.1.3 – Oxidation stability (OIT) × (×) ISO/TR 10 837 DIN EN 253, Section 4.2.1.3 Manufacturer's
GKR Guideline R 9.3.17 certificate per
200°C/> 20 minutes batch
1.4 – if necessary dry loss × GKR Guideline R 9.3.17 GKR Guideline R 9.3.17
> 0.1 % Execution of the
Execution of the In general twice
tests described
1.5 – if necessary homogeneity × × GKR Guideline R 9.3.17 GKR Guideline R 9.3.17 tests described per year1)
on each delivery
Non-homogeneities < 0.02 mm2
493
494
Table A5-1. Continuation.
Serial Application Tests Execution as per Requirements as per/ Test/frequency

Item standard, Section values
No. in:
DIN EN DVS Type of tests On On suitability internal outside
253 2207-5 FM HZ test supervision supervision
2 Condition and dimensions
2.1 5.2.3 – Surface condition × DIN 8075 DIN 8075
DIN EN 253 DIN EN 253, Section 4.2.2.4
GKR-Guideline R 9.3.17 GKR-Guideline R 9.3.17
Unacceptable features Continuous
inspection during
2.2 5.2.2 – Dimensional stability × DIN EN 253 DIN EN 253, Section 4.2.2.3 production
GKR-Guideline R 9.3.17 Execution of the In general twice
tests described per year1)
see permissible limits of
deviation
2.3 5.2.4 – Hot storage × DIN EN 253 DIN EN 253, Section 4.2.2.6 Once per week
GKR-Guideline R 9.3.17 GKR-Guideline R 9.3.17
Deformation ≤ 3%
3 Mechanical tests
3.1 4.2.2.5 – Elongation at tear in the × DVS 2203-2 DIN EN 253, Section 4.2.2.5 Once per week Generally twice
tensile test ISO/DIS 6259, Section 1.2 GKR Guideline R 9.3.17 per year1)
DIN 53 455
≤ 350%
Test speed = 100 mm/min
3.2 5.2.5 – Long-term internal ×3) (×) DIN 8075 DIN EN 253, Section 4.2.1.4 Once per week, Generally twice
pressure test ISO 1167 if stipulated in per year, if
Execution of the
detail stipulated in
tests described
detail1)
3.3 5.2.6 6.4 Tensile creep test in the × × DVS 2203-4 DIN EN 253, Section 4.2.2.7 Four times per Generally twice
wetting agent bath (ISO/DIS 6259 Section GKR-Guideline R 9.3.17 year per year1)
1.2)
> 1500 h in the water bath with
2% wetting agent at 80°C;
= 4.0 N/mm2
Explanations:
1) Inspection of the execution and the indications of the internal supervision; if necessary taking of samples for laboratory tests
2) HZ = result on the semi-finished product. FM = result on the moulding compound (pellets)
3) As type test on the extruded specimen tube and as alternative to the tensile creep test in product supervision.
x Execution of the test described.
(X) Execution, if stipulated in detail

a Per machine, dimension, type of compound, or per per production run
b At least per type of compound, machine and group diameter once per year.
Table A5-2. Monitoring tests on welded joints (works and site welds)
Consecutive Application standard, Type of tests Execution as per Requirements Test/frequency

item No. Section in: as per
Process Workshop welds Site welds
DIN EN DVS 2207-5 tests welding outside welding outside
253 (448) supervisor supervision supervisor supervision
1 – 7.1 Visual examination Visual inspection DVS 2207-5, 100% 100%
Section 7.1
2 – 6.1 Short-term tensile test DVS 2203-2 DVS 2207-5,
DN 53 455 Section 7.2 As part of the As part of the
3 – 6.2 Technological bending DIN 2203-5 DVS 2207-5, welder and welder and
test DIN 2207-5, Section 6.2.1 Section 7.2 Execution work work
In general In general
of the examinationsb) examinationsb)
4 – 6.3 anual peel test DIN 2207-5, Section 6.3.1 DVS 2207-5, twice per twice per
tests
(alternative to Item 3) Section 6.3.2 year1) year1)
described
5 – 6.4 Tensile creep test in DVS 2203-4 DVS 2207-5, Four times per
wetting agent bath DVS 2207-5, Section 6.4 Section 7.3 yeara)
DIN 53 444
6 – 6.5 Imperviousness test DVS 2207-5, Section 6.5 DVS 2207-5, 10 ... 20% 100%
Section 7.4
Explanations:
1) Inspection of the execution and the indications of the internal supervision; if necessary taking of samples for laboratory tests
a) At least for each compound type, machine and diameter group once per year
b) Per method, type of material and welding machine
Welder examinations based on DVS 2212
Project-related work tests at the beginning of work; at least half yearly
495
Annex 6: Determination of the time factor and a fictitious joining factor for a welded joint
If creep tests are only carried out under one test stress (for 2. The slope of the curve of the single-axis tensile creep test cor-
example where σ = 4.0 N/mm2), from the results for the base responds in its slope to the curves of the multi-axis long-term
material and the welding specimens only the ratio of the internal pressure tests to DIN 8075; shift of position only on
evaluated times-to-failure (geometrical mean value "XG") can be the time axis.
formed and as the time factor
3. The slope of the curves of welded specimens corresponds to
x G(S) the slope of the base material specimens (parallel trend). Ex-
=
f s(t) ------------- perience has shown that this is only applicable to high quality
x G(B)
butt joints!
be specified.
In the example in Fig.A6-1 the fictitious joining factor is
This time factor is not identical with the joint factor (fs) calculated
from the significance ratio of the stresses. =
f′ s ( σ ) =
2,0/4,0 0,5
If nevertheless – in the absence of basic curves for the tube
material from tensile creep tests – a comparison factor is formed The time factor from the results of the tensile creep test works out
by including known long-term internal pressure curves (for at
example the minimum value curves from DIN 8075) for PE-HD
tubes, this is based on the following assumed conditions: =
fs ( t ) =
67/1500 0,045
1. The long-term internal pressure curves of the casing pipes
correspond in their slope to the minimum curves of DIN 8075. This fictitious joining factor cannot be used as a calculation value.
Comparative stress in N/mm2 is the long-term internal pressure test
Applied stress
in the tests R
As
ef
e
su
re
m
nc
pt
e
io
sp
n:
ec
w
im
el
di
en
ng
Z-
sp
S-
ec
Z-
im
V
(8
en
0o
cu
)
rv
e
Time-to-failure in years
Time-to-failure in hours
Figure A6-1. Formation of a fictitious joining factor f′s(σ ) from test results of the tensile creep test (Z-S-Z-V) for only one test stress; for example
σ = 4.0 N/mm2.
496
Annex 7: Stressing of welding sleeves in plastic jacket pipes
Like the PE-casing pipes, the welding sleeves are exposed to The calculations have been carried out taking into account the
mechanical loads. The stresses are caused by relaxation with temperature, using values of E (σ = 0.75 N/mm2
and 1 N/mm²).
– friction in the subsoil
The following conclusions should be drawn:
– possible drag of the sleeve and
– With the usual plastic jacket pipes applications axial stresses
– restricted elongation due to temperature. of max 2 N/mm2 are to be expected in the sleeve wall.
Because the level of the mechanical stresses has a critical – In extreme cases stresses of up to 4.5 N/mm2 are also possi-
influence on the working life of the joint, the stresses occurring ble.
are estimated for 3 different cases of loading. The significant
loads are in each case the stresses in the axial direction. – The effect of the drag on the axial stress is small.
Estimates: – sheath friction σR = µ ∙ p -– In the case of the traffic loads, the "parking SLW 60" load re-
presents the most unfavourable stress. Because of the disper-
– drag σSt sion of the load coming from the wheel loads with depth, this
– restricted elongation due load represents the critical load for the sleeve joint when there
– to temperature σT = αT ∆T E is little cover above it. The probability that an SLW 60 will park
over a sleeve is however very remote, because the axle load of
Calculation assumptions: DN 250, Da = 400mm, t = 6 mm an SLW 60 is twice the maximum possible according to the
Case 1: Fitted welding sleeve without drag, Road Traffic Authorization Order.
hü = 60 cm in the expansion buffer, µ = 0.25 – Expansion pads reduce both the sheath friction and the drag
Case 2: Welding sleeve with high drag, loads and increase the stress due to restricted thermal expan-
hü = 60 cm in the sand bed, µ = 0.5 sion. In all, however, the stress-relieving effect predominates.
This occurs in particular with high mechanical stress (for ex-
Case 3: High drag, parking heavy truck with 60 t ample depth of cover or traffic loads).
(called: SLW 60),
This information is at present under discussion in the specialist
hü = 1.5 m in the sand bed, µ = 0.5.
circles. The calculations based on other hypotheses and
The results of the guide calculations should be taken from Table assumptions lead to different results, but are of the same order of
A7-1. magnitude.
Table A7-1. Axial stresses in the sleeve wall.
σR σST σT σres
[N/mm2] [N/mm2] [N/mm2] [N/mm2]
Case 1 µ = 0.25 0.3 0 approx 1 1.3
σ = 1 N/mm2
T = + 25 oC
E = 120 N/mm2
Case 2 µ = 0.5 0.6 0.2 approx 0.8 1.6
σ = 0.75 N/mm2
T = + 30 oC
E = 180 N/mm2
Case 3 µ = 0.5 2.7 0.7 approx 0.8 4.2
σ = 0.75 N/mm2
T = + 30 oC
E = 180 N/mm2
497

C:\DVS Merkblätter\2207\2207-05\BEIBL1\e2207-5b1.fm
DVS – DEUTSCHER VERBAND Welding of Thermoplastics Directive D

Welding of PE Casing Pipes DVS 2207-5
FÜR SCHWEISSEN UND
Supplement 1 V
VERWANDTE VERFAHREN E.V. – Fittings and Isolating Valves – (July 1997) S 
Content: 2 Material and semi-finished products
1 Scope PE-HD in accordance with paragraph 4.2 of DIN EN 253 must be

2 Material and semi-finished products used as a material for fittings to be made by welded joints.
3.1 Preparation and requirements for carrying out the process In order to ensure suitability for welding, the mass flow rate of the
3.1.1 Inspection of the condition of the heating tools and air materials to be welded must satisfy the requirements of DIN
supply EN 253, paragraph 4.2.1.2. This means that the mass flow rate
3.1.2 Operating test of the equipment and machines used (MFR 190/5) of the materials to be welded may not differ by more
3.1.3 Work and workplace than 0.5 g/10 minutes.
3.2 Heated plate welding (HS)
3.2.1 Equipment requirements PE-HD in accordance with DIN 8075 must be used as welding
3.2.2 Preparation of the welded material / joint sub-faces filler under paragraph 7.3 of DVS 2207-5, with state of the art
strength properties in respect of its creep behaviour, depending
3.2.3 Welding process

3.3 Hot gas extrusion welding (WE) upon the welding method used.
3.3.1 Equipment requirements Only qualifying tubes with appropriate, informative test
3.3.2 Preparation of the welded material / joint sub-faces certificates under or on the basis of DIN EN 253, or moulding
3.3.3 Welding process materials in accordance with DVS 2207-5, may be used as semi-
3.4 Hot gas string bead welding (WZ) finished products.
4. Testing welded joints
4.1 Non-destructive testing methods – visual inspection
4.2 Destructive testing methods
4.2.1 Tensile test
4.2.2 Technological bend test
4.2.3 Tensile creep test The following welding processes are used for producing PE
4.3 Imperviousness test casing pipe fittings:
5 Requirements on the welded joints In the factory:
5.1 Visual inspection
5.1.1 Indications of good HS welded joints – Heated plate welding (HS) for segmental construction or in
5.1.2 Indications of good WE welded joints conjunction with “outward necked” pipes;
5.1.3 Indications of good WZ welded joints
5.2 Requirements for the tensile test – Continuous and intermittent hot gas extrusion welding (WE)
5.3 Requirements for the technological bend test (DVS 2209-1), possibly with a root pass produced by hot-gas
5.4 Requirements for the tensile creep test string-bead welding (WZ), if necessary.
5.5 Requirements for the imperviousness test
If production on site is necessary, e.g. for modifications, repairs,
6 Quality assurance
etc:
7 Standards and directives
– Hot gas extrusion welding and
1 Scope – Under exceptional circumstances – restricted access, etc –

hot gas string-bead welding.
This Supplement to Directive DVS 2207-5 applies to all PE-HD
In addition to the process stipulations, characteristics and
factory and site casing pipe welded joints on segmental bonded
requirements in Directive DVS 2207-5 for welding PE casing
prefabricated fittings (elbows, T-pieces, adapters and anchor
pipes, predominantly in site production, the following stipulations
points) in accordance with DIN EN 448 and underground
must be observed in the production of fittings.
isolating valves within the scope of plastic casing pipe systems
for district heating networks in accordance with DIN EN 488. Only suitable, calibrated and regularly-maintained machines and
The HS (heated plate) welding method must be used for factory equipment may be used to execute welds. The appropriate
casing pipe joints and the WE (hot gas extrusion) method in working instructions – process and parameter stipulations – must
exceptional and special cases. be available at the workplace: see also DVS 2208-1 and DVS
2209-2.
Site casing pipe joints must be made using the WE method and
the WZ (hot gas string-bead) method in exceptional and special Welds must only be made by qualified welders certificated for the
cases. process under Directive DVS 2212.
A working out of the common DVS-/AGFW-working group “Schweißen von PE-Mantelrohren”
498
3.1 Preparation and requirements for carrying out the process – A user-friendly adjustment facility for aligning the work at the
Equipment operation tests and parameter checks must be welding point (to minimise face offset).
carried out before work commences, and the following conditions
guaranteed. Table 1. Permissible gap widths and deviations from plane-paralle-
lism of the clamped, machined pipe faces
3.1.1 Inspection of the condition of the heating tools and air supply (a) By bending and beaming up the equipment guides and
jigs1)
The proper condition of the heating tools and energy media must (b) Deviations from the plane-parallelism of the machined
be verified at appropriate intervals before and during the work. faces when clamped with minimal contact pressure
– Superficial condition (PTFE coating) of the heated plates; between the ends of the pipes pushed together.
– Heat regulation, temperature maintenance, maintenance of Permissible gap width Nominal external casing pipe diameter
settings;
[mm] [mm]
– Water- and oil-free air supply for extrusion and hot gas
processes; maintenance units for stationary compressed air ≤ 0.5 ≤ 355
supply;
≤ 1.0 400 ≤ 560
– Correct allocation and dimensions of hot gas jets (WZ and WE)
and welding tools (welding shoes for WE) for the types of weld ≤ 1.3 630 ≤ 800
to be completed. ≤ 1.5 > 800
3.1.2 Operating test of the equipment and machines used
– Sufficient heated plate output and an even heat flux – also in
The operational safety of the machines and equipment used the case of split heated plates – into the welding zones; no
must be tested: residual parting marks in the weld and bead;
– Target/actual comparison of the parameters set for sufficient – Permissible overall temperature deviation of both the opposing
working time/preheating time with suitable measuring points of the heated plate and across the entire area of the
equipment and probes. The steady state condition must be working surfaces (including standard machine deviation);
achieved.
∆TTotal ≤ 10 (≤ ∅ 355 mm) up to ≤ 20 °C (≥ ∅ 800 mm)2) (dia-
– A test weld and at least one test idle cycle specimen for larger meter-dependent)
components.
– Plane-parallelism of the heated plate – split heated plates
3.1.3 Work and workplace correspondingly dimensionally stable and firmly mounted; per-
missible deviation from plane-parallelism within the effective
The working sequence and execution must ensure: surface area in accordance with table 2.
– A self-contained, clean working area with no interference from – Reliably-operating control/regulatory facilities for the appli-
other working areas, draughts or invasion by dust, dirt, cation of reproducible welding parameters within the limits of
moisture or the like; permissible application.
– The provision of clean, undeformed workpieces. If prefabri-
– A data recording facility displaying the pressure-(path)-time
cation takes place outside the welding area, internal and exter-
graph is advantageous
nal temperature differences must not differ by more than
approximately ∆T ≤ 5 °C from each other and the workplace;
Table 2. Permissible deviations from plane parallelism of the heated
– Cleaning processes only with grease-free cleaners and plates, including split elements, within the effective surface
sufficient ventilation time. The cleaning processes or surface area.
machining of the joint faces must be repeated at the welding
site, if necessary, in the case of prefabricated segments and Permissible deviation from Nominal external casing pipe
joint faces. plane parallelism diameter
The requirements of DVS 2207-5, paragraph 5, must be fulfilled. [mm] [mm]
3.2 Heated plate welding ≤ 0.4 ≤ 355
3.2.1 Equipment requirements ≤ 0.5 400 ≤ 560
The machines and equipment used must guarantee a safe, ≤ 0.8 630 ≤ 800
reproducible process with sufficiently constant welding
≤ 1.2 > 800
parameters, c.f. DVS 2208-1. This requires:
– Secure clamping (fixing and aligning) and control of the work 3.2.2 Preparation of the welded material/joint sub-faces
with even transmission of compressive forces over the entire
welding surface/circumference of the pipe (a); diameter- The following points must be checked for workpieces clamped
dependent admissible gap widths by bending up and into the machine before the welding process commences:
machining deviations from plane-parallelism in accordance – Alignment of the joint sub-faces with minimal offset, so that the
with table 1; see also DVS 2208-1, paragraph 4.1.2; requirements for the finished weld can be guaranteed;
– Adapted jigs enveloping the pipe, which do not cause any
– Sufficient contact of the welding surfaces around the entire
inadmissible embossing/notching of its surface;
circumference of the pipe must be ensured. If necessary, the
– Chucking/clamping of the work close to the welding plane, with prefabricated workpieces must be machined while clamped
appropriately-shaped jigs in the case of segmental mitred into the machine (by a plane integral to the machine). The
welds; permissible gap width/deviation from plane parallelism must
1) Clamped pipe ends, carefully machined flat, are used for measurement. Two reference specimens (spacers) are placed on the axis of the pipe parallel
to the plane of the guide/power spar and the pipe ends brought into contact with each other at the joint pressure applicable to the pipe. The difference
in gap widths measured, unpressurised and under joint pressure, must not exceed a tolerance range of 0.25 mm.
2) Measured in the working position in a draught-free environment with the heated plate temperature set at 210°C
499
satisfy the requirements of table 1, point (b) of this Supple- “Intermittent” variant I is used for T-pieces with mounted
ment. discharge pipes and for special forms of weld when producing
fittings from PE casing pipes. In particular, it is used if the face
– The cleanliness of the welding (workpiece) faces must be
geometry charges in the course of the weld, which cannot be
verified (see also paragraph 3.1.3).
accomplished reliably using the invariable welding shoe shapes
of “continuous” process variant II.
The heated plate welding process and guide settings for the
process parameters are described in DVS 2207-1. The Alignment pressure Joint pressure
parameters specified for execution of the process (heated plate
temperature, pressure and time increments) must be observed.
Pressure
The heating plate temperature range is between 200 and 220 °C.
Notes on the process stages shown in diagrammatic form in
Fig. 1: Heating-up pressure
Alignment Joining
– Alignment: Heating-up time Cooling time Time
time time
Change-over time
Initial fusion of the welding surfaces until the parts to be
welded are in full contact with the heated plate (small molten Figure 1. Diagrammatic representation of stages in the process of
bead) around the entire circumference (inside and out). heated plate welding (based on DVS 2207-1).
The alignment time (tAG) emerges from the necessary depth of
3.3.1 Equipment requirements
burn-off.
The equipment used must guarantee even preheating (initial
Alignment pressure = joining pressure: pAG ≈ 0.15 N/mm2
fusion) of the joint faces and continuous feed of the
homogenously plasticised welding filler into the welding groove
– Heating-up/melting process: (V- or fillet weld) with the exercise of sufficient welding pressure
The depth of fusion of the joints required for welding is created through the welding shoe/the workpiece to be welded on to the
at reduced pressure (fixing pressure only). welding deposit. This principally requires the following:
Guideline for tAS – dependent on wall thickness – in accor- – Adjustment/alignment of the hot gas jet to the shape and path
dance with working instruction or DVS 2207-1. of the weld;
Heating-up pressure pAW ≈ 0.01 N/mm2 – A simple welding unit readjustment facility for the enclose
support of the welding shoe (tool) on the circumference of the
– Change-over time (tU): pipe and centred longitudinal guidance across the path of the
weld;
The time between lifting off the heated plate and the welding
faces encountering each other for joining/welding must be kept – Appropriate shaping and a welding shoe adapted to the
as short as possible. dimensions of the weld (width of joint coverage, weld camber,
contact length, the front “shoe tip” closing the joint, edge
Guide settings under working instruction or DVS 2207-1. rounding and recessing), in accordance with the process
(The change-over time should be ≥ tU 5 ≤ 8 seconds, directive and working instructions;
depending upon the thickness of the wall, where pipe wall – PTFE or equivalent plunger for suitable shaping (weld shape
thicknesses are 3 – 15 mm. and width) for manual pressure on the weld deposit at the
– Jointing ends, etc. and for intermittent execution of the process.
The joining pressure (pF) is established quickly with bead 3.3.2 Preparation of the parts to be welded/joint sub-faces
formation during the joining period (tF).
– The specific welding parameters of PE moulding material must
tF approximately 5 to 15 seconds – depending upon the wall match. The melt flow rate (MFR 190/5) of the workpieces and
thickness. the fillers must not deviate from each other by more than
The cooling time (tK) for the joint/cross-section of the weld 0.5g/10 minutes under DIN EN 253. Control measurements
follows, maintaining the joining pressure (pF) up to approxi- must be taken if necessary.
mately ≤ 70 °C. – The surfaces to be welded (joint faces and surface areas in the
Guide settings for tK and pF in accordance with working vicinity of the edges of the joint) must be machined; see also
instruction or DVS 2207-1. DVS 2207-5, paragraph 5.
Mechanical stresses on the welded joint must be precluded – Secure anchorage of the workpiece and maintenance of the
until it has cooled close to the temperature of the pipe. joint shape and root gap specific to the process in accordance
with working instructions and process directive DVS 2207-4
3.3 Hot gas extrusion welding must be guaranteed. If necessary, tack welds or a WZ root
pass in the intermittent process must be provided.
Hot gas extrusion welding is described in Directives DVS 2207-4
and its Supplement (parameters) and DVS 2207-5. The major – The cleanliness of the welding surfaces and the welding filler
requirements and specifications are set out below, in conjunction material must be verified, see also section 3.1.3.
with DVS 2207-5, paragraph 5.2.
As well as process variant II (in accordance with DVS 2209),
applied predominantly to longitudinal and circumferential welds Continuous observance of the parameters of face/welding
on PE casing pipes, variant I, the intermittent process, is used. deposit temperature, welding pressure on the welding deposit
Experience has shown that the greater demands of long-term and an appropriate welding speed must be ensured. This
strength (welding factor “fs”) are not achieved by process variant I requires:
due to manual execution with separate functions and the
– Controlled, safe tool guidance;
observance of parameters which can be influenced to a high
degree by the welder, unlike the mechanised and partially – Penetration tests on the joint faces in the entire weld face im-
mechanised process variants in accordance with DVS 2207-5, mediately in front of the welding tool. Necessary depth of
table 4; see DVS 2207-4, paragraph 17. fusion ≥ 0.5 mm.
500
– Continuous observation of the weld site and any necessary 4.2 Destructive test methods
readjustment of the welding unit (centring and bearing on the
pipe) and adjustment of the advance control system. 4.2.1 Tensile test
– Subsequent manual pressing of the welding deposit into the The tensile test is carried out in accordance with paragraph 6.1 of
ends of the weld and other problem areas with the welding Directive DVS 2207-5.
tool, and with the hand plunger in insufficiently accessible ar- Note on table 1 of Directive 2207-5:
eas.
If the dimensions of the test specimen cannot be maintained for
– In the intermittent process, face heating must be undertaken design reasons, smaller dimensions (specimen length) may be
carefully and inspected (penetration tests). The welding filler selected, provided that the remaining specifications are fulfilled.
material must be introduced directly into the welding area and An appropriate conversion of machine speed to the same
pressed in and down with the plunger for a sufficient period. specimen deformation speed must be made (c.f. Fig. 2).
– Remachining the edges of the weld (removing weld flashes),
without damaging the surfaces of the pipe and with minimal External mitre
scraping depths of ≤ 0.1 x s, but ≤ 1 mm.
Abutment plane
Working instructions and process directives must be observed. (upper edge)
3.4 Hot gas string-bead welding

The process is described in Directive DVS 2207-3. In general,
only lower long-term weld strengths are achieved in the hot gas
welding process with the introduction of welding filler, e.g. hot Internal
mitre
gas string-bead welding with a welding rod, than in the process
described above. This is all the more applicable if the welding
has to be carried out under difficult conditions, e.g. on site and in
trenches. Figure 3. Location for sampling from segmented elbows
a) Specimen from the abutment plane for the tensile test
For these reasons, hot gas welding should not be used for PE b) Specimen from the internal and external mitre for the
casing pipes or the production of fittings, or only used under technological bend test.
exceptional circumstances. Should this process nevertheless be
integrated into production, e.g. for root passes or in inaccessible In the case of segmental prefabricated fittings, particularly those
joint face positions, the requirements of DVS 2207-3 must be with a large diameter, one (or, if necessary, two) test specimens
fulfilled. with reasonable leg coils may be taken from the abutment area
and on the diagonal of the weld to the axis of the specimen, c.f.
Fig. 3.
4 Testing welded joints
4.2.2 Technological bend test
The tests described below may be used to test welded joints, The technological bend test is conducted in accordance with
taking account of the existing requirements. A decision on the paragraph 6.2 of Directive DVS 2207-5. The dimensions of the
applicability and informative content of individual test procedures specimen must be selected in accordance with table 2 therein.
or combinations thereof must be made on the basis of the When testing specimens from the outer or inner mitre of a
circumstances of each individual case. segmental elbow (see Fig. 2), the excess of deformation angle
Reference is made to Directive DVS 2207-5, paragraph 6, in “α” achieved in the test above the existing angle of the specimen
respect of the informative content of individual test procedures. “β” must be regarded as the result.
In the case of mounted discharge pipe T-pieces with a fillet weld,
4.1 Non-destructive test methods – Visual inspection specimens are taken, tested and analysed in accordance with
In general, visual inspection is the only non-destructive test Fig. 3.
applied to PE casing pipes. All welded joints are inspected for
visible errors in execution and external indications of internal 4.2.3 Tensile creep test
defects in execution. The tensile creep test is implemented and evaluated in
accordance with paragraph 6.4 of Directive 2207-5. The
Radiographs and ultrasound tests are not customary within the
specimen geometry is identical to that in the tensile test.
scope of this Directive. Should such test processes be used for
corresponding welding processes, weld shapes and weld The component strength of fittings may also be verified in an
dimensions under exceptional circumstances, Directive DVS internal pressure creep test in water, analogous to the
2206 must be consulted. stipulations in DIN 16963-5. Apertures in fittings must then be
L fKurz
V Kurz = V Normal × ----------------------
L fNormal
LfNormal = Specimen length in accordance with DVS 2203-2,

table 1
LfKurz = Shortened specimen length
VNormal = Machine feed for specimen length Lf;
Guide setting for PE-HD under DVS 2203-2, table 3
= 50 mm/min
VKurz = Machine speed for shortened specimen length
Figure 2. Example of a shortened specimen from a prefabricated fitting.
501
closed so that the resultant longitudinal and lateral forces are 5.1.2 Indications of good WE welded joints
completely removed from the fitting itself. A good WE welded joint displays the following crucial formation
characteristics (Fig. 5):
An imperviousness test must be carried out using compressed air
at approximately 0.2 to 0.3 bar. No leaks (bubbles) must be
visible one minute after coating the welds with a harmless
foaming aqueous solution (e.g. a modern biodegradable
domestic washing-up liquid in the lowest possible concentration).
Should there be any doubt or dispute, the pressure must be
maintained for ≥ 10 minutes. Figure 5. Extrusion weld with well-formed cap and good root penetration
(in accordance with DVS 2206).
5 Requirements imposed on welded joints – Even weld camber running centrally to the joint, joint edge cov-
erage by V-weld ≥ 2 mm (3 ± 1 mm)
The requirements imposed on welded pipe joints in paragraph 7
– Smooth weld form, reflecting the shape of the welding shoe,
of Directive DVS 2207-5 apply to fittings.
with the weld surface not showing any signs of disintegration,
The requirements for welded joints to be inspected in accordance overheating, rising bubbles, inhomogeneity, inclusions, etc.
with paragraph 4 of this Supplement are set out below.
– Minimal face offset.
5.1 Visual inspection – Notch-free, penetrative weld root with slight root sag; root con-
cavity and lack of fusion at the edges of the weld (notches with
The subjects of visual inspection are:
sharp edges) are serious faults in production.
– Maintenance of the process-specific weld formation, particu-
– Weld edge machining depth ≤ 10% of the pipe wall thickness
larly in respect of the weld shape, dimensions, geometry and
and ≤ 1 mm
symmetry;
– Inspection of the surface characteristics for any damage to the 5.1.3 Indications of good WZ welded joints
surface of the pipe in the vicinity of the weld as a consequence A good WZ welded joint has the following particular features
of the handling of the fittings, clamping, the effects of tempe- (Fig 6):
rature etc. during implementation of the process.
Welds (face shape, bead/weld formation, presence of blowholes,
large pores, accumulations of pores, root and edge notches, root
suck-backs and lack of side wall fusion in weld cross-sections)
are assessed in accordance with evaluation group 2 in DVS
2202-1. Should deviations from the requirements occur in
individual cases, they must be specified in advance.
Increased face offset limits of ∆s ≤ 0.2 s (s = thickness of the
thinner wall) are accepted for PE casing pipe fittings at the
relatively low wall thickness usual within the scope compared to
the pipe diameters on one hand and the difficult production
conditions of some structural forms with internal medium pipes
on the other, such as outward necked T-pieces in heated plate
welding. Under particularly difficult conditions for fittings – e.g.
the outward-necked T-piece – up to ∆s ≤ 0.3 s is admissible, if
the associated greater weakness is observed in static testing.
5.1.1 Indications of good HS welded joints

Crucial features of good HS welded joints on visual inspection Figure 6. Hot-gas welded butt joint with diagram of welding filler
are (Fig. 4): principle
a) Well-filled weld without backing run (weld structure e.g.
one ∅ = 3 mm + one ∅ = 4 mm + twice ∅ = 4 mm)
b) Weld with inadmissible root gap notches – non-penetrative
root.
– Even, slightly reinforced cap with straight passes;

– Flat transitions between the individual passes and continuous
joint edge coverage;
– Process-specific double bead on both sides, each pass without
Figure 4. Good bead formation in heated plate welding. indications of burning
– Minimal face offset
– Even formation of a double bead throughout the entire length
of the weld/circumference of the pipe (inside and outside); – Notch-free weld penetration with slight sag. Root suck-back is
inadmissible.
– Individual beads as symmetrical as possible, rounded shape,
not pressed into a peak by excessive joint pressure; – Similarly evident “heat delustering” on both sides of the weld
as an indication of the even application of heat.
– Root of the central groove outside the cross-section of the
pipe, double bead width in the approximate vicinity of the pipe 5.2 Requirements for the tensile test
wall;
The requirements of Directive DVS 2207-5, paragraph 7.2 and
– Minimum face offset. table 3, apply.
502
5.3 Requirements for the technological bend test 7 Standards and directives
Fig. 14, apply. DIN EN 253 Preinsulated bonded pipe systems for directly
burried hot water networks – Pipe assembly for
5.4 Requirements for the tensile creep test steel service pipe, polyurethane thermal insulation
and outer casing of polyethylen.
table 4, apply, with the exception of the footnote. DIN EN 448 Preinsulated bonded pipe systems for directly
burried hot water networks – Fitting assemblies for
5.5 Requirements for the imperviousness test steel service pipes, polyurethane thermal insulation
and outer casing of polyethylene.
The independent impervious test on factory mass-produced
fittings may be waived, if the following requirements are fulfilled: DIN EN 488 Preinsulated bonded pipe systems for directly
burried hot water networks – Steel valve assembly
– Use of certifiably qualified, quality-assured semi-finished prod- for steel service pipes, polyurethane thermal
ucts and similarly certificated welding fillers, if applicable; insulation and outer casing of polyurethane.
– Certified welding process with qualified, regularly-serviced DIN 8075 Polyethylene (PE) pipes – PE 63, PE 80, PE 100,
welding tools; PE-HD – General quality requirements, testing
– Use of qualified, certified welders under DVS 2212-1 and –2, DIN 16776-1 Polyethylene (PE) moulding components,
under similarly qualified, certified supervision (e.g. under DVS classification and description
2213 and 2214); DIN 16963-5 Pipe joints and components of polyethylene (PE)
– Compliance with test certificates under Directive DVS 2207-5, for pipes under pressure, PE 80 and PE 100 – Part
table A 5-2, pos. 1 to 5. 5: General quality requirements, testing
In the case of individual production, particularly the production of DVS 2202-1 Imperfections in thermoplastic welding joints –
fittings or valve jacket casings on site, they must be subjected to Features, description, evaluations
an imperviousness test at excess air pressure in accordance with DVS 2203-1 Testing of welded joints of thermoplastics – Test
paragraph 4.3, after installation in the pipe system and prior to methods, requirements
filling with foam: see also Directive DVS 2207-5, paragraph 6.5. DVS 2203-2 Testing of welded joints of thermoplastics – Tensile
No leaks, atypical deformation or other inadmissible changes test
may take place.
and tubes – Tensile creep test
6 Quality assurance DVS 2203-5 Testing of welded joints of thermoplastics plates
and tubes – Technological bend test
Directive DVS 2207-5, paragraph 6, must be applied analogously DVS 2206 Testing of components and constructions made of
to quality assurance. thermoplastic materials
This particularly affects the following, if possible on the basis of DVS 2207-1 Welding of thermoplastics, Heated tool welding of
an ISO 9000 ff. quality assurance/quality management system: pipes, pipeline, components and sheets made from
– Effective quality assurance measures for the factory produc- PE-HD
tion of casing pipe fittings within the scope of factory produc- DVS 2207-3 Hot gas welding of thermoplastic polymers; panels
tion; and pipes
– The use of approved, regularly-maintained machines and DVS 2207-4 Welding of thermoplastics, Extrusion welding –
equipment subjected to certified regular operating tests panels and pipes
– The use of qualified welders with examination certificates in DVS 2207-5 Welding of thermoplastics – Welding of PE casing
the welding process used under DVS 2212-1 and –2, under pipes – Tubes and tubular components
qualified supervision (e.g. under DVS 2213 and DVS2214); DVS 2208-1 Welding of thermoplastics – Machines and devices
– Specimen tests after machine setting and at regular inter- for the heated tool welding of pipes, pipeline
vals during production under DVS 2207-5, Annex 5, table A components and sheets
5-2. DVS 2209-1 Welding of thermoplastics – extrusion welding;
– Final testing/visual inspection of all the welded fittings. procedures, characteristics
– Quality certification of semi-finished products and welding filler DVS 2209-2 Welding of thermoplastics – Hot gas extrusion
materials welding – Requirements for welding machines and
tools
– Documentation of certificates and test results for welding work.
DVS 2212-1 Examination of plastic welders – Group I – Hot gas
welding with torch separate from filler rod (WF), hot
gas string-bead welding (WZ), heated tool butt
welding (HS)
DVS 2212-2 Examination of plastic welders – Examination
group II – Hot gas extrusion welding (WE)
DVS 2213 Specialist for plastic welding – Examination
DVS 2214 Regulations for the examination of the specialist for
plastic welding
503
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Erstellt am:
16.11.2003
02.12.2014
September 2003
Non-contact heated tool butt welding of
FÜR SCHWEISSEN UND
pipes, pipeline components and sheets Technical Code
Methods – Equipment – Parameters DVS 2207-6
Content: parallelism of the surfaces to be joined. The joining areas have to

be heated up without contacting the heating tool yet maintaining
1 Scope a defined distance in order to achieve a thermoplastic condition
2 General description of methods (heating up). After reaching a plasticised state the radiant heated
3 Requirements on welding equipment tool butt is removed (adjusting) and the components are joined
3.1 General under pressure (joining). The welding joint has to be cooled down
3.2 Special requirements for distance control whilst retaining the joining pressure in the finished joining
4 Radiant heated tools position.
4.1 Radiators
The following joining methods are distinguished at heated tool
4.1.1 Types of radiators
butt welding machines with radiant heating:
4.1.2 Temperature exactness
5 Welding, procedure and parameters – Welding with joining pressure control: the joining pressure is
5.1 General requirements adjusted and kept constant by the machine.
5.2 Measures before welding
– Welding with joining distance limitation: the joining distance is
5.2.1 Welding requirements
limited with adjustable distance bolts.
5.2.2 Cleaning
5.3 Preparation of the components to be welded – Welding with combined joining pressure control and joining
5.4 Welding procedure distance limitation: the joining distance is limited by machine
5.4.1 Start-up control and adjusted to the joining force control by a thermal
5.4.2. Heating up reduction after falling below a certain joining force.
5.4.3 Changeover
5.4.4 Joining
5.4.5 Cooling 3 Requirements on welding equipment
5.5 Safety indications
6 Testing of welded joints 3.1 General
7 Standards and Technical Codes
7.1 Standards The requirements on welding machines for the non-contact
7.2 Technical Codes heated tool butt welding method are mentioned in the Technical
8 Explanations Code DVS 2208-1. Further detailed requirements are listed in
Appendix: Indications and protocol for testing of equipment section 3.2.
Welding protocols
3.2 Special requirements for distance control
1 Scope Welding machines with an automatic joining process demand the
adjustment for an exact distance control. With manual controlled
In this Technical Code the non-contact heated tool butt welding machines the position of the guiding devices must be exactly
and the requirements for devices and machines are described. adjustable by distance bolts.
With the mentioned features the processor can check which With the application of mechanic distance limits (distance bolts)
devices or machines are most suitable for the safety realizable these have to be suitably protected so that dirt or falling in of
performance of his welding works appropriate to the materials shavings is absolutely avoided. The reproducible position
involved. exactness must be  0,05 mm.
This Technical Code relates to methods and the different types of
processes of heated tool butt welding where the heating up of the
joining areas is done without any contact. Machines, devices and 4 Radiant heated tools
their parameters for the welding of pipeline components, sheets
and other components out of PP (PP-H/PP-B/PP-R) and PVDF Heated tool and machine are a unit. Therefore the machine has
are described. Occasionally the system dependency according to to be re-calibrated after exchange of the heated tool.
the manufacturer’s instructions with material combinations of PP
and PVDF have to be considered. Concerning the welding The construction of the heated tool must guarantee a perfect
suitability of materials PP and PVDF see the topic “scope” in DVS heating up of the joining areas to the welding temperature under
2207-11 and DVS 2207-15. working conditions. The handling of the heated tool must enable
keeping the adjustment time according to table 2.
With the welding of other plastics e. g. PFA, E-CTFE the
parameters have to be checked and possibly adjusted. The The voltage supply in the heated tool area has to be protected
welding joint quality must be proved depending on the system against thermal damages, just as the active surface of the heated
(machine, parameters, component). tool against mechanical damages.
The mounting and guidance of the heated tool must enable a
plane parallel position of heated tool to the joining areas.
2 General description of methods
The used heated tool must be plane parallel within its active
With the non-contact heated tool butt welding the joining areas of surface and the maximum deviation must be lower than 0,2 mm.
the parts to be welded have to be shaved in order to reach a plan The measurement is done at 23 ± 2 °C.
504
4.1 Radiators The welding works must be supervised. The type and scope of
supervision has to be agreed. It is recommended to record the
The heated tools for non-contact welding are radiant heated tools procedure data in welding protocols (example see appendix) or
which are classified depending on wave ranges. data carriers.
4.1.1 Types of radiators Within the scope of the quality assurance it is recommended to
produce and test samples of joints before beginning and during
The following types of radiators are usual: the welding works.
– Short-wave or bright radiators (wave range up to 1,6 µm) Every welder has to be trained. The intended application range
– Medium-wave radiators (wave range > 1,6 up to 3,5 µm) may be decisive for the kind of qualification. The welding exam
– Long-wave or dark radiator (wave range  3,5 µm) certificate according to DVS 2212-1 in the groups I-4 res. I-8 in
conjunction with the complementing training certificate on non-
The general structure of radiators is that a filament is embedded contact heated tool butt welding issued by an authorized training
in a metallic or ceramic mass which can be heated up to a institute or by the particular machine manufacturer is valid as
temperature of 1000 °C with the wire. An infrared radiation (IR) is qualification proof.
created.
5.2 Measures before welding
4.1.2 Temperature exactness
The temperature deviations measured on the heated tool 5.2.1 Welding requirements
opposite to the temperature adjustment result from technically The welding zone must be protected against bad weather
limited inexactness (regulator deviation and temperature influences (e. g. moisture and temperatures below + 5 °C res.
distribution on the active surface), installation position of the tool higher than + 40 °C). If it is ensured by suitable measures (e. g.
(e. g. natural convection, shielding effects) and environmental preheating, tent, heating) that a component temperature
influences (e. g. draught). sufficient for welding can be kept – as far as the welder is not
hindered in his handling – work may be carried out at any outside
Table 1. Maximum allowed technically limited temperature temperature. If necessary, an additional proof must be provided
deviations. by carrying out sample welds under the mentioned conditions,
see section 6.
Heated tools for pipes Heated tools
If the semi-finished product is heated up unevenly under
and fittings for sheets
influence of sunshine, a temperature compensation in the area of
Active surface < 250  250...  2000 independent the welding joint can be reached by covering. A cooling down
cm² during the welding process by uncontrolled draught has to be
avoided. During the welding of pipes the pipe ends have to be
Regulator 3 3 3 closed.
deviation °C
The joining areas of the parts to be welded may not be damaged
Temperature 5 7 8 and have to be free of contaminations (e. g. dirt, oil, shavings).
distribution on
active surface °C The welding process may only be started with a stable heated
tool temperature according to manufacturer instructions. This has
Technically limited 8 10 11 to be guaranteed by adequate measures, e. g. timed lock, lock of
total deviation °C menu prompt, etc. In order to guarantee an exact temperature
distribution on the heated tool surface, the heated tool in neutral
position should be stored in a suitable protection device.
Since each heated tool has its own radiation characteristic the
tool and machine must be adjusted (calibrated) to each other. 5.2.2 Cleaning
This results in different heated tool surface temperatures with the
same input temperature adjusted on the machine. This has to be The surfaces to be joined should be clean and free of grease and
considered during the measurement of the heated tool only similarly clean tools and heated tools are to be utilised if a
temperature. perfect welding joint is to result.
The measurements are done at an ambient temperature of 23 5.2.2.1 Cleaning agents
± 2 °C and a reference temperature which is within the operating
range of the machine. The use of cleaning agents is mentioned in the manufacturer’s
instructions.
Since the heated tools could have high temperatures, the
measurement has to be done with an adequate measuring The paper for cleaning must be clean, unused, absorbent, non-
device. With the use of non-contact measuring devices (dark fraying and non-coloured.
radiators), a measuring spot diameter of maximum 20 mm has to
be kept. 5.2.2.2 Cleaning of the heated tool
The heated tool may not be cleaned in heated up condition
because of the high heated tool temperatures. Contaminations
5 Welding, procedure and parameters have to be removed from the cold heated tool whereby the
manufacturer’s instructions have to be considered.
With the heated tool butt welding method with radiator heating,
the welding parameters depend on the system. In the following 5.2.2.3 Cleaning of joining areas
the method parameters and method indications for the welding
with joining pressure and joining distance limitation are given. Before shaving the joining areas it has to be ensured that the
used tools and components are clean and free of grease in the
welding zone, if necessary cleaning agents should be used.
The quality of welding joints depends on the qualification of the 5.3 Preparation of components to be welded
welders, suitability of the used machines, devices and
The nominal wall thicknesses of the parts to be welded must
components as well as the compliance of welding guidelines. The
correspond in the joining area.
welding joint can be tested and inspected by destructive and/or
visual methods. During clamping the components to be welded must be aligned in
505
the welding machine in a horizontal and vertical direction. The Table 2. Start-up and changeover time.
slight longitudinal mobility of the part to be welded on has to be
fixed e. g. by adjustable roller blocks or oscillating suspension. Wall thickness Start-up time Changeover time
[mm] (maximum) [s] (maximum) [s]
The joining areas have to be planed with a clean and grease-free
tool directly before welding, so that they are plane parallel in up to 3,0 <3 <3
clamped condition. The maximum deviation of plan parallelism of > 3,0 up to 7,0 3 3
joining areas must be  0,3 mm.
> 7,0 up to 15,0 4 4
The misalignment has to be checked simultaneously with the
control of the gap width. The misalignment of joining areas has > 15,0 5 5
an essential influence to the strength of the welding joint. A
minimum misalignment should be reached. The allowed gap of
0,1 x wall thickness may not be exceeded. A larger misalignment
means a quality reduction.
The treated welding areas should be neither contaminated nor Bead notch
touched by hand. Any additional cleaning is not necessary Pipe surface,
and means no quality improvement. Shavings which have outside
fallen into the welding areas have to be removed without
contamination. If contamination happens after treatment, e. g. by K-size
touch with hands, the welding areas can be treated with a
cleaning agent in the event that an additional shaving is
technically impossible.
5.4.1 Start-up Figure 1. Bead design at heated tool butt welding (principle on example
pipe).
The start-up of the heated tool between the joining areas must be
done quickly (start-up time) as otherwise the additional heating
would be uneven and unregulated, see table 2. 5.4.4.1 Pressure controlled joining
With the joining pressure limitation, the joining pressure must be

5.4.2 Heating up
kept until the end of the cooling time. The material specific joining
Alignment is not done. pressures are indicated by the manufacturer.
The heated tool is put in heating up position and the components
to be welded are brought together. The distance of the 5.4.4.2 Distance controlled joining
components to be welded to the heated tool is usually adjusted
with distance bolts. A plasticised zone in the joining are is created The joining distance is calculated starting with the contact of the
during heating up. The decisive influences are radiation source, parts to be welded. The material specific joining distances are
radiator temperature, component material, distance to indicated by the manufacturer.
component, start-up time (see table 2), heating up time.
The heating up parameters have to be chosen so that a minimum 5.4.4.3 Distance-/Pressure controlled joining
plasticised zone depending from the material is created without
causing a thermal destruction on the surface. The joining distance is calculated starting with the contact of the
parts to be welded. After the joining distance is reached the
General valid parameters cannot be indicated due to major joining pressure is measured. After falling below a limit value it is
differences in the reflecting behaviour of different heated tool changed to joining pressure and kept until the end of the cooling
surface as well as the variety of influence factors and their time.
combination with each other. Experiences have shown that
plasticised zone thicknesses of 10 – 20 % result in good welding
joint strengths of the materials welded with this method. 5.4.5 Cooling
In general the welding parameters have to be chosen by the The cooling process must be done completed whilst maintaining
manufacturer so that the requirements according to DVS 2203-1 the complete joining distance/joining pressure. The cooling times
are fulfilled. depend on the wall thickness and are indicated by the
manufacturer. Increased mechanical loads during or directly after
5.4.3 Changeover re-clamping are only allowed after corresponding elongated
cooling phase.
After the heating up the heated tool is extended and the
components to be welded are joined together quickly until directly
before the contact. The changeover time should be as short as 5.5 Safety indications
possible (see table 2) as otherwise the plasticised zones would
cool down and the welding joint quality would be influenced With the decomposition of fluorpolymers (PVDF, PFA, E-CTFE)
negatively. toxic vapours appear. This is the reason why the contact
between the high tempered heated tool and the parts to be
5.4.4 Joining welded has to be avoided. This is also valid for shavings incurred
by planing.
The areas to be welded should meet with a speed of nearly zero.
Different bead sizes are created by heat convection and gravity
influence on the total circumference of pipes. In addition, melt 6 Testing of welded joints
viscosity differences, e. g. existing between pipe and fitting, have
an influence to the bead size.
Non-destructive and destructive tests can be used for testing
The K-size (distance between the lowest point of the bead notch welded joints. These methods are listed in table 3. Tests and
(notch ground) and the surface of the component to be welded, sampling should be done by spot checks during the welding
picture 1, must be higher than 0. works – depending from agreement.
506
Table 3. Possible test methods for welding connections. 7.2 Technical Codes
Test method Heated tool butt welding DVS 2202-1 Failures on welding connections out of
sheets, pipes, fittings thermoplastics; Features, description,
evaluation
Visual test DVS 2202-1 DVS 2203 Testing of welded joints out of thermoplastics;
Radiation test Statement about e. g. holes, not about quality -1 – Test methods - Requirements
is possible -2 – Tensile test
Tensile test DVS 2203-2, short-term factor. Factors acc. to -4 – Long-term tensile test
DVS 2203-1, supplement 1, table 1 -5 – Technologic bending test
DVS 2203-4, long-term factor. Factors acc. to DVS 2207 Welding of thermoplastics;
DVS 2203-1, supplement 2, table 1 -11 – Heated tool welding of pipes, pipeline
Technologic DVS 2203-5. components and sheets out of PP
bending test Minimum bending angle acc. to DVS 2203-1, -15 – Heated tool welding of pipes, pipeline
supplement 3, pictures 2 to 4 components and sheets out of PVDF
Minimum bending angle acc. to DVS 2203-1, DVS 2208-1 Welding of thermoplastics; Machines and
supplement 3, pictures 8 to 10 devices for heated tool welding of pipes, pipe-
Long-term Length of each pipe piece acc. to DIN 16963, line components and sheets
internal table 6 DVS 2212-1 Exam of plastic welders; test group I-4 res. I-8
pressure test PVDF acc. to ISO 10931-2, section 7.2, table 5 draft
EG-machine Technical Code 89/392 (2. revision 91/368/EWG,
PP acc. to DIN 16 963-5, table 4, sections 3. revision 93/44)
5.4.3.1 and 6.4
BGV A2 (VBG 4) Electric equipment and production facilities
Not meaningful for long-term welding factor VBG 5 Pressure operated engines
> 0,5
VBG 22 Engines of chemical industry, rubber and
plastics industry
Reliability regulation
7 Standards and Technical Codes
7.1 Standards 8 Explanations

DIN 8077 Pipes out of polypropylene (PP); PP-H
100, PP-B 80, PP-R 80; Dimensions The draft has been established according to the latest state-of-
the-art. It follows to the content of the Technical Codes DVS
DIN 8078 Pipes out of polypropylene (PP); PP-H 2208-1, DVS 2207-11 and 2207-15.
(Type 1), PP-B (Type 2), PP-R (type 3);
General quality requirements, Testing
DIN 16962-5 Pipe joints and pipeline components for Appendix: Indications for machine control
pressure pipelines out of polypropylene
(PP); PP-H (type 1), PP-B 80, PP-R 80; – Visual check regarding damages
General quality requirements, Testing
– Operating test
ISO 10931-2 Plastics piping system for industrial
applications – Polyvinylidene fluoride – Control of clamping device according to DVS 2208-1, sections
(PVDF); Pipes 4.1 and 4.2
DIN EN ISO 15013 Extruded sheets out of polypropylene – Control of guiding elements according to DVS 2208-1, sections
(PP); Requirements and test methods; 4.1 and 4.2
Sheet group 1.1 / 2.1 / 3.1 – Control of device for welding joint preparation regarding cutting
DIN EN 292- 1 Safety of machines performance and plane parallelism according to DVS 2208-1,
DIN EN 292- 2 Fundamental terms, general design section 4.1
principles – Control of heated tool regarding damages, plane parallelism,
DIN EN 60204- 1 Electric equipment of machines easy operation and floating suspension of positioning and
removing res. set down devices according to section 4 and
DIN EN 294 Safety distances against reaching of
DVS 2208-1, sections 4.1 and 4.2
dangerous areas
DIN EN 418 Emergency stop – Control of heated tool regarding temperature exactness
according to 4.1.2
DIN VDE 0100 Regulations for installation of power
sets with nominal voltages up to 1000 – Check of control and regulation equipment for pressure and
Volt time with minimum and maximum diameter res. with minimum
and maximum sheet thickness and joint length according to
DIN VDE 0105 Part 1 Regulations for the operation of power section 3
sets; General regulations
– Check of scale and display indication with applied pressure on
DIN VDE 281 Part 1 PVC-power lines
the joining area by means of load cells at pressure controlled
DIN VDE 0551 Regulation for safety transformers machines. This is done at pipe machines on the smallest,
(German edition of EN 60742) average and largest diameter, each with the highest pressure
DIN VDE 0700 Part 1 Safety of electric equipment for the rating and at sheet machines on the smallest, average and
domestic use and similar purposes; largest sheet thickness and maximum joint length.
General requirements – Check of the distance measuring system according to
DIN VDE 0700 Part 30 Mobile electric heating tools manufacturer’s indication for distance controlled machines
DIN VDE 0721 Regulations for industrial electro – Check of reliability according to DVS 2208-1, section 2.7
heating equipment – Record of results in the test protocol, see example
507
Appendix
Test protocol for heated tool butt welding machines (pipeline components)
Product/Manufacture Type
Machine/Serial number Dimension range*
Heated tool serial number * also valid for required heated tools
Date of last check
 Personal safety and reliability Test result Evaluation

Current supply cable incl. plug
Tools and operating devices
Condition and density of the hydraulic system (if existing)
Visual and acoustic control devices
Emergency function (if not existing, input = 0)
 Clamping device and guiding elements

Gap measuring Gap difference mm
Condition of clamping elements and surfaces
Condition of guiding elements
Condition of slides
 Chip removing tools

Condition of cutting elements
Chip condition Chip thickness mm
Plan parallelism of joining areas after treatment
Condition of joining areas after treatment
 Radiant heated tools Preset temperature °C

Plan parallelism Deviation* mm
Temperature distribution Deviation* °C
Temperature exactness Deviation* °C
Surface condition
Operational test (for the indicated dimension range)
Joining pressure control / Joining distance Deviation* %/mm
Reading accuracy joining pressure Deviation* %
(manometric pressure) (if applicable)
Joining pressure build-up time / Joining distance Deviation* %

* (deviation from reference value)
Reference values acc. to DVS
 Operation manual (if missing, input = 0)
Evaluation of total condition (for comments about total condition please use supplementary sheet)
Evaluation key for tests and condition Evaluation key for measurements
1 = without claim 1 = within allowed tolerances
2 = minor claim 2 = deviation with minor influence
3 = claim which reduces the use 3 = deviation which reduces the use
4 = further use is not allowed 4 = unacceptable deviation
Date of check: Testing authority with stamp and signature:
Auditor:
508
Test protocol for heated tool butt welding machines (sheets)
Product/Manufacture Type
Machine/Serial number Dimension range*
Heated tool serial number * also valid for required heated tools
Date of last check
 Personal safety and reliability Test result Evaluation

Current supply cable incl. plug
Tools and operating devices
Condition and density of the hydraulic/pneumatic system (if existing)
Visual and acoustic control devices
Emergency function (if not existing, input = 0)
 Clamping device and guiding elements

Condition of clamping elements and surfaces
Condition of guiding elements
Condition of slides
Table misalignment mm
 Elevating spar
Plan parallelism
Straightness and alignment
Elevation adjustment
 Radiant heated tools Preset temperature °C

Plan parallelism Deviation* mm
Elevation adjustment in working position
Temperature distribution Deviation* °C
Temperature exactness regarding set value Deviation* °C
Surface condition
Operational test (for the indicated dimension range)
Joining pressure control / Joining distance Deviation* %/mm
Reading accuracy joining pressure Deviation* %
(manometric pressure) (if applicable)
Joining pressure build-up time / Joining distance Deviation* %

* (deviation from reference value)
Reference values acc. to DVS
 Operation manual (if missing, input = 0)
Evaluation of total condition (for comments about total condition please use supplementary sheet)
Evaluation key for tests and condition Evaluation key for measurements
1 = without claim 1 = within allowed tolerances
2 = minor claim 2 = deviation with minor influence
3 = claim which reduces the use 3 = deviation which reduces the use
4 = further use is not allowed 4 = unacceptable deviation
Date of check: Testing authority with stamp and signature:
Auditor:
509
510
Material
Protocol form for non-contact heated tool butt welding of sheets Sheet of
Customer Executive company Welding equipment:
Name of order Name of welder Identification no. Label:

Type:
No. of order Name of company of the welding supervisor Machine No.:
Year of construction:
Weld no. Date Sheet Measured Joining Start-up Heating-up Changeover Joining Joining Cooling time Environ- Notes
thickness heated tool pressure time time4) time4) pressure distance3) under joining mental
temperature1) (machine build-up pressure4) temperature
table)2) time2)4)
mm oC min/max N s s s s mm min oC

1) controlled by the machine
2) pressure controlled machines: according to the indications of the manufacturer res. from machine tests plus movement pressure res. force
3) distance controlled machines: according to the indications of the manufacturer
4) the measured values have to be entered
Protocol form for non-contact heated tool butt welding of pipes and pipeline  aboveground Material Sheet of
components  buried
Customer Executive company Welding machine: Weather: Precautions:

1 = sunny 1 = none
Label: 2 = dry 2 = umbrella
Name of order Name of welder Ident-no.
Machine No.: 4 = wind 4 = heating

No. of order Name of company of the welding supervisor Year of construction:
Multiple selections: order as above (e.g. 3 4 = rain and wind)
Weld no. Date Pipe Measured Movement Joining Start-up Heating-up Changeover Joining Joining Cooling time Environ- Key no. Notes
dimension heated tool pressure2) pressure time time4) time4) pressure distance3) under joining mental
d x s temperature1) (machine build-up pressure4) temperature Weather Precautions
table)2) time2)4)
mm oC min/max N N s s s s mm min oC
Welder signature:: Date and signature of welding supervisor

1) controlled by the machine
2) pressure controlled machines: according to the indications of the manufacturer res. from machine tests plus movement pressure res. force
3) distance controlled machines: according to the indications of the manufacturer
4) the measured values have to be entered
511
File: D:\Eigene Dateien\Kunden\DVS\Ri+Me\2207\2207-11\englisch\e2207-11.fm
Erstellt am:
21.09.2008
09.10.2008
December 2008

FÜR SCHWEISSEN UND Heated tool welding of pipes, piping parts and Technical Code
VERWANDTE VERFAHREN E.V. panels made of PP DVS 2207-11
Translation of the German edition from August 2008
Contents: 2 General requirements
1 Scope of application The quality of the welded joints is dependent on the qualification
2 General requirements of the welders, on the suitability of the utilised machines and jigs
3 Measures before the welding as well as on the compliance with the technical codes for
welding. The weld can be tested using non-destructive and/or
3.1 Prerequisites for the welding
destructive procedures.
3.2 Cleaning
3.2.1 Cleaning agents The welding work must be monitored. The contracting parties
3.2.2 Cleaning of the heated tools must reach agreement on the type and scope of the monitoring. It
is recommended to document the process data on welding
3.2.3 Cleaning of the joining faces
record sheets (for a specimen, see the appendix) or on data
4 Heated tool butt welding carriers.
4.1 Heated tool butt welding of pipes, piping parts, fittings and
panels Within the framework of the quality assurance, it is recommended
to manufacture and test trial welds in the given working
conditions before commencing and during the welding work.
4.1.2 Preparation for the welding

4.1.3 Execution of the welding Every welder must be trained and must possess a valid
5 Sleeve welding with an incorporated electric heating qualification certificate. The planned area of application may
element determine the type of the qualification. DVS 2212-1 applies to the
heated tool butt welding of panels as well as to pipeline
construction.
5.2 Welding device
5.3 Preparation for the welding The machines and jigs used for the welding must comply with the
requirements in DVS 2208-1.
6 Heated tool sleeve welding
6.1 Process description 3 Measures before the welding
6.2 Welding jigs
6.3 Preparation for the welding 3.1 Prerequisites for the welding
6.4 Execution of the welding The immediate welding area must be protected from un-
7 Testing of the welded joints favourable weathering influences (e. g. wind or the action of
8 Standards, technical codes and guidelines which are also moisture). If suitable measures (e. g. preheating, tenting or
applicable heating) ensure conditions permissible for the welding, the work
9 Explanations may be carried out at any outdoor temperature – provided that
Appendix: the dexterity of the welder is not hindered (see the explanations).
Processing instructions (short versions) If necessary, additional evidence must be provided by manu-
Welding record sheets facturing trial welds in the specified conditions (see Section 7).
If the semi-finished product is heated non-uniformly due to solar
radiation, the temperatures must be equalised by covering the
1 Scope of application area of the welding point in good time. It is necessary to avoid
any draught-induced cooling during the welding operation. When
This technical code applies to the heated tool butt welding of pipes are welded, the pipe ends must be closed in addition.
panels according to DIN EN ISO 15013 and to the heated tool PP pipes from the ring coil are oval and curved immediately after
butt welding, heated tool sleeve welding and sleeve welding with the unrolling. The pipe end to be welded must be straightened
an incorporated electric heating element of pipes and fittings before the welding, e. g. by means of careful heating-up with the
which are made of PP-H, PP-B and PP-R polypropylenes aid of a hot gas device and/or using a suitable clamping or round
according to DIN 8077, DIN 8078 and DIN 16962 and serve to pressing jig.
transport gases, liquids and solids.
The joining faces of the parts to be welded must not be damaged
Paying attention to the following instructions, it may be assumed and must be free from contaminations (e. g. dirt, grease and
that a melt flow rate MFR1) 190/5 of 0.4 - 1.0 g/10 min is suitable. chips).
This range roughly corresponds to the melt flow rate MFR 230/
2.16 of 0.2 - 0.6 g/10 min. 3.2 Cleaning
In the case of deviating melt flow rates, the proof of suitability For the manufacture of flawless welded joints, it is decisively
must be provided in the tensile creep test according to important that not only the joining faces but also the tools and the
DVS 2203-4 or Supplement 1. heated tools are clean and free from grease.
old designation MFI = melt flow index
512
3.2.1 Cleaning agents 4.1.2 Preparation for the welding
The cleaning fluid or cloths which have already been moistened The heated tool temperature necessary for the welding must be
with it in the factory and are kept in a lockable plastic box must checked before the beginning of the welding work. This is carried
consist of a solvent with 100% vaporisation, e. g. of 99 parts out, for example, with a quick-display temperature gauge for
ethanol with a degree of purity of 99.8% and one part MEK surface measurements with a contact area > 10 mm. The control
(methyl ethyl ketone, denaturation). Agents tested according to measurement must be taken within the heated tool area
DVGW VP 603 comply with this stipulation. The use of spirit may corresponding to the semi-finished product. So that a thermal
lead to a quality reduction because of the water contained in it. equilibrium can occur, the heated tool may be used, at the
earliest, ten minutes after the nominal temperature has been
The paper for the cleaning must be clean, unused, absorbent,
reached.
non-fraying and undyed. Ensure subsequent extraction.
For optimum welds, it is necessary to clean the heated tool
3.2.2 Cleaning of the heated tools according to Section 3.2.2 before every welding operation. The
The heated tools must be cleaned with paper before every anti-adhesive coating or covering of the heated tool must be
welding operation. No residues of cleaning agents or paper may undamaged in the working area.
remain on the heated tool. The respective joining forces or joining pressures must be
stipulated for the machines to be used. These may refer, for
3.2.3 Cleaning of the joining faces example, to information from the manufacturer or to calculated or
Before the chip-producing machining of the joining faces, it must measured values. In the case of pipe welding, it is also necessary
be ensured that the utilised tools and the workpieces are clean to read the movement force or movement pressure arising during
and free from grease beyond the welding area. If necessary, the slow movement of the workpiece off the display instrument of the
cleaning must be carried out with a cleaning agent. welding machine and to add this to the previously determined
joining force or to the joining pressure. Preference should be
The joining faces must be machined immediately before the given to electronically controlled machines – if at all possible,
beginning of the welding. with recording.
Any chips must be removed without touching the joining faces. The nominal wall thicknesses of the parts to be welded must
If the surface is soiled after the chip-producing machining (e. g. match in the joining region.
because of contact with the welder's hands), the welding faces Pipes and fittings must be aligned axially before they are
must be treated with a cleaning agent if an additional chip- clamped in the welding machine. The easy longitudinal mobility
producing machining operation is not possible for process-related of the part to be welded on must be ensured, for example, using
reasons. adjustable dollies or a swinging suspension.
Immediately before the welding, the faces to be joined must be
4 Heated tool butt welding subjected to chip-producing machining with a clean and grease-
free tool so that they have parallel faces in the clamped condition.
4.1 Heated tool butt welding of pipes, piping parts, fittings The permissible gap widths under the alignment pressure are
and panels shown in Table 1.
4.1.1 Process description Table 1. Maximum gap widths between the machined welding faces.
During heated tool butt welding, the joining faces of the parts to
be welded are aligned to the heated tool under pressure Pipe outside diameter d Gap width Panel width
(alignment), are subsequently heated up to the welding mm mm mm
temperature at a reduced pressure (heating-up) and, when the ≤ 355 0.5
heated tool has been removed (changeover), are joined together
under pressure (joining). Figure 1 shows the principle of the 400 ... < 630 1.0 ≤ 1,500
process. 630 ... < 800 1.3 > 1,500 ≤ 2,000
preparation 800 ... ≤ 1,000 1.5 > 2,000 ≤ 2,300
> 1,000 2.0 > 2,300 ≤ 3,000
The misalignment must be checked at the same time as the gap

width. The misalignment of the joining faces in relation to each
other must not exceed the permissible dimension of 0.1 x wall
thickness on the outside of the pipe or on the panel. A larger
pipe heated tool pipe misalignment results in a reduction in quality which restricts the
load-bearing capacity of the joint. In this case, an evaluation may
be carried out according to the DVS 2202-1 technical code taking
heating-up
account of the requirements on the joint.
The machined welding faces must not be either soiled or touched
by the welder's hands since another chip-producing machining
operation would otherwise be necessary. An additional
cleaning operation is not required and does not give rise to
any improvement in quality. Any chips which have fallen into
the pipe must be removed.
welding joint 4.1.3 Execution of the welding
In the case of heated tool butt welding, the faces to be joined are
heated up to the welding temperature using a heated tool and,
when the heated tool has been removed, are joined together
under pressure. The heated tool temperature is 210 ± 10°C. In
principle, it is necessary to strive for the upper temperature with
lower wall thicknesses and for the lower temperature with higher
Figure 1. Principle of heated tool butt welding using the example of wall thicknesses. The step-by-step sequence of the welding
pipes. operation is illustrated on Figure 2.
513
pressure possible, with a linear rise. The times necessary for this purpose
are shown in Table 2, Column 5. The joining pressure is
joining pressure 0.10 ± 0.01 N/mm².
alignment pressure
A mechanical load on the joint is permissible, at the earliest, after
the end of the cooling process. For this purpose, the full joining
heating-up pressure must be maintained during the cooling time at the
pressure ambient temperature (see Table 2, Column 5).
time Subject to the following prerequisites, it is permitted to shorten
changeover time
heating-up the cooling time by as much as 50%, i. e. joining pressure relief
time cooling time and removal of the welded part from the welding machine:
alignment joining pressure build-up time – the joint is manufactured in workshop conditions,
time
total joining time
– the removal from the welding machine and the temporary
total welding time storage cause only a slight load on the joint and
– the joining parts have wall thicknesses ≥ 15 mm.
Figure 2. Process steps in heated tool butt welding. Further processing with a full mechanical load on the joint may
only take place after complete cooling according to Table 2,
Alignment Column 5.
In this respect, the joining faces to be welded are pressed on to
A uniform double bead must exist after the joining. The bead
the heated tool until the entire faces are in contact with the
formation provides orientation with regard to the uniformity of the
heated tool with parallel faces. This can be recognised by the
welds with each other. Different bead formations may be caused
formation of the beads. The alignment is finished when the bead
by the various types of flow behaviour of the joined materials.
heights around the entire pipe circumference or on the entire top
The weldability may be assumed from the experience with the
side of the plate have reached the values specified in Table 2,
commercially available semi-finished PP products in the specified
Column 2. The bead heights are regarded as an indicator that the
MFR range, even if this may lead to asymmetric welding beads.
whole area of the joining faces is in contact with the heated tool.
K must always be > 0 (see Figure 3).
The alignment pressure of 0.10 N/mm² is effective throughout the
alignment operation.
Heating-up
For the heating-up, the faces must be in contact with the heated
tool at a low pressure. To this end, the pressure is reduced to
nearly zero (≤ 0.01 N/mm²). During the heating-up, the heat
penetrates into the faces to be welded and heats these up to the
welding temperature. The heating-up times are shown in Table 2,
Column 3.
Changeover
After the heating-up, the joining faces must be detached from the
heated tool which must be taken out without damaging or soiling
the heated joining faces. The joining faces must then be moved
together quickly until they almost touch. The changeover time
should be kept as short as possible (see Table 2, Column 4)
since the plastified faces would otherwise cool down. This would
exert a detrimental influence on the weld quality. Figure 3. Bead formation in the case of heated tool butt welding
(principle using the example of a pipe).
Joining
The faces to be welded should come into contact at a speed of For a short version of the processing instructions, see the
nearly zero. The required joining pressure is applied, if at all appendix.
Table 2. Guide values for the heated tool butt welding of pipes, fittings and panels made of PP at an outdoor temperature of approx. 20°C with
moderate air movement (intermediate values must be interpolated).
1 2 3 4 5
Alignment Heating-up Changeover Joining
Heated tool temperature 210 ± 10°C
Nominal wall Changeover Joining Cooling time under
Bead height at the heated tool time pressure joining pressure
thickness s
at the end of the alignment time (Heating-up (maximum build-up (minimum values)
(minimum values) p = ≤ 0.01 N/mm2) time) time p = 0.10 ± 0.01 N/mm²
(alignment p = 0.10 N/mm2)
mm mm s s s min
Up to 4.5 0.5 up to 135 5 6 6
4.5 ... 7 0.5 135 ... 175 5 ... 6 6 .. 7 6 ...12
7 ... 12 1.0 175 ... 245 6 ... 7 7 .. 11 12 ... 20
12 ... 19 1.0 245 ... 330 7 ... 9 11 ... 17 20 ... 30
19 ... 26 1.5 330 ... 400 9 ... 11 17 ... 22 30 ... 40
26 ... 37 2.0 400 ... 485 11 ... 14 22 ... 32 40 ... 55
37 ... 50 2.5 485 ... 560 14 ... 17 32 ... 43 55 ... 70
514
5 Sleeve welding with an incorporated electric heating The out-of-roundness of the pipe must not exceed 1.5% of the
element outside diameter, max. 3 mm, in the welding area.
Corresponding round pressing clamps must be used if
5.1 Process description necessary.
The joining faces (i.e. the surface of the pipe and the inside of the In the area of the welding zone, the complete surface of the pipe
fitting) overlap, are heated up to the welding temperature by or of the pipe spigot on the fitting must be subjected to chip-
electrical energy with the aid of resistance wires positioned in the producing machining. A rotating peeling device with constant wall
fitting (heater spiral) and are welded in this way (see Figure 4). thickness removal of approx. 0.2 mm should be used. Attention
machined must be paid to the formation of a small annular gap!
joining faces
The pipe end must be deburred on the inside and outside. Chips
must be removed without touching the joining face.
The fitting may only be removed from the protective packaging

immediately before the assembly.
insert If the machined pipe surface is contaminated after the chip-

fitting depth pipe producing machining, this must be cleaned according to Section
3.2.3. In this respect, it must be ensured that no contamination is
rubbed into the welding zone. The joining face of the fitting must
be cleaned according to Section 3.2.3.
It must be possible to check the insert depth of the pipe either

with a mark to be applied or using a suitable jig. The fitting must
not be tilted or pushed on to the pipe end with force (low-stress
joining plane assembly). The saddle piece must be tightly clamped on the pipe
with the aid of a suitable jig according to the information from the
manufacturer.
Figure 4. Sleeve welding with an incorporated electric heating element
(principle). The contact bushes for the connection of the welding cable must
be easily accessible.
5.2 Welding device
It is only allowed to use welding devices which are adapted to the The fitting and the pipe must be at the same temperature level
parts to be welded. Preference should be given to automatic before the welding. In the case of welding devices with automatic
welding devices – if at all possible, with recording. The welding temperature compensation, it must be ensured that the recorded
device must supply the welding parameters required for the fitting ambient temperature corresponds to the conditions at the
to be welded in each case, e. g. welding time, amperage and location of the welding. If necessary, the welding device as well
voltage. The device must be switched off automatically as soon as the pipe and the fitting must be protected from (for example)
as the necessary heat quantity has been supplied to the welding direct solar radiation.
zone.
5.3 Preparation for the welding
The correct insert depth must be checked on the basis of the
For the manufacture of flawless welded joints, decisive mark. If necessary, suitable measures or jigs must be used in
significance is attached to clean surfaces and to stress-free order to prevent any changes in the positions of the components
installation. The assembly of fittings is facilitated by the selection to be welded.
of pipes with restricted diameter tolerances according to
DIN 8077. Cables serve to connect the welding device with the fitting to be
For axial pipe joints, the pipes must, if necessary, be cut off at a welded. The welding cables must be attached in a weight-
right angle with a suitable tool. In the case of conical collapsing of relieved form. The contact faces must be clean. As a rule, the
the cut edge of the pipe, the unmachined pipe must exhibit the nom- welding device acquires the fitting data required for the welding
inal diameter d at the planned insert depth, at least in the region of by reading in a component-specific bar code. The displayed data
the heater spiral (Figure 5). If necessary, the pipe end must be (e. g. dimensions) must coincide with the component data. After
shortened correspondingly immediately before the welding. the welding operation has started, this proceeds automatically.
The welding duration is usually displayed by the welding device.
Just like the other data displayed by the device, it must also be
indicated on the welding record sheet unless the data is stored.
Pay attention to error messages! For example if the power supply

is interrupted, a prematurely terminated welding operation can be
repeated on one occasion in so far as there are no defects on the
fitting or on the welding device (error message) and the fitting
still allowed wrong manufacturer permits this. It is necessary to wait for the entire
cooling time before carrying out the welding once again.
The cables can be removed when the device has been switched
off. If there are any welding indicators on the fitting, these must
be checked. The joint may only be moved after the cooling.
Information about this is provided by the fitting manufacturer.
heater heater If the manufacturer provides any information about additional
spiral spiral cooling times (e. g. until the pressure test), attention must be paid
zone zone to this.
For a short version of the processing instructions, see the

Figure 5. Conical collapsing of the pipe end. appendix.
515

In the case of heated tool sleeve welding (see Figure 6), the pipe approx
and the fitting are welded in an overlap. The pipe end and the
fitting are heated up to the welding temperature with the aid of
sleeve-shaped and spigot-shaped heated tools and are
subsequently welded.
The heated tools and the fittings are dimensionally coordinated in
such a way that a joining pressures builds up during the joining.
Heated-tool-sleeve-welded joints with a pipe diameter up to
50 mm can be executed manually. In the case of diameters as
from 63 mm, the level of the joining force necessitates the use of
a welding jig. Figure 7. Bevelling of the pipe end.
preparation heated tool
Table 3. Dimensions for the pipe bevel and the insert depth.
Pipe outside diameter d Pipe bevel b Insert depth l

[mm] [mm] [mm]
16 13
20 14
25 16
heated spigot 2
fitting heated sleeve pipe 32 18
40 20
heating-up
50 23
63 27
75 31
90 3 35
110 41
welded joint
125 46
Before the beginning of the welding, the welding temperature of

250 - 270°C at the heated tools must be checked according to
Section 4.1.2.
The heated bush and the heated spigot must be free from
Figure 6. Heated tool sleeve welding (principle). contaminations and must be cleaned according to Section 3.2.2
before every welding operation. The anti-adhesive coating of the
6.2 Welding jigs heated spigot and the heated bush must be undamaged in the
welding area.
The heated tools are heated electrically and are coated anti-
adhesively. 6.4 Execution of the welding
6.3 Preparation for the welding For the heating-up, the fitting and the pipe are quickly and axially
pushed on to the tools attached to the heated tool as far as the
The fitting must be cleaned on the inside and the pipe on the stop in the case of machine welding or as far as the mark in the
outside according to Section 3.2. The joining faces of the parts to case of manual welding and are fixed. It is imperative to
be welded must be machined immediately before the beginning prevent the front face of the pipe from bumping into the end
of the welding. The pipe end must be bevelled according to of the heated bush. The heating-up time according to the time
Figure 7 and Table 3. The joining face of the pipe must be indicated in Table 4, Column 2 begins thereafter.
machined according to the information from the fitting supplier. In
the case of manual welds, the insert depth must then be marked When the heating-up time has elapsed, the fitting and the pipe
on the pipe end at the distance l according to Table 3. must be pulled off the heated tools with a jolt and must be pushed
together immediately as far as the stop or the mark without any
twisting (max. changeover time: see Table 4, Column 3).
In the case of manual welding, the joined parts must be kept in a
fixed position according to the time indicated in Table 4, Column
4. The joint may only be subjected to the stresses of the further
laying work when the cooling time (Table 4, Column 5) has
elapsed.
516
Table 4. Guide values for the heated tool sleeve welding of pipes and fittings made of PP at an outdoor temperature of 20°C with moderate air
movement.
1 2 3 4 5
Heating-up Changeover Cooling
Heated tool temperature 250 - 270°C
Pipe outside
Changeover time Cooling time
diameter d
Heating-up time for Heating-up time for (maximum time)
SDR2) 11, SDR 7.4 and SDR 66 SDR2) 17 and SDR 17.6
Fixed Total
mm s s s s min
16
5 6
20 4 2
25 7 1) 10
32 8
40 12 6 4
20
50 18
63 24 10
30
75 30 15 8 6
90 40 22 40
110 50 30 50
10 8
125 60 35 60
Because the wall thickness is too low, the welding process is not recommendable.
Standard Dimension Ratio ~ d/s (ratio of the outside diameter to the wall thickness).
For a short version of the processing instructions, see the appendix.
Various test procedures are applied for the individual welding

processes. A distinction is made between non-destructive and
destructive test procedures. They are listed in Table 5.
Depending on the agreement, checking and sampling operations
should be carried out on a random basis during the welding work.
Table 5. Test procedures for welded joints.
Sleeve welding with an incorpo-

Heated tool butt welding Heated tool sleeve welding
Test procedure rated electric heating element
Panels, pipes and fittings Pipes and fittings
Fittings
DVS 2202-1 DVS 2202-1
DVS 2202-1 Table 3 Table 2
Visual inspection
Table 1 The machining of the pipe surface must be visible beyond the
welding area.
Radiographic and
Applicable. Statement possible, for example, about voids, not about quality.
ultrasonic tests
DVS 2203-2
Tensile test Short-time tensile welding factor Not applicable
DVS 2203-1, Supplement 1
DVS 2203-4
Tensile creep test Tensile creep welding factor DVS 2203-4, Supplement 1
DVS 2203-5
Minimum bending angle according to
Technological DVS 2203-1, Supplement 3, Figs. 2 and 3 Not applicable
bending test
Minimum bending path according to
DVS 2203-1, Supplement 3, Figs. 8 and 9
DIN 16962-5, Section 5.4.3.1
Length of each pipe piece according to
Internal pressure Table 5 DIN 16962-5, Sections 3.2.3.1 and 4.2 at 95°C
creep test
Not meaningful for long-time welding
factor > 0.5.
517
Sleeve welding with an incorpo-

Heated tool butt welding Heated tool sleeve welding
Test procedure rated electric heating element
Fittings
Torsion shear test Not applicable
Also as a site test for pipe wall thicknesses ≥ 4 mm.
Radial peeling test Not applicable
Site test for pipe wall thicknesses ≥ 4 mm
DIN EN 12814-4, Section 8
Compression test Not applicable
Also suitable as a site test
Peel decohesion Not applicable
Not applicable DIN EN 12814-4, Section 7
test
8 Standards, technical codes and guidelines which are 9 Explanations

also applicable
The technical code was adjusted to the state of the art with
DIN 8077 Pipes made of polypropylene (PP); PP-H, regard to improved cleaning agents and to the development of
PP-B, PP-R and PP-RCT; dimensions larger piping parts. Non-contact heated tool welding is dealt with
DIN 8078 Pipes made of polypropylene (PP); PP-H, in DVS 2207-6.
PP-B, PP-R and PP-RCT; general quality The welding of thermoplastics at ambient temperatures < 5°C is
requirements and testing generally considered to be problematical. This relates not so
DIN EN 12814-4 Testing of welded joints between thermo- much to the material-specific properties of the plastic but, to a
plastics; Part 4: Peeling test greater extent, to the restricted dexterity of the welder. Therefore,
the prerequisite for open-air welding at any outdoor temperatures
DIN EN ISO 15013 Extruded panels made of polypropylene
(PP); requirements and test procedures is an environment which enables the welding personnel to
perform the individual work steps without any quality-reducing
DIN EN ISO15494 Plastic piping systems for industrial appli- influences. In this respect, it is necessary to pay attention to the
cations; polybutene (PB), polyethylene information from the manufacturers and to the dew point curve.
(PE) and polypropylene (PP); requirements The parts to be joined must exhibit an identical temperature level.
on piping parts and on the piping system; Trial welds must be produced and tested.
metric series
With regard to the condition of the pipe end, it must be ensured
DIN 16962 Pipe joints and piping parts for pressure that, within the framework of the welding preparations, any white
piping made of polypropylene (PP) frost, ice and moisture are removed from the area of the joining
DVGW VP 603 Test basis for cleaning agents and their re- zone (≥ 0.5 x fitting length) by supplying heat (e. g. hot gas
ceptacles for the preparation of welded device). Fittings must be stored in closed, frost-free rooms and
joints between polyethylene pipes may only be transported to the welding location in the number
DVS 2202-1 Defects in welded joints between thermo- required in each case.
plastics; characteristics, description and At present, a qualitative evaluation of sleeve-welded joints in the
evaluation internal pressure creep test is possible to an inadequate extent
DVS 2203-1 Testing of welded joints between thermo- only. In conjunction with the tensile creep test, an initial approach
plastics; test procedures – requirements is included in DVS 2203-6, Supplement 1 and in DVS 2207-15,
for explanations for Section 6.
Supplement 1 Requirements in the tensile test
Supplement 2 Requirements in the tensile creep test
Supplement 3 Requirements in the technological bending
test, bending angle / bending path
DVS 2203-2 -, tensile test
DVS 2203-4 -, tensile creep test
DVS 2203-4, -, tensile creep test; testing of sleeve-weld-
Supplement 1 ed joints between pipes
DVS 2203-5 Technological bending test
DVS 2203-6, Testing of joints between polymer materi-
Supplement 1 als; torsion shear and radial peeling tests
for joints manufactured by means of sleeve
welding with an incorporated electric heat-
ing element and heated tool sleeve welding
DVS 2208-1 Welding of thermoplastics; machines and
devices for the heated tool welding of
pipes, piping parts and panels
DVS 2212-1 Qualification testing of plastics welders;
Qualification Test Groups I and II
DVS 2207-15 Welding of thermoplastics; heated tool
made of PVDF
Betr.Sich.V Operational Safety Ordinance
518
Re. 4.1 Heated tool butt welding of pipes, piping parts, 4. Guarantee the roundness of the pipes using round pressing
fittings and panels clamps, permissible out-of-roundness: ≤ 1.5%, max. 3 mm.
Processing instructions (short version) 5. Clean the joining faces beyond the welding area with a
cleaning agent according to Sections 3.2.1 and 3.2.3 with
1. Create permissible working conditions, e. g. welding tent.
unused, absorbent, non-fraying and non-dyed paper.
2. Connect the welding device to the mains or to the alternating Machine the pipe surface in the welding area, if at all
current generator and check its function. possible with a rotating peeling device and wall thickness
3. Align and clamp the parts to be welded, e. g. with dollies. removal of approx. 0.2 mm. Remove the chips without
touching the pipe surface.
4. Close the pipe ends against draughts.
6. Clean the machined pipe surface (in so far as it is
5. Clean the joining faces beyond the welding area with a
contaminated subsequently) and, if necessary, also the
cleaning agent according to Sections 3.2.1 and 3.2.3 with inside of the fitting according to the information from the
unused, absorbent, non-fraying and non-dyed paper.
manufacturer with a cleaning agent according to Sections
Machine the joining faces, in the case of pipes using a plane
3.2.1 and 3.2.3 with unused, absorbent, non-fraying and
(for example).
non-dyed paper and ensure extraction.
6. Take out the plane in the case of a pipe welding machine.
7. Push the pipes into the fitting and check the insert depth with
7. Remove the chips from the welding area without touching a mark or using a suitable jig. Prevent any change in the
the joining faces. position of the pipe.
8. Check the plane parallelism by moving the joining faces 8. Connect the cables to the fitting in a weight-relieved form.
together (max. gap width according to Table 1).
9. Input the welding data (e. g. using a bar code reading pen),
9. Check the misalignment (max. 0.1 x wall thickness). check the displays on the device and start the welding
10. Check the heated tool temperature (210 ± 10°C). process.
11. Clean the heated tool with a cleaning agent according to 10. Check the correct welding sequence on the welding device
Sections 3.2.1 and 3.2.2 with unused, absorbent, non-fraying (e. g. by checking the display and, if present, the welding
and non-dyed paper and ensure extraction. indicators). Pay attention to error messages.
12. Determine the movement pressure or the movement force 11. Detach the cables from the fitting.
before every welding operation and make a note of it on the
welding record sheet. 12. Unclamping of the welded parts when the cooling time
according to the information from the manufacturer has
13. Determine the setting values for the alignment, heating-up elapsed. Remove the utilised holding jigs.
and joining pressures.
13. Complete the welding record sheet unless there was any
14. Stipulate the guide values according to Table 2. automatic recording.
15. Move the heated tool into the welding position.
16. Align the faces to the heated tool until a bead arises Re. 6 Heated tool sleeve welding
(according to Table 2, Column 2). Processing instructions (short version)
17. Heating-up at a reduced pressure ≤ 0.01 N/mm², heating-up 1. Create permissible working conditions, e. g. welding tent.
time according to Table 2, Column 3.
2. Connect the welding device to the mains or to the alternating
18. At the end of the heating-up, detach the joining faces to be current generator and check its function.
welded from the heated tool and move this out of the welding
position. 3. Clean the heated tools with a cleaning agent according to
Sections 3.2.1 and 3.2.3 with unused, absorbent, non-fraying
19. Within the changeover time (Table 2, Column 4), quickly and non-dyed paper.
move together the faces to be welded until they almost
touch. The faces must come into contact at a speed of nearly 4. Check the welding temperature (250 - 270°C).
zero. Immediately afterwards, build up the joining pressure 5. Clean all the non-machined joining faces with a cleaning
with a linear rise in the build-up time (Table 2, Column 5). agent according to Sections 3.2.1 and 3.2.3 with unused,
20. A bead must exist after the joining at a pressure of absorbent, non-fraying and non-dyed paper and ensure
0.10 N/mm². According to Figure 4, K must be > 0 at every extraction.
point. 6. Bevel the pipe end cut off at a right angle according to Figure
21. Cooling under the joining pressure according to Table 2, 7 and Table 3 or machine it according to the information from
Column 5. the fitting manufacturer. If necessary, mark the insert depth.
22. Unclamping of the welded parts when the cooling time has 7. Simultaneously push the fitting and the pipe on to the heated
elapsed. In the case of workshop work, see the joining in spigot or into the heated bush as far as the stop or the mark.
Section 4.1.3. Do not bump the pipe end into the end of the heated bush.
23. Complete the welding record sheet. 8. Comply with the heating-up time according to Table 4,
Column 2.
Re. 5 Sleeve welding with an incorporated electric
heating element 9. Pull the fitting and the pipe off the heated tools with a jolt,
immediately push them together as far as the mark or the
Processing instructions (short version) stop (for max. changeover time: see Table 4, Column 3) and
1. Create permissible working conditions, e. g. welding tent. fix them in this position (see Table 4, Column 4).
2. Connect the welding device to the mains or to the alternating 10. Let the joint cool down. Only subject the welded joint to
current generator and check its function. mechanical loads when the cooling time according to Table
4, Column 5 has elapsed.
3. Deburr the outside of the pipe end cut off at a right angle. In
the case of excessively pronounced collapsing of the pipe 11. Complete the welding record sheet
end, shorten the pipe. See Figure 5.
519
520
Welding record sheet for the heated tool welding above ground Material Page of
of pipes underground
Constructor Executing company Welding device: Weather conditions: Protection mesures:
1 = sun 1 = none
Order description Name of welder ID-No. Manufacturer: 2 = dry 2 = umbrella
No. of Order Name and company of welding supervisor Machine-No.: 4 = wind 4 = heating
Year built: I several Conditions apply, order of numbers as above

Seam Date Pipe Measured heating- Moving Joining Parameters Heating-up Changeover Joining Cooling time Ambient Key-number
No. dimension element temperature pressure pressure time time pressure under joining temperature
ød×s (Machine table) Alignment Heating up Joining built-up time pressure weather protection
min max
[mm] [ C] [ C] [bar] [bar] [bar] [bar] [bar] [s] [s] [s] [min] [ C]
From control-interval, frequency see section 4.2.

Values from manufacturer of welding machine or from machine-check plus moving pressure.
Insert measured values.
Welding record sheet for heated tool butt welding of panels Material Sheet of
Building sponsor Executing company Welding device:
Order (description) Name of welder ID-number Manufacturer:

Type:
Number of order Name and company of supervisor Number of machine:
Year of building:
Seam Date Thickness Measured Reference values Heating-up Changeover Joining Cooling time Temperature Comments
number of sheet heated tool time time pressure under joining of environment
temperature Alignment Heating-up Joining build-up time pressure
[mm] [ C] min/max [bar] [bar] [bar] [s] [s] [s] [s] [ C]
From control-interval, frequence see chapt. 4.2.

Values from manufacturer of welding machine or from machine-check.
Measured values.
521
522
Welding record sheet for electrofusion welding o above ground Material Page of
of pipes and fittings o underground
Building sponsor Executing company Welding device: Weather conditions Protection
1 = sun 1 = none
Order (description) Name of welder ID-number Manufacturer: 2 = dry 2 = umbrella
Number of order Name and company of supervisor Number of machine: 4 = wind 4 = heating
Year built: If more than one condition applies order of numbers as above
Seam Date Pipe Fitting data Adjustment of device Resistance Induced Welding time Temperature Key-number Operating conditions
number demension of fitting voltage of
ød×s A B Serial manual automatic Joining Cooling environment Weather Protection Line- Gene-
[mm] number [Ohm] [Volt] [s] [s] [ C] powered rator

Values on agreement. A = Manufacturers sign B = Fitting identification

Measured values. 1 = Socket 2 = Elbow 3 = Tee 4 = Reducer
5 = Saddle 6 = Cap 7 = Transition piece
Welding record sheet for heated tool socket welding o above ground Material Page of
of pipes and fittings o underground
Building sponsor Executing company Welding device: Weather conditions Protection
1 = sun 1 = none
Order (description) Name of welder ID-number Manufacturer: 2 = dry 2 = umbrella
Number of order Name and company of supervisor Number of machine: 4 = wind 4 = heating
Year built: If more than one condition applies order of number as above
Seam Date Pipe Fitting data Measured Heating Changeover Cooling time Temperature Key-number Comments
number dimension heated tool time time of
ød×s A B Serial temperature fixed total environment Weather Protection
number (spigot/socket)
[mm] [ C] [s] [s] [s] [min] [ C]

Values on agreement. A = Manufacturers sign B = Fitting identification

Measured values. 1 = Socket 2 = Elbow 3 = Tee 4 = Reducer
5 = Saddle 6 = Cap 7 = Transition piece
523
File: D:\Eigene Dateien\Kunden\DVS\Ri+Me\2207\2207-12\e2207-12.fm
Erstellt am:
15.10.2008
16.10.2008
January 2009

FÜR SCHWEISSEN UND Heated tool welding of pipes, piping parts Technical Code
VERWANDTE VERFAHREN E.V. and panels made of PVC-U DVS 2207-12
Translation of the German edition from December 2006
Contents: heated tool butt welding of panels as well as to pipeline

construction.
The machines and jigs used for the welding must comply with the
requirements in DVS 2208-1.
3 Measures before the welding
3.2 Cleaning 3 Measures before the welding
3.2.1Cleaning agents
3.2.2Cleaning of the heated tools 3.1 Prerequisites for the welding
3.2.3Cleaning of the joining faces
4 Heated tool butt welding of pipes, piping parts, fittings and The immediate welding area must be protected from
panels unfavourable weathering influences (e. g. wind or the action of
4.1 Process description moisture). If suitable measures (e. g. preheating, tenting or
4.2 Preparation for the welding heating) ensure conditions permissible for the welding, the work
may be carried out at any outdoor temperature – provided that

5 Testing of the welded joints the dexterity of the welder is not hindered (see the explanations).
6 Standards, technical codes and guidelines which are also If necessary, additional evidence must be provided by manufacturing
applicable trial welds in the specified conditions (see Section 5).
7 Explanations If the semi-finished product is heated non-uniformly due to solar
Appendix: Processing instructions (short versions) radiation, the temperatures must be equalised by covering the
Welding record sheets area of the welding point in good time. It is necessary to avoid
any draught-induced cooling during the welding operation. When
1 Scope of application pipes are welded, the pipe ends must be closed in addition.
This technical code applies to the heated tool butt welding of and must be free from contaminations (e. g. dirt, grease and
panels according to DIN EN ISO 1163-1 for the fabrication of chips).
tanks and construction elements as well as of pipes and fittings
which are made of PVC-U and serve to transport gases, liquids 3.2 Cleaning
and solids.
For the manufacture of flawless welded joints, it is decisively
Paying attention to the following instructions and on the basis of important that not only the joining faces but also the tools and the
the practical experience, it may be assumed that panels heated tools are clean and free from grease.
according to ISO 11833-1, Group 2 and DIN 16927 as well as
pipes and fittings according to DIN 8061 and DIN 8062 are 3.2.1 Cleaning agents
suitable. If necessary, reference may be made to the data sheets
of the suppliers of the semi-finished products – in cases of doubt, The cleaning fluid or cloths which have already been moistened
Works Certificate 2.1 according to DIN EN 10204. with it in the factory and are kept in a lockable plastic box must
consist of a solvent with 100 % vaporisation, e. g. of 99 parts
ethanol with a degree of purity of 99.8 % and one part MEK
2 General requirements (methyl ethyl ketone, denaturation). Agents tested according to
DVGW VP 603 comply with this stipulation. The use of spirit may
The quality of the welded joints is dependent on the qualification lead to a quality reduction because of the water contained in it.
of the welders, on the suitability of the utilised machines and jigs
The paper for the cleaning must be clean, unused, absorbent,
as well as on the compliance with the technical codes for
non-fraying and undyed.
welding. The weld can be tested using non-destructive and/or
destructive procedures.
3.2.2 Cleaning of the heated tools
The welding work must be monitored. The contracting parties The heated tools must be cleaned with a cleaning cloth or paper
must reach agreement on the type and scope of the monitoring. It
before every welding operation. No residues of cleaning agents
is recommended to document the process data on welding
or paper may remain on the heated tool. Ensure subsequent
record sheets (for a specimen, see the appendix) or on data
extraction.
carriers.
Within the framework of the quality assurance, it is recommended 3.2.3 Cleaning of the joining faces
to manufacture and test trial welds in the given working Before the chip-producing machining of the joining faces, it must
conditions before commencing and during the welding work.
be ensured that the utilised tools and the workpieces are clean
Every welder must be trained and must possess a valid and free from grease beyond the welding area. If necessary, the
qualification certificate. The planned area of application may cleaning must be carried out with a cleaning agent. Ensure
determine the type of the qualification. DVS 2212-1 applies to the subsequent extraction.
524
The joining faces must be machined immediately before the given to electronically controlled machines – if at all possible,
beginning of the welding. with recording.
Any chips must be removed without touching the joining faces. The nominal wall thicknesses of the parts to be welded must
match in the joining region.
If the surface is soiled after the chip-producing machining (e. g.
because of contact with the welder's hands), the welding faces Pipes and fittings must be aligned axially before they are
must be treated with a cleaning agent if an additional chip- clamped in the welding machine. The easy longitudinal mobility
producing machining operation is not possible for process-related of the part to be welded on must be ensured, for example, using
reasons. adjustable dollies or a swinging suspension.
subjected to chip-producing machining with a clean and grease-
4 Heated tool butt welding of pipes, piping parts, fittings free tool so that they have parallel faces in the clamped condition.
and panels The permissible gap widths under the alignment pressure are
shown in Table 1.
During heated tool butt welding, the faces of the parts to be Table 1. TMaximum gap widths between the machined welding
welded are aligned to the heated tool under pressure (alignment), faces.
are subsequently heated up to the welding temperature at a
reduced pressure (heating-up) and, when the heated tool has Pipe outside diameter d Gap width Panel width
been removed (changeover), are joined together under pressure mm mm mm
(joining). Figure 1 shows the principle of the process. ≤ 63 0.5 –
preparation > 63 ... ≤ 110 1.0 ≤ 1,500
> 110 ... ≤ 225 1.3 > 1,500 ≤ 2,000
> 225 ... ≤ 400 1.5 > 2,000 ≤ 2,300
– 2.0 > 2,300 ≤ 3,000
pipe heated tool pipe The misalignment must be checked at the same time as the gap
heating-up other must not exceed the permissible dimension of 0.1 x wall
thickness on the outside of the pipe or on the panel. The
objective must be a minimum misalignment. A larger
misalignment results in a reduction in quality which restricts the
load-bearing capacity of the joint. In this case, an evaluation may
be carried out according to the DVS 2202-1 technical code taking
account of the requirements on the joint.
welding joint The machined welding faces must not be either soiled or touched
operation would otherwise be necessary. An additional cleaning
operation is not required and does not give rise to any
improvement in quality. Any chips which have fallen into the pipe
must be removed.

Figure 1. Principle of heated tool butt welding using the example of In the case of heated tool butt welding, the faces to be joined are
pipes.
heated up to the welding temperature using a heated tool and,
4.2 Preparation for the welding under pressure. The heated tool temperature is 230 ± 8°C. The
The heated tool temperature necessary for the welding must be step-by-step sequence of the welding operation is illustrated on
checked before the beginning of the welding work. This is carried Figure 2.
out, for example, with a quick-display temperature gauge for
surface measurements with a contact area with an edge length of
approx. 10 mm. The control measurement must be taken within Pressure
the heated tool area corresponding to the semi-finished product.
So that a thermal equilibrium can occur, the heated tool may be Alignment pressure Joining pressure
used, at the earliest, ten minutes after the nominal temperature 0.60
has been reached.
For optimum welds, it is necessary to clean the heated tool Heating-up
according to Section 3.2.2 before every welding operation. The pressure
0.01
anti-adhesive coating or covering of the heated tool must be Time
Changeover time
undamaged in the working area.

The respective joining forces or joining pressures must be Heating-up time Cooling time
stipulated for the machines to be used. These may refer, for Alignment Joining pressure build-up time
example, to information from the manufacturer or to calculated or time
Total joining time
measured values. In the case of pipe welding, it is also necessary
to read the movement force or movement pressure arising during Total welding time
slow movement of the workpiece off the display instrument of the
welding machine and to add this to the previously determined
joining force or to the joining pressure. Preference should be Figure 2. Process steps in heated tool butt welding.
525
Alignment A mechanical load on the joint is permissible, at the earliest, after

In this respect, the joining faces to be welded are pressed on to pressure must be maintained during the cooling time at the
the heated tool until the entire faces are in contact with the ambient temperature (see Table 2, Column 5).
formation of the beads. The alignment is finished when the bead A uniform double bead must exist after the joining. The bead
heights around the entire pipe circumference or on the entire top formation provides orientation with regard to the uniformity of the
side of the panel have reached the values specified in Table 2, welds with each other. Different bead formations may be caused
Column 2. The bead heights are regarded as an indicator that the by the different types of flow behaviour of the joined materials.
whole area of the joining faces is in contact with the heated tool. On the basis of the experience with the commercially available
The alignment pressure of 0.60 N/mm² is effective throughout the semi-finished PVC-U products according to the standards, it may
alignment operation. be assumed that these are weldable even if this may lead to
asymmetric welding beads. K must always be > 0 (see Figure 3).
Heating-up
nearly zero (≤ 0.01 N/mm²). During the heating-up, the heat
Column 3.
Changeover
heated tool which must be taken out without damaging or soiling
together quickly until they almost touch. The changeover time Figure 3. Bead formation in the case of heated tool butt welding
should be kept as short as possible (see Table 2, Column 4) (principle using the example of a pipe).
exert a detrimental influence on the weld quality. For a short version of the processing instructions, see the appendix.
Joining
The faces to be welded should come into contact at a speed of 5 Testing of the welded joints
nearly zero. The required joining pressure is applied, if at all
possible, with a linear rise. The times necessary for this purpose Various test procedures are applied for the individual welding
are shown in Table 2, Column 5. The joining pressure is processes. A distinction is made between non-destructive and
0.60 ± 0.01 N/mm². The low melt viscosity demands exact control destructive test procedures. They are listed in Table 3.
of the joining pressure build-up in order to obtain a sufficient Depending on the agreement, checking and sampling operations
melting zone depth. should be carried out on a random basis during the welding work.
Table 2. Guide values for the heated tool butt welding of pipes, fittings and panels made of PVC-U at an outdoor temperature of approx. 20°C
with moderate air movement (intermediate values must be interpolated).
1 2 3 4 5
thickness
s Heated tool temperature 230 ± 8°C
Bead height at the Heating-up time Changeover time Joining Cooling time
heated tool at the = 15 x wall thickness (maximum time) pressure = 2 x wall thickness
end of the alignment (heating-up build-up time under joining pressure
time p ≤ 0.01 N/mm2) = 1+0.5 x wall p = 0.60 N/mm2 ± 0.01
(minimum values) thickness (minimum values)
(alignment
p = 0.60 N/mm2)
mm mm s s s min
1.9 28.5 2 4
3 0.5 45 6
3
4 60 8
6 90 4 12
8 1.0 120 5 16
≤2
10 150 6 20
12 180 7 24
15 225 9 30
1.5
20 300 11 40
25 375 14 50
526
Table 3. Test procedures for welded joints. DIN 16963-5 Pipe joints and fittings for pressure piping made
of PE – General quality requirements and
Test Heated tool butt welding testing
procedure Panels, pipes and fittings
DVS 2202-1 Defects in welded joints between thermoplastics
Visual DVS 2202-1, Table 1 – Characteristics, description and evaluation
inspection DVS 2203-1 Testing of welded joints between thermo-
Radiographic DVS 2206 applicable; plastics; test procedures – requirements
and ultrasonic Statement possible, for example, about voids, Supplement 1 Requirements in the tensile test
tests not about quality Supplement 2 Requirements in the tensile creep test
Tensile test DVS 2203-2; Supplement 3 Requirements in the technological bending test,
bending angle / bending path
Short-time tensile welding factor according to
DVS 2203-1, Supplement 1 DVS 2203-2 –, tensile test
DVS 2203-4 –, tensile creep test
Tensile creep DVS 2203-4;
test DVS 2203-5 –, technological bending test
Tensile creep welding factor according to
DVS 2206 Testing of components and structures made of
thermoplastics
Technological DVS 2203-5; DVS 2208-1 Welding of thermoplastics – Machines and
bending test Minimum bending angle according to devices for the heated tool butt welding of
DVS 2203-1, Supplement 3, Figs. 5 and 6 pipes, piping parts and panels
Minimum bending path according to DVS 2212-1 Qualification testing of plastics welders –
DVS 2203-1, Supplement 3, Figs. 11 and 12 Qualification Test Groups I and II
DVGW VP 603 Provisional test basis for cleaning agents and
Internal With reference to DIN 16963-5, Section their receptacles for the preparation of welded
pressure 5.4.3.1; length of each pipe piece according to joints between polyethylene pipes
creep test Table 6
Testing temperature: 60°C, testing stress:
11.3 N/mm², creep rupture time: ≥ 200 hours
Not meaningful for long-time tensile welding 7 Explanations
factor > 0.5
The technical code was elaborated according to the state of the
art.
6 Standards, technical codes and guidelines which are
The welding of thermoplastics at ambient temperatures below
also applicable
5°C is generally considered to be problematical. This relates not
ISO 11833-1 Plastics – Panels made of unplasticised poly- so much to the material-specific properties of the plastic but, to a
vinyl chloride – Panels with a thickness greater greater extent, to the restricted dexterity of the welder. Therefore,
than 1 mm the prerequisite for open-air welding at any outdoor temperatures
is an environment which enables the welding personnel to
DIN EN ISO Plastics – Unplasticised polyvinyl chloride perform the individual work steps without any quality-reducing
1163-1 (PVC-U) moulding materials – Designation influences. In this respect, it is necessary to pay attention to the
system and basis for specifications information from the manufacturers and to the dew point curve.
DIN EN 10204 Metallic products – Types of test certificates The parts to be joined must exhibit an identical temperature level.
DIN 8061 Pipes made of unplasticised polyvinyl chloride – Trial welds must be produced and tested.
General quality requirements With regard to the condition of the pipe ends, it must be ensured
DIN 8062 Pipes made of unplasticised polyvinyl chloride – that, within the framework of the welding preparations, any white
Dimensions frost, ice and moisture are removed from the area of the joining
zone (≥ 0.5 x fitting length) by supplying heat (e. g. hot gas
DIN 16927 Panels made of unplasticised polyvinyl chloride
device). Fittings must be stored in closed, frost-free rooms and
– Technical terms of delivery
may only be transported to the welding location in the number
required in each case.
527
Appendix: Processing instructions (short versions) 14. Determine the setting values for the alignment, heating-up
Re. 4.1 Heated tool butt welding of pipes, piping parts,
fittings and panels 15. Stipulate the guide values according to Table 2.
Processing instructions (short version)
1. Create permissible working conditions, e. g. welding tent.
2. Connect the welding device to the mains or to the alternating 17. Align the faces to the heated tool until a bead arises
current generator and check its function. (according to Table 2, Column 2).
3. Align and clamp the parts to be welded, e. g. with dollies. 18. Heating-up at a reduced pressure ≤ 0.01 N/mm², heating-up
4. Close the pipe ends against draughts. time according to Table 2, Column 3.
5. Clean the joining faces beyond the welding area with a
19. At the end of the heating-up, detach the joining faces to be
cleaning agent according to Section 3.2.1 with unused,
welded from the heated tool and move this out of the welding
absorbent, non-fraying and non-dyed paper.
position.
6. Machine the joining faces, in the case of pipes using a plane
(for example). 20. Within the changeover time (Table 2, Column 4), quickly
7. Take out the plane in the case of a pipe welding machine. move together the faces to be welded until they almost
touch. The faces must come into contact at a speed of nearly
8. Remove the chips from the welding area without touching zero. Immediately afterwards, build up the joining pressure
the joining faces. with a linear rise in the joining pressure build-up time (Table
9. Check the plane parallelism by moving the joining faces 2, Column 5).
21. A bead must exist after the joining at a pressure of 0.60 N/
10. Check the misalignment (max. 0.1 x wall thickness). mm². According to Figure 3, K must be > 0 at every point.
11. Check the heated tool temperature (230 ± 8°C).
22. Cooling under the joining pressure according to Table 2,
12. Clean the heated tool with a cleaning agent according to Column 5.
Sections 3.2.1 and 3.2.2 with unused, absorbent, non-
fraying and non-dyed paper and ensure extraction. 23. Unclamping of the welded parts when the cooling time has
13. Determine the movement pressure or the movement force elapsed.
welding record sheet. 24. Complete the welding record sheet.
528
Welding record sheet for the heated tool welding of Material Page of
panels
Constructor Executing company
Welding device:
Manufacturer:
Job description Name of welder ID-No.
Type:
Machine-No.:
No. of job Name and company of welding supervisor
Year built:
Seam Date Panel thickness Measured heating- Parameters Heating-up Changeover Joining pressure Cooling time Ambient- Remarks
No. element temperature time time built-up time under joining temperature
Alignment Heating-up Joining pressure
min max
[mm] [ C] [ C] [bar] [bar] [bar] [s] [s] [s] [min] [ C]

Values from manufacturer of welding machine or from machine-check.
529
530
Welding record sheet for the heated tool welding above ground Material Page of
of pipes underground
Constructor Executing company Welding device: Weather conditions: Protection mesures:
1 = sun 1 = none
Order description Name of welder ID-No. Manufacturer: 2 = dry 2 = umbrella
No. of Order Name and company of welding supervisor Machine-No.: 4 = wind 4 = heating
Year built: If several Conditions apply, order of numbers as above

Seam Date Pipe Measured heating- Moving Joining Parameters Heating-up Changeover Joining Cooling time Ambient Key-number
No. dimension element temperature pressure pressure time time pressure under joining temperature
ød×s (Machine table) Alignment Heating up Joining built-up time pressure weather protection
min max
[mm] [ C] [ C] [bar] [bar] [bar] [bar] [bar] [s] [s] [s] [min] [ C]

Values from manufacturer of welding machine or from machine-check plus moving pressure.
November 2012

FÜR SCHWEISSEN UND Heated tool welding of pipes, piping parts Technical Code
VERWANDTE VERFAHREN E.V. and panels made of PVC-C DVS 2207-13
Contents: The welding work must be monitored. The contracting parties

must reach agreement on the type and scope of the monitoring. It
1 Scope of application is recommended to document the process data on welding record
2 General requirements sheets (for specimens, see the appendix) or on data carriers.
to manufacture and test trial welds in the given working conditions
3.2 Cleaning
before commencing and during the welding work.
3.2.2 Cleaning of the heated tools Every welder must be trained and must possess a valid qualifica-
3.2.3 Cleaning of the joining faces tion certificate according to the DVS 2212-1 guideline for PVC-U
4 Heated tool butt welding in the WZ and WF processes as well as, at present, an HS pro-
4.1 Process description cess with another material (requirements for PVC-C are under
4.2 Preparation for the welding preparation). The planned area of application may determine the
4.3 Execution of the welding type of the qualification.
4.3.1 Heated tool temperature
4.3.2 Alignment
4.3.3 Heating-up 3 Measures before the welding
4.3.4 Changeover
4.3.5 Joining pressure build-up time 3.1 Prerequisites for the welding
4.3.6 Joining The welding area must be protected from unfavourable weather-
5 Testing of the welded joints ing influences (e.g. the action of moisture, great air currents and
6 Literature temperatures below + 5°C). If suitable measures (e.g. preheating
7 Explanation or heated assembly tents) ensure that a semi-finished product
Appendix: Processing instructions (short version) temperature sufficient for the welding can be complied with, the
Welding record sheets work may be carried out at any outdoor temperature – provided
that the handling of the welder is not hindered. In any case, it is
recommendable to provide additional evidence by manufacturing
1 Scope of application trial welds in the conditions of the construction measure (see
Section 5).
This technical code applies to the heated tool butt welding of
panels, pipes and piping parts made of PVC-C. If the semi-finished product is heated non-uniformly due to solar
The PVC-C panels are used for the fabrication of storage and area of the welding point in good time. It is necessary to avoid
process tanks and miscellaneous construction elements by means any draught-induced cooling or non-uniform heat distribution during
of heated tool butt welding. These components are predominantly the welding operation. When pipes are welded, it is recommended
utilised in the field of the storage of liquids and solids as well as in to close the pipe ends in addition.
the field of process chemistry.
The PVC-C panels and piping parts must comply with the DVS
and must be free from contaminations (e.g. dirt, grease, deposits,
2205-1 technical code, Supplement 9 and Supplement 11, as well
chips etc.).
as with the properties specified for compounds in ASTM D 1784-03,
Cell 23448. The Vicat softening temperature must exceed 105°C.
3.2 Cleaning
The fittings made of PVC-C must exhibit the same properties as
For the manufacture of flawless welded joints, it is decisively im-
the piping. If these are not available, it is recommended to fabricate
portant that not only the joining faces but also the tools and the
these from pipes. Piping and fittings predominantly serve to trans-
heated tools are clean and free from grease.
port liquids, gases and solids.
2 General requirements The cleaning fluid or the cloths which have been moistened with
cleaning fluid in the factory and are kept in a lockable plastic box
The quality of the welded joints is dependent on the qualification must consist of a solvent with 100 % or complete vaporisation.
of the welders, on the suitability of the utilised machines and jigs For example, the cleaning fluid consists of 99 parts ethanol with a
as well as on the compliance with the technical codes for welding. degree of purity of 99.8 % and one part MEK (methyl ethyl ketone
The weld can be tested using non-destructive and/or destructive for denaturation). Agents tested according to DVGW VP 603
procedures. comply with this stipulation. If commercially available spirit which
531
has a lower purity and may contain other additives is used, this 4.2 Preparation for the welding
may lead to a quality reduction due to the water contained in it
and to other contaminations. The heated tool temperature necessary for the welding must be
checked before the beginning of the welding work. This is carried
The paper for the cleaning must be clean, unused, absorbent, out, for example, with a quick-display temperature gauge for sur-
non-fraying and undyed. face measurements. The control measurement must be taken in
the working area of the heated tool for the corresponding semi-
3.2.2 Cleaning of the heated tools finished product. So that a thermal equilibrium can occur, the
The heated tools must be cleaned with cleaning cloths or paper heated tool may be utilised, at the earliest, ten minutes after the
before every welding operation. No residues of the cleaning agent nominal temperature has been reached. It is recommended to
or of the paper may remain on the heated tool. Ensure subsequent record the temperature measurement at several positions in the
extraction. heated tool area used for the welding operation concerned in order
to check the uniformity of the temperature distribution.
3.2.3 Cleaning of the joining faces In order to achieve optimum welds, it is necessary to clean the
Before the chip-producing machining of the joining faces, it must heated tool with absorbent, non-fraying and non-dyed paper before
be ensured that the utilised tools and the workpieces are clean every welding operation. The anti-adhesive coating or covering of
and free from grease beyond the welding area. If necessary, the the heated tool must be undamaged in the working area.
cleaning must be carried out with a cleaning agent. Ensure sub-
sequent extraction. The respective joining forces or joining pressures must be stipu-
lated for the machines to be utilised. These may refer, for example,
The joining faces must be machined immediately before the be- to information from the manufacturer or to calculated or measured
ginning of the welding. values. In the case of pipe welding, it is also necessary to read
Immediately before the welding, the faces to be joined must be the movement force or movement pressure arising during slow
subjected to chip-producing machining with a clean and grease- movement of the workpiece off the display instrument of the
free tool so that they have parallel faces in the clamped condition. welding machine and to add this to the previously determined
In the case of fresh saw cuts, it is not necessary to mechanically joining force or to the joining pressure.
clean the welding faces of panels. It is urgently advised not to In the joining area, the nominal wall thicknesses of the parts to be
perform any cleaning with chemical agents or solvents. welded must be within the tolerances in DIN EN ISO 15013 for
Any chips which may be present must be removed without touch- plates and in DIN 8079 or DIN EN ISO 15493 for pipes.
ing the joining faces.
Pipes and fittings must be aligned axially before they are clamped
in the welding machine. The easy longitudinal mobility of the part
4 Heated tool butt welding to be welded on must be ensured, for example, using adjustable
dollies or a swinging suspension.
4.1 Process description The permissible gap widths a of the parts to be joined before the
In the case of heated tool butt welding, the joining faces of the alignment are shown in Table 1.
parts to be welded are aligned at the heated tool under pressure
(alignment), are subsequently heated at a reduced pressure Table 1. Maximum gap widths between the machined welding faces.
(heating-up) and, when the heated tool has been removed
(changeover), are joined under pressure (joining). Fig. 1 shows Panel width Pipe diameter Da Gap width
[mm] [mm] [mm]
the principle of the process.
–  63 0.25
All the welds must be executed with machines and devices which
satisfy the requirements according to the DVS 2208-1 technical  1,500 > 63 to  110 0.50
code. > 1,500 to  2,000 > 110 to  225 0.70
> 2,000 to  2,300 > 225 to  400 0.80
Preparation > 2,300 to  3,000 1.00

Pipe Pipe thickness s on the outside of the pipe or on the panel. If the mis-
Heated tool alignment is > 0.1 x s, this results in a distinct quality reduction
which substantially restricts the load-bearing capacity of the welded
joint due to the notch sensitivity of the PVC-C. In this case, an
Heating-up evaluation should be carried out according to the DVS 2202-1
technical code taking account of the requirements on the welded
joint and of the structure.
by the welder's hands since another cleaning operation according
Bead caused by the heating-up
to Section 3.2.3 would otherwise be necessary.
If piping parts are welded, it must be ensured that any chips
Welded joint which have fallen into the pipe are removed after the planing opera-
tion without soiling the welding faces.
Welding bead In the case of heated tool butt welding, the faces to be joined are
heated up to the welding temperature using the heated tool and,
Figure 1. Principle of heated tool butt welding using the example of a pipe when the heated tool has been removed, are joined together un-
weld. der pressure (Fig. 2).
532
.
Alignment Joining
. Heating-up
Pressure in N/mm²
Alignment time Heating-up time Cooling time
Changeover time Joining pressure build-up time
Figure 2. Process steps in the case of heated tool butt welding.
4.3.1 Heated tool temperature The alignment pressure of 0.50 ± 0.01 N/mm² is effective through-
out the alignment operation.
For wall thicknesses up to 5 mm, the heated tool temperature is
230°C. Wall thicknesses > 5 mm are welded at a reduced heated
4.3.3 Heating-up
tool temperature according to Fig. 3.
The permissible temperature tolerance of the heated tool is ± 4 K.
The step-by-step sequence of the welding operation is illustrated
nearly zero (0.01 N/mm²). Here, it is recommended to enter a
on Fig. 3.
maximum value, e.g. 0.05 N/mm². During the heating-up, the heat
240 penetrates into the faces to be welded and heats these up to the
Heated tool temperature [°C]

235 Column 3.
Upper limit
230 4.3.4 Changeover
225 After the heating-up, the joining faces must be detached from the
Lower limit heated tool. The heated tool must be taken out without damaging
220 or soiling the heated joining faces. The joining faces must then be
215 moved together quickly until they almost touch. The changeover
time must be kept under two seconds (see Table 2, Column 4)
210 since the plastified areas would otherwise cool down. This would
0 5 10 15 20 25 30 exert a negative influence on the welding quality.
Wall thickness [mm] 4.3.5 Joining pressure build-up time
Figure 3. Heated tool temperatures as a function of the wall thickness. The joining pressure build-up time is four seconds, irrespective of
the wall thickness of the parts to be welded. In this case, the
4.3.2 Alignment pressure should have a linear rise.
During the alignment, the joining faces to be welded are pressed
on to the heated tool until the entire faces are in contact with the 4.3.6 Joining
heated tool with parallel faces. This can be recognised by the for- The faces to be welded should come into contact at a speed
mation of the alignment beads. The alignment is finished when of nearly zero. The required joining pressure is applied without
the bead heights around the entire pipe circumference or on the delay with a rise as linear as possible. The joining pressure is
entire top side of the plate have reached the values specified in 0.50 ± 0.01 N/mm².
Table 2, Column 2. The bead development on the heated tool is
regarded as an indicator that the whole area of the joining faces
is in contact with the heated tooI.
533
Table 2. Guide values for the heated tool butt welding of pipes, fittings and panels made of PVC-C at an outdoor temperature of 20°C with
moderate air movement (no draughts) – intermediate values must be interpolated.
1 2 3 4 5
thickness s
Bead height Pressure nearly Joining pressure Cooling time
(at the heated tool at the end zero, build-up time = 2 x wall thickness
of the alignment time) p = 0.01 N/mm² under joining pressure
(minimum pressure for the p = 0.50 N/mm² ± 0.01 N/mm²
alignment: (minimum values)
p = 0.50 N/mm² ± 0.01 N/mm²)
[mm] [mm] [s] [s] [min]
2 28 4
3 0.5 42 6
4 56 8
6 86 12
8 1.0 122 16
2s 4
10 168 20
12 222 24
15 294 30
1.5
20 392 40
25 490 50
The joining pressure must be maintained during the cooling time Table 3. Possible test procedures for welded joints.
(see Table 2, Column 5). Increased mechanical stresses during
or immediately after the unclamping are only permissible after Test procedure Heated tool butt welding
prolonged cooling. Panels, pipes and fittings
The assembly or the further processing may only take place after Visual inspection DVS 2202-1 technical code, Table 1
the complete cooling of the weld. DVS 2206-1 technical code
After the joining, a double bead as uniform as possible must exist Tensile test DVS 2203-2 technical code
around the entire circumference. Different bead formations may Short-time tensile welding factor
be caused by the different types of flow behaviour of the joined DVS 2203-1 technical code, Supplement 1
materials. On the basis of the experience with the commercially Tensile creep test DVS 2203-4 technical code
available PVC-C parts until now, the following is applicable: If Tensile creep welding factor
PVC-C pipes and fittings comply with the DIN 8079/80, DIN EN DVS 2203-1 technical code, Supplement 2
ISO 15493 or DIN EN ISO 15877 standard and semi-finished
Technological DVS 2203-5 technical code
PVC-C products correspond to the properties with reference to
bending test Minimum bending angle not yet stipulated
DIN EN ISO 11833, it may be assumed that these are weldable
(the entered testing speed is for PVC-U and
even if this may lead to asymmetric welding beads. K must always
it is missing for PVC-C)
be greater than 0 (see Fig. 4).
Internal pressure DIN 8080, according to Table 1
creep test 95°C,  = 5.7 N/mm², service life: > 165 h
6 Literature
DIN EN ISO Plastics – Panels made of unplasticised poly-

11833 vinyl chloride – Types, dimensions and proper-
ties
DIN EN ISO Plastics – Extruded panels made of polypro-
15013 pylene (PP) – Requirements and testing
Figure 4. Bead formation in the case of heated tool butt welding, K must DIN EN ISO Plastic piping systems for industrial applica-
always be greater than zero (principle using the example of a 15493 tions – Acrylonitrile butadiene styrene (ABS),
pipe weld). unplasticised polyvinyl chloride (PVC-U) and
chlorinated polyvinyl chloride (PVC-C) – Re-
quirements on piping parts and the piping
5 Testing of the welded joints system; metric series
DIN EN ISO Plastic piping systems for hot and cold water
Various test procedures are applied for the individual welding plumbing – Chlorinated polyvinyl chloride
15877
processes. A distinction is made between non-destructive and (PVC-C)
destructive test procedures. They are listed in Table 3. Depend-
ing on the agreement, testing and sampling operations should be DIN 8079 Pipes made of chlorinated polyvinyl chloride
carried out on a random basis during the welding work. (PVC-C) – Dimensions
534
DIN 8080 Pipes made of chlorinated polyvinyl chloride Appendix: Processing instructions (short version)
(PVC-C) – General quality requirements and
testing 1. Create permissible working conditions, e.g. housing or tent.
ASTM D 1784-03 Standard specification for rigid poly(vinyl 2. Connect the welding device to the mains or to the alternating
chloride) (PVC) compounds and chlorinated current generator and check its function.
poly(vinyl chloride) (CPVC) compounds
3. Align and clamp the parts to be welded, e.g. with dollies.
DVS 2202-1 Defects in welded joints between thermoplas-
tics; characteristics, description and evalua- 4. At the opposite pipe ends, close the pipes to be welded
technical code against draughts.
tion
DVS 2203-1 Testing of welded joints between thermoplas- 5. Machine the joining faces, in the case of pipes using a plane
tics; test procedures – requirements (for example). It is urgently advised not to use any chemical
technical code
cleaning agents or solvents.
DVS 2203-2 Testing of welded joints between thermoplas-
tics; tensile test 6. Take out the plane in the case of a pipe welding machine.
technical code
Testing of welded joints between thermoplas- 7. Remove the chips from the welding area without touching the
DVS 2203-4 welding faces (clean, grease-free brooms, paintbrushes, paper
technical code tics; tensile creep test
cloths or dry, oil-free compressed air).
DVS 2203-5 Testing of welded joints between thermoplas-
8. Check that the joining faces are parallel by moving them
technical code tics; technological bending test
DVS 2205-1 Calculation of tanks and apparatus made of 9. Check the misalignment (max. 0.1 x wall thickness).
technical code, thermoplastics – Reduction coefficients A1
for moulding materials made of PVC-C 10. Check the heated tool temperature (e.g. 230 ± 4°C).
Supplement 9
Calculation of tanks and apparatus made of 11. Clean the heated tool with absorbent, non-fraying and non-
DVS 2205-1 dyed paper.
technical code, thermoplastics – Creep curves for pipes
Supplement 11 made of PVC-C 12. Read the movement pressure or the movement force off the
pipe welding machine and make a note of it on the welding
DVS 2206-1 Non-destructive testing of tanks, apparatus record sheet.
technical code and piping made of thermoplastics; dimen-
sional checking and visual inspection 13. Stipulate the setting values for the alignment, heating-up and
joining pressures.
DVS 2208-1 Welding of thermoplastics – Machines and
technical code devices for the heated tool welding of pipes, 14. Calculate the guide values (heating-up and cooling times)
piping parts and panels according to Table 2.
DVS 2212-1 Qualification testing of plastics welders; 15. Move the heated tool into the welding position.
guideline Qualification Test Groups I and II
16. Align the faces to the heated tool at a pressure of 0.50 N/mm²
BetrSichV Operational safety ordinance until a bead arises (according to Table 2, Column 2).
DVGW VP 603 Cleaning agents for welded joints between PE 17. Heating-up at a reduced pressure < 0.01 N/mm², heating-up
pipes in the gas and water sectors time according to Table 2, Column 3.
welded from the heated tool and remove this from the
7 Explanation welding plane.
The technical code was elaborated according to the state of the art. 19. Within the changeover time (Table 2, Column 4), quickly
The welding of thermoplastics at ambient temperatures below touch. They must come into contact at a speed of nearly
5°C is generally considered to be problematical. This relates not zero. Immediately afterwards, build up the joining pressure
so much to the material-specific properties of the plastic but, to a with a linear rise in max. 4 s.
greater extent, to the restricted dexterity of the welder. Therefore,
the prerequisite for open-air welding at any outdoor temperatures is 20. A bead must exist after the joining at a pressure of 0.50 N/mm².
an environment which enables the welding personnel to perform According to Fig. 4, K must be > 0 at every point.
the individual work steps without any quality-reducing influences. 21. Cooling under the joining pressure of 0.50 N/mm².
In this respect, it is necessary to pay attention to the information
22. Unclamping of the welded parts when the cooling time has
from the manufacturers and to the dew point curve. The parts to
elapsed.
be joined must exhibit an identical temperature level. Trial welds
must be produced and tested. 23. Complete the welding record sheet.
With regard to the condition of the pipe ends, it must be ensured
that, within the framework of the welding preparations, any white
frost, ice or moisture is removed from the area of the joining
zones (> 0.5 x fitting length) by supplying heat (e.g. hot gas de-
vice). Fittings must be stored in closed, frost-free rooms and may
only be supplied to the welding point in the number required in
each case.
535
536
Record sheet for the heated tool butt welding Material Sheet of
of panels
Building owner Executing company Welding machine:
Title of the order Name of the welder Code no. Make:
Type:
No. of the order Name and company of the welding supervisor Machine no.:
Weld Date Panel Measured heated tool Setting values2) Heating-up Changeover Joining pressure Cooling time Ambient Remarks
no. thickness temperature1) time3) time3) build-up time3) under joining temperature
pressure
min. max. Alignment Heating-up Joining
[mm] [°C] [°C] [bar] [bar] [bar] [s] [s] [s] [min] [°C]
1) From the control interval, frequency according to Section 4.2.

2) According to information from the manufacturer of the welding machine or from the machine test.
Record sheet for the heated tool butt welding  Overground Material Sheet of
of piping parts  Underground

Building owner Executing company Welding machine: Weather Protective measures
1 = sunny 1 = none
Title of the order Name of the welder Code no. Make: 2 = dry 2 = screen
Type: 3 = rain or snowfall 3 = tent
No. of the order Name and company of the welding Machine no.: 4 = wind 4 = heating
supervisor
Year of construction: In the case of multiple designations, sequence of the numbers as above
Weld Date Pipe data Measured heated Movement Joining pressure Setting values2) Heating-up Changeover Joining Cooling time3) Ambient Code no.
no. d×s tool temperature1) pressure (machine table) time3) time3) pressure under joining temperature3)
build-up time3) pressure
min. max. Alignment Heating-up Joining Weather Protection
1) From the control interval, frequency according to Section 4.2.

2) According to information from the manufacturer of the welding machine or from the machine test plus the movement pressure or force.
537
April 2009

FÜR SCHWEISSEN UND Welding by bending using a heated tool Technical Code
VERWANDTE VERFAHREN E.V. for panels made of PP and PE DVS 2207-14
Contents: panel to be folded at an angle is put on a flat, thermally insulating

support and the wedge-shaped heated tool is placed on the fold-
1 Scope of application ing position (see Fig. 1).
2 Process description
3 General requirements Heated tool
4.2 Cleaning
4.2.2 Cleaning of the heated tool
4.2.3 Cleaning of the folding zone
4.3 Checking of the heated tool temperature
5 Execution of the welding
5.1 Alignment
5.2 Heating-up
5.3 Changeover and joining
Figure 1. Welding by bending using a heated tool with heating on one
5.4 Cooling
side (principle).
6.1 Specimen preparation
In the case of panels with s > 6 mm, a flat heated tool which
6.2 Execution of the testing heats up the rear side of the panel is arranged on the underside
6.3 Evaluation of the machine (see Fig. 2). This serves to prevent any non-
7 Literature uniform stretching (tapering) in the folding zone and to achieve a
8 Explanations reduction in the stresses.
Appendix: Welding record sheet
Upper
heated tool
This technical code applies to welding by bending using a heated

tool for panels made of polypropylene1) (PP-H, PP-B and PP-R)
according to DIN EN ISO 15013 and for panels made of PE1)
according to DIN EN ISO 14632.
Paying attention to the instructions in this technical code, weld-
ability may be assumed within the melt flow rates MFR2) 190/5
named below:
1 0.4 –1.0 g/10 min (PP) – approximately corresponds to the
melt flow rate MFR2) 230/2.16 of 0.2 – 0.6 g/10 min
2 0.3 –1.7 g/10 min or 0.2 – 0.7 g/10 min (PE)
The main areas of application for welding by bending using a Lower
heated tool are in tank and apparatus construction as well as in heated tool
ventilation and air conditioning technology. DVS 2207-1 and
DVS 2207-11 are technical codes which are also applicable. Figure 2. Welding by bending using a heated tool with heating on both
sides (principle).
2 Process description The wedge faces of the upper heated tool have a bevel angle
adapted to the folding [α]. The heated tool is pressed in by
Welding by bending using a heated tool, also called folding weld- approx. 75 % of the panel thickness under the effect of heat and
ing, is a mixed form of forming and heated tool butt welding and is subsequently withdrawn. Thereafter, the panel is folded ac-
is carried out on stationary machines, predominantly in the work- cording to the bevel angle. In this respect, the plastified joining
shop area. In the case of panel thicknesses of s ≤ 6 mm, the faces are joined with each other under joining pressure. In order
1)
The material designation should be understood as a generic term for the group of thermoplastics and includes the PE 63, PE 80 and PE 100 types. The
information corresponds to the current status of the standardisation.
2)
MFR = melt flow rate (old designation: MFI = melt flow index)
538
to shorten the heating-up time, panels with s ≥ 15 mm can be (methyl ethyl ketone, denaturation). Cleaning agents tested
provided with a groove milled in a wedge shape (depth: approx. according to DVGW 603 comply with this stipulation.
0.5 x wall thickness) on the top side of the panel into which the
The cleaning fluid may be used in the form of cloths which have
heated tool is pressed.
been moistened in the factory and must be kept in a lockable
In order to be able to apply the joining pressure, the bevel angle receptacle (e.g. plastic box). In so far as paper is utilised for the
of the heated tool must be smaller than the folding angle. A bevel cleaning, this must be clean, unused, absorbent, non-fraying and
angle of α = 87° ± 1° is recommended for rectangular folds and undyed. Ensure subsequent extraction.
α = 57° ± 1° for folds of 60°. After the folding, the panel must be
The use of spirit may lead to a quality reduction in the welded
fixed for the duration of the cooling time.
joint because of the water contained in it.
The process can be applied accordingly to the PVDF material.
Panels made of PVC-U and PVC-C are predominantly heated 4.2.2 Cleaning of the heated tool
and bent without any contact.
For optimum fold welds, it is necessary to clean the heated tool
according to Section 4.2.1 before every welding operation, partic-
ularly if the material is changed. No residues of cleaning agents
3 General requirements or paper may remain on the heated tool. The anti-adhesive coat-
ing or covering of the heated tool must be undamaged in the
The quality of the welds is influenced by the qualification of the working area.
welder, by the suitability of the utilised machines and jigs as well
as by the process parameters. The quality of welds executed by 4.2.3 Cleaning of the folding zone
bending using a heated tool can be investigated with the aid of
destructive test procedures. The folding zone must be cleaned immediately before the weld-
ing. The cleaning must be carried out beyond the welding area
The welding work must be monitored. The contracting parties with a cleaning agent according to Section 4.2.1. If the folding
must reach agreement on the type and scope of the monitoring. zone is soiled once again (e.g. because of contact with the weld-
Within the framework of the quality assurance, it is appropriate to er's hands), the area concerned must be recleaned.
have trial welds manufactured before the beginning and during
the welding work and to test these. The process data of the weld- 4.3 Checking of the heated tool temperature
ing work must be entered on welding record sheets without delay
(for a specimen, see the appendix) or must be documented on The heated tool temperature necessary for the welding must be
data carriers. checked before the beginning of the welding work. This is carried
out, for example, with a quick-display temperature gauge for sur-
The welders must be trained and must possess a valid qualifica- face measurements whose sensor exhibits a contact area
tion certificate. The type and scope of the qualification are deter- > 10 mm. The control measurement must be taken at the bevels
mined by the area of application in which the welder is active. in the case of the upper heated tool and on the front face of the
Welding by bending using a heated tool is assigned to the heated lower heated tool. So that a thermal equilibrium can occur, the
tool butt welding of panels to which the plastics welder qualifica- heated tool may be used, at the earliest, ten minutes after the
tion test according to DVS 2212-1 applies. nominal temperature has been reached.
The machines and jigs used for the welding must comply with the
requirements in DVS 2208-1. Requirements extending beyond Table 1. Heated tool temperature.
these are described in this technical code.
PE-HD PP
4 Measures before the welding Upper heated tool1) 210 ± 10 °C

Lower heated tool2) ∼ 130 °C ∼ 140 °C
1) In the case of low wall thicknesses and PE 100, choose the higher
The folding area must be undamaged and must be protected temperature.
from unfavourable ambient influences such as cold, draughts, the
2) Dependent on the design of the machine. Preliminary tests are
action of moisture and similar influences. If suitable measures advisable. It must be possible to bend the panel without any great
(e.g. protected workplace and drying of the folding zone) ensure resistance.
conditions permissible for the welding, the work may be carried
out at any ambient temperature – provided that the dexterity of
the welder is not hindered. If necessary, additional evidence must
be provided by manufacturing trial welds under the ambient influ- 5 Execution of the welding
ences to be expected (see Section 8).
5.1 Alignment
If the panel to be folded was heated non-uniformly due to solar
radiation, the temperatures must be equalised in the area of the At the beginning of the welding operation, the folding zone is
folding zone in good time before the welding. It is necessary to heated up to the welding temperature using the upper heated tool
avoid any abrupt cooling during the welding operation, e.g. due to in the case of heating on one side or using two heated tools in the
draughts. case of heating on both sides. Pressure or the dead weight of the
upper heated tool results in a wedge-shaped recess in the panel.
This is designated as alignment. The alignment operation is
4.2 Cleaning
concluded when the heated tool has penetrated into the panel by
For the manufacture of flawless welded joints, it is essentially 0.7 x wall thickness (see Fig. 1 and Fig. 2).
important that not only the folding zone but also the tools and the
heated tools are clean and free from grease. Wherever neces- 5.2 Heating-up
sary, the zones affected by soiling must be cleaned using a suita-
When the penetration depth has been reached, the joining zone
ble cleaning agent.
is heated up on both sides of the heated tool in order to plastify
the joining faces. Guide values for the heating-up times, depend-
ing on the nominal wall thickness of the panel, are included in
The cleaning agent, a cleaning fluid is most suitable, must DVS 2207-1, Table 2, Column 3 for PE and in DVS 2207-11,
consist of a solvent with 100 % vaporisation, e.g. of 99 parts Table 2, Column 3 for PP. Optimum results are obtained when
ethanol with a degree of purity of 99.8 % and one part MEK these heating-up times are shortened by 20 %.
539
5.3 Changeover and joining

After the heating-up, the heated tool must be taken or swivelled
out without damaging or soiling the plastified joining faces. The
folding operation must be carried out immediately thereafter Clamp
since the plastified joining faces may otherwise cool down.
The changeover time (the time between the detachment of the
heated tool from the joining faces and the end of the folding oper-
ation) influences the quality and load-bearing capacity of the
welded joint. Guide values for the changeover times are included
in DVS 2207-1, Table 2, Column 4 for PE and in DVS 2207-11, Steel T section
Table 2, Column 4 for PP.
5.4 Cooling
The bent panel remains clamped during the cooling phase. The
cooling time is included in DVS 2207-1, Table 2, Column 5 for PE
Steel plate
and in DVS 2207-11, Table 2, Column 5 for PP. No mechanical
with polished
loads on the joint are permissible before the end of the cooling
surface
time.
After the folding and the joining, the weld executed by bending
using a heated tool must exhibit a uniform double bead. K must
always be > 0 (see Fig. 3). Non-uniform bead formations are an
indication that the execution of the welding was not optimum. Edges broken
with a scraper
Figure 4. Testing of welds executed by bending using a heated tool

(principle).
6.3 Evaluation
The fracture pattern, the position of the fracture plane, the degree
of deformation as well as the type and scope of inhomogeneities
serve as the evaluation criteria. Fractures in the joining plane (in
so far as these are not of a ductile kind) or fracture faces with
pronounced shrinkage cavity points (air inclusions or voids) pro-
Figure 3. Bead formation in the case of welding by bending using a vide initial indications of mistakes during the execution of the
heated tool (representation of the principle). welding.
The evaluation may only be made by correspondingly trained

6 Testing of the welded joints specialist personnel. The results must be summarised in a test
report. If the test results are diffuse, the test must be repeated. If
necessary, additional test procedures must be used.
No special test procedures are available for the testing of welds
executed by bending using a heated tool. It is therefore recom-
mended to perform the testing with reference to DVS 2207-25.
Depending on the agreement, checking and sampling operations 7 Literature
DIN EN ISO 1872-1 Polyethylene moulding materials, designa-
tion systems and basis for specifications
6.1 Specimen preparation
DIN EN ISO 14632 Extruded panels made of polyethylene
At least six uniformly distributed specimens must be taken from a (PE-HD); requirements and test proce-
weld executed by bending using a heated tool and must be dures
prepared according to the information on Fig. 4. The legs of the DIN EN ISO 15013 Extruded panels made of polypropylene
angular test specimen are trimmed to a length of 7 x wall thick- (PP); requirements and test procedures
ness with a suitable tool and the edges are broken with a scraper
(see Fig. 4). The width of the specimens [b] should comply with DVGW VP 603 Test basis for cleaning agents and their
DVS 2203-5, Table 1. receptacles for the preparation of welded
joints between polyethylene pipes
6.2 Execution of the testing DVS 2202-1 Defects in welded joints between thermo-
plastics; characteristics, description and
A jig according to Fig. 4 must be used for executing the test. The assessment
testing speeds are 50 mm/min for specimens made of PE and DVS 2203-5 Testing of welded joints between panels
PP-R and 20 mm/min for specimens made of PP-H and PP-B. and pipes made of thermoplastics; techno-
The tests relate to the deformation behaviour of the joint until an logical bending test
incipient crack or a fracture arises in the joining plane. If neces-
sary, the specimen can be deformed until the bead comes into DVS 2207-1 Welding of thermoplastics; heated tool
contact with the support (polished steel plate) without the occur- welding of pipes, piping parts and panels
rence of any incipient cracks or fractures. made of PE-HD
DVS 2207-11 Welding of thermoplastics; heated tool
made of PP
540
DVS 2207-25 Welding of thermoplastics; heated tool 8 Explanations

welding of window sections made of PVC-U
DVS 2208-1 Welding of thermoplastics; machines and The technical code corresponds to the current state of the art.
devices for the heated tool welding of The recommendations must be varied according to the machine
pipes, piping parts and panels design.
DVS 2212-1 Qualification testing of plastics welders; The welding of thermoplastics at ambient temperatures < 5°C is
Qualification Test Groups I and II generally considered to be problematical. This relates not so
much to the material-specific properties of the plastic but, to a
Betr.Sich.V Operational Safety Ordinance greater extent, to the restricted dexterity of the welder. In this
respect, it is necessary to pay attention to the information from
the manufacturers and to the dew point curve. Trial welds must
be produced and tested if necessary.
541
542
Material Sheet of
Record sheet for welding by bending using a heated tool for panels
Building owner Executing company Welding machine
Title of the order Name of the welder Code no. Make
Type
No. of the order Name and company of the welding supervisor Machine no.
Weld no. Date Panel Measured heated tool temperature 1) Angle Melt Heating-up Cooling Ambient Angle Remarks
thickness Upper heated tool Lower heated tool of the upper penetration time 3) time 3) temperature 3) after
min. max. min. max. heated tool 2) depth 3) 4) folding 3)
[mm] o
[ C] o o
[ C] [oC] [oC] [o] [mm] [s] [min] [oC]

1) From the control interval

2) According to information from the manufacturer of the welding machine or from the machine test
3) The measured values must be entered
4) Not possible with all machines
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Erstellt am:
14.01.2008
07.11.2014
March 2008

FÜR SCHWEISSEN UND Heated tool welding of pipes, Technical Code
VERWANDTE VERFAHREN E.V. piping parts and panels made of PVDF DVS 2207-15
Translation of the German version from december 2005
Contents: is recommended to document the process data in welding record

sheets (for specimen, see appendix) or on data carriers.
1 Scope of application Within the framework of the quality assurance, it is recommended
2 General requirements to manufacture and test trial welds in the given working
3 Measures before the welding conditions before commencing and during the welding work.
3.2 Cleaning Every welder must be trained and must possess a valid
3.2.1 Cleaning agents qualification certificate. The planned area of application may
3.2.2 Cleaning of the heated tools determine the type of the qualification. DVS 2212-1 applies to the
3.2.3 Cleaning of the joining faces heated tool butt welding of panels as well as to pipeline
4 Heated tool butt welding of pipes, piping parts, fittings and construction. A supplementary certificate of proficiency must be
panels provided for pipes with an outside diameter > 225 mm as well as
4.1 Process description for heated tool sleeve welding.
4.2 Preparation for the welding The machines and jigs used for the welding must comply with the
4.3 Execution of the welding requirements in DVS 2208-1.

5.2 Welding jigs 3 Measures before the welding
5.4 Execution of the welding 3.1 Prerequisites for the welding
7 Standards and technical codes which are also applicable The immediate welding area must be protected from unfavour-
8 Explanations able weathering influences (e. g. wind or the action of moisture).
Appendix: If suitable measures (e. g. preheating, tenting or heating) ensure
Processing instructions (short versions) conditions permissible for the welding, the work may be carried
Testing of the welded joints out at any outdoor temperature – provided that the dexterity of
Welding record sheets the welder is not hindered (see explanations). If necessary, addi-
tional evidence must be provided by manufacturing trial welds in
the specified conditions (see Section 6).
1 Scope of application If the semi-finished product is heated non-uniformly due to solar
This technical code applies to the heated tool butt welding of area of the welding point in good time. It is necessary to avoid
panels and to the heated tool butt and sleeve welding of pipes any draught-induced cooling during the welding operation. When
and fittings which are made of PVDF and serve to transport pipes are welded, the pipe ends must be closed in addition.
gases, liquids and solids.
Paying attention to the following instructions and on the basis of and must be free from soiling (e. g. dirt, grease and chips).
the practical experience, it may be assumed that melt flow rates
MFR1) 230/5 of 1.0 - 25 g/10 min are suitable for densities of 3.2 Cleaning
1.70 - 1.80 g/cm³. For this purpose, reference must be made to
the data sheets from the suppliers of the semi-finished products – For the manufacture of flawless welded joints, it is decisively
in cases of doubt, Works Certificate 2.1 according to DIN EN important that not only the joining faces but also the tools and the
10204. heated tools are clean and free from grease.

2 General requirements The cleaning fluid or cloths which have already been moistened
with it in the factory and are kept in a lockable plastic box must
The quality of the welded joints is dependent on the qualification consist of a solvent with 100 % vaporisation, e. g. of 99 parts
of the welders, on the suitability of the utilised machines and jigs ethanol with a degree of purity of 99.8 % and one part MEK
as well as on the compliance with the technical codes for (methyl ethyl ketone, denaturation). Agents tested according to
welding. The weld can be tested using non-destructive and/or DVGW VP 603 comply with this stipulation. The use of spirit may
destructive procedures. lead to a quality reduction because of the water contained in it.
The welding work must be monitored. The contracting parties The paper for the cleaning must be clean, unused, absorbent,
must reach agreement on the type and scope of the monitoring. It non-fraying and undyed. Ensure subsequent extraction.
1) old designation for melt index: MFI = melt flow index
543
3.2.2 Cleaning of the heated tools The nominal wall thicknesses of the parts to be welded must
The heated tools must be cleaned with paper before every match in the joining region.
welding operation. No residues of cleaning agents or paper may Pipes and fittings must be aligned axially before they are
remain on the heated tool. clamped in the welding machine. The easy longitudinal mobility
of the part to be welded on must be ensured, for example, using
3.2.3 Cleaning of the joining faces adjustable dollies or a swinging suspension.
Before the chip-producing machining of the joining faces, it must Immediately before the welding, the faces to be joined must be
be ensured that the utilised tools and the workpieces are clean subjected to chip-producing machining with a clean and grease-
and free from grease beyond the welding area. If necessary, the free tool so that they have parallel faces in the clamped condition.
cleaning must be carried out with a cleaning agent. The permissible gap widths under the alignment pressure are
The joining faces must be machined immediately before the shown in Table 1.
beginning of the welding.
Any chips must be removed without touching the joining faces. Table 1. Maximum gap widths between the machined welding faces.
If the surface is soiled after the chip-producing machining (e. g. Pipe outside diameter d Gap width Panel width
because of contact with the welder's hands), the welding faces [mm] [mm] [mm]
must be treated with a cleaning agent if an additional chip-
producing machining operation is not possible for process-related 355 0.5 -
reasons. 400 ... < 630 1.0 1500
- 1.3 > 1500  2000

4 Heated tool butt welding of pipes, piping parts, fittings
and panels - 1.5 > 2000  2300
4.1 Process description - 2.0 > 2300  3000
During heated tool butt welding, the faces of the parts to be
welded are aligned to the heated tool under pressure (alignment),
are subsequently heated up to the welding temperature at a The misalignment must be checked at the same time as the gap
reduced pressure (heating-up) and, when the heated tool has width. The misalignment of the joining faces in relation to each
been removed (changeover), are joined together under pressure other must not exceed the permissible dimension of 0.1 x wall
(joining). Fig. 1 shows the principle of the process. thickness on the outside of the pipe or on the panel. The objec-
tive must be a minimum misalignment. A larger misalignment
results in a reduction in quality which restricts the load-bearing
capacity of the joint. In this case, an evaluation may be carried
out according to the DVS 2202-1 technical code taking account
of the requirements on the joint.
operation would otherwise be necessary. An additional
cleaning operation is not required and does not give rise to
any improvement in quality. Any chips which have fallen into
the pipe must be removed.

Figure 1.
Principle of heated tool In the case of heated tool butt welding, the faces to be joined are
butt welding using the heated up to the welding temperature using a heated tool and,
example of pipes. when the heated tool has been removed, are joined together
under pressure. The heated tool temperature is 240 � 8°C. The
4.2 Preparation for the welding step-by-step sequence of the welding operation is illustrated on
Fig. 2.
The heated tool temperature necessary for the welding must be
out, for example, with a quick-display temperature gauge for
surface measurements with a contact area of approx. 10 mm.
The control measurement must be taken within the heated tool
area corresponding to the semi-finished product. So that a
thermal equilibrium can occur, the heated tool may be used, at
the earliest, ten minutes after the nominal temperature has been
reached.
For optimum welds, it is necessary to clean the heated tool
according to Section 3.2.2 before every welding operation. The
anti-adhesive coating or covering of the heated tool must be
undamaged in the working area.
The respective joining forces or joining pressures must be
stipulated for the machines to be used. These may refer, for
example, to information from the manufacturer or to calculated or
measured values. In the case of pipe welding, it is also necessary
to read the movement force or movement pressure arising during
Figure 2. Process steps in heated tool butt welding.
Alignment
given to electronically controlled machines – if at all possible, In this respect, the joining faces to be welded are pressed on to
with recording. the heated tool until the entire faces are in contact with the
544

formation of the beads. The alignment is finished when the bead
heights around the entire pipe circumference or on the entire top
side of the panel have reached the values specified in Table 2,
Column 2. The bead heights are regarded as an indicator that the
whole area of the joining faces is in contact with the heated tool.
The alignment pressure of 0.10 N/mm² is effective throughout the
alignment operation.
Heating-up
nearly zero ( 0.01 N/mm²). During the heating-up, the heat
Column 3. Figure 3. Bead formation in the case of heated tool butt welding (principle
using the example of a pipe).
Changeover
heated tool which must be taken out without damaging or soiling 5 Heated tool sleeve welding
together quickly until they almost touch. The changeover time 5.1 Process description
In the case of heated tool sleeve welding (see Fig. 4), the pipe
and the fitting are welded in an overlap. The pipe end and the
exert a detrimental influence on the weld quality.
fitting are heated up to the welding temperature with the aid of
Joining sleeve-shaped and spigot-shaped heated tools and are
The faces to be welded should come into contact at a speed of subsequently welded.
nearly zero. The required joining pressure is applied, if at all
possible, with a linear rise. The times necessary for this purpose
are shown in Table 2, Column 5. The joining pressure is
0.10 ± 0.01 N/mm². The low melt viscosity demands exact
control of the joining pressure build-up in order to obtain a
sufficient melting zone depth.
pressure must be maintained during the cooling time at the
ambient temperature (see Table 2, Column 5).
A uniform double bead must exist after the joining. The bead
formation gives an orientation about the uniformity of the welds in
relation to each other. Different bead formations may be caused
by various types of flow behaviour of the joined materials. The
weldability may be assumed from the experience with the
commercially available semi-finished PVDF products in the
specified MFR range, even if this may lead to asymmetric
welding beads. K must always be > 0 (see Fig. 3).
For a short version of the processing instructions, see the
appendix. Figure 4. Heated tool sleeve welding (principle).
Table 2. Guide values for the heated tool butt welding of pipes, fittings and panels made of PVDF at an outdoor temperature of approx. 20°C
with moderate air movement (intermediate values must be interpolated).
1 2 3 4 5
thickness s
Heated tool temperature 240  8°C Changeover time Joining pressure Cooling time under
(maximum time) build-up time joining pressure
Bead height at the Heating-up time p = 0.10 ± 0.01 N/mm²
heated tool at the end 10 x wall thickness t  1.2 x wall thickness
of the alignment time + 40 s (heating-up + 2 min
(minimum values) p  0.01 N/mm²) (minimum values)
(alignment
p = 0.10 N/mm²)
[mm] [mm] [s] [s] [s] [min]
1.9 … 3.5 0.5 59 … 75 3 3…4 5…6
3.5 ... 5.5 0.5 75 ... 95 3 4 ... 5 6 ... 8.5
5.5 ... 10.0 0.5 … 1.0 95 ... 140 4 5 ... 7 8.5 ... 14
10.0 ... 15.0 1.0 … 1.3 140 ... 190 4 7 ... 9 14 ... 19
15.0 ... 20.0 1.3 … 1.7 190 ... 240 5 9 ... 11 19 ... 25
20.0 ... 25.0 1.7 … 2.0 240 ... 290 5 11 ... 13 25 ... 32
545
The heated tools and the fittings are dimensionally coordinated in 5.4 Execution of the welding
such a way that a joining pressure builds up during the joining.
For the heating-up, the fitting and the pipe are quickly and axially
Heated-tool-sleeve-welded joints with a pipe diameter up to
pushed on to the tools attached to the heated tool as far as the
40 mm can be executed manually. In the case of diameters as
set stop in the case of machine welding or as far as the mark in
from 50 mm, the level of the joining force necessitates the use of
the case of manual welding and are fixed. It is imperative to
a welding jig.
prevent the front face of the pipe from bumping into the end
of the heated bush. The heating-up time according to the time
5.2 Welding jigs indicated in Table 4, Column 3 begins thereafter.
The heated tools are heated electrically and are coated anti- When the heating-up time has elapsed, the fitting and the pipe
adhesively. must be pulled off the heated tools with a jolt and must be pushed
together immediately as far as the stop or the mark without any
5.3 Preparation for the welding twisting (max. changeover time: see Table 4, Column 4).
The fitting must be cleaned on the inside and the pipe on the In the case of manual welding, the joined parts must be kept in a
outside according to Section 3.2. The joining faces of the parts to fixed position according to the time indicated in Table 4, Column
be welded must be machined immediately before the beginning 5. The joint may only be subjected to the stresses of the further
of the welding. The pipe end must be bevelled according to Fig. 5 laying work when the cooling time (Table 4, Column 6) has
and Table 3. The joining face of the pipe must be machined elapsed.
according to the information from the fitting supplier. In the case
of manual welds, the insert depth must then be marked on the For a short version of the processing instructions, see the
pipe end at the distance I according to Table 3. appendix.

destructive test procedures. They are listed in Table 5.
Depending on the agreement, checking and sampling operations
ISO 10931 Plastics piping systems for industrial applica-

tions – Polyvinylidene fluorides (PVDF)
Figure 5. Bevelling of the pipe end. DIN EN 10931, Plastics piping systems for industrial applica-
draft tions – Polyvinylidene fluorides – Require-
Table 3. Dimensions for the pipe bevel and the insert depth. ments on piping parts and the piping system
DIN EN 10204 Metallic products – Types of test certificates
Pipe outside diameter d Pipe bevel b Insert depth l
[mm] [mm] [mm] DIN EN 12814-4 Testing of welded joints between thermoplas-
tics – Part 4: Peeling test
16 13 DVS 2202-1 Defects in welded joints between thermoplas-
20 14 tics- Characteristics, description and evalua-
tion
25 16
2 DVS 2203-1 Testing of welded joints between panels and
32 18 pipes made of thermoplastics – Test proce-
dures – Requirements
40 20
50 23 Supplement 2 Requirements in the tensile creep test
63 27 Supplement 3 Requirements in the technological bending
test – Bending angle / bending path
75 31
3 -2 - Tensile test
90 35
-4 - Tensile creep test
110 41 -4, - Tensile creep test – Testing of sleeve-weld-
Supplement 1 ed joints between pipes
Before the beginning of the welding, the welding temperature of -5 Technological bending test
250 - 270°C at the heated tools must be checked according to DVS 2208-1 Welding of thermoplastics – Machines and
Section 4.2. devices for the heated tool butt welding of
The heated bush and the heated spigot must be free from pipes, piping parts and panels
contaminations and must be cleaned according to Section 3.2.2 DVS 2212-1 Qualification testing of plastics welders –
before every welding operation. The anti-adhesive coating of the Qualification Test Groups I and II
heated spigot and the heated bush must be undamaged in the DVGW VP 603 Provisional test basis for cleaning agents and
welding area. their receptacles for the preparation of welded
joints between polyethylene pipes
BetrSichV Operational Safety Ordinance
546
Table 4. Guide values for the heated tool sleeve welding of pipes and piping parts made of PVDF at an outdoor temperature of 20°C with
moderate air movement.
1 2 3 4 5 6
Pipe outside Pipe wall Heating-up Changeover Cooling
diameter d thickness min. Heated tool temperature 250 - 270°C Changeover time Cooling time
Heating-up time (maximum time)
Fixed Total
[s] [min]
[mm] [mm] [s] [s]
16 1.5 4
20 6 6 2
1.9
25 8
4
32 10
2.4
40 12 12 4
50 18
63 20
75 3 22 18 6
6
90 25
110 30 24 8
Test procedure Heated tool butt welding Heated tool sleeve welding
Visual inspection DVS 2202-1, Table 1 DVS 2202-1, Table 2

Radiographic Applicable
and ultrasonic tests Statement possible, for example, about voids, not about quality
Tensile test DVS 2203-2 Not applicable

Short-time tensile welding factor
Tensile creep test DVS 2203-4 DVS 2203-4, Supplement 1

Tensile creep rupture
welding factor
Technological DVS 2203-5 Not applicable

bending test Minimum bending angle according
to DVS 2203-1, Supplement 3, Fig. 4
Minimum bending path according
to DVS 2203-1, Supplement 3, Fig. 10
Internal pressure ISO 10931-3. Test temperature 95°C, test pressure 11.5 N/mm²,
creep test creep rupture time  200 hours
Not meaningful for long-time welding factor > 0.5
Torsion shear test Not applicable See appendix

Also as a site test for pipe wall thicknesses  3 mm
Radial Not applicable See appendix
peeling test Also as a site test for pipe wall thicknesses  3 mm
ompression test Not applicable DIN EN 12814-4, Section 8

8 Explanations Trial welds must be produced and tested.
The technical code was revised editorially and was adjusted to With regard to the condition of the pipe end, it must be ensured
the state of the art with regard to improved cleaning agents. that, within the framework of the welding preparations, any white
Possibilities for the testing of sleeve-welded joints were frost, ice and moisture are removed from the area of the joining
incorporated. Non-contact heated tool welding is dealt with in zone ( 0.5 x fitting length) by supplying heat (e. g. hot gas
DVS 2207-6. device). In principle, this must be carried out before the
machining of the pipe surface. Fittings must be stored in closed,
The welding of thermoplastics at ambient temperatures below frost-free rooms and may only be transported to the welding
5°C is generally considered to be problematical. This relates not location in the number required in each case.
so much to the material-specific properties of the plastic but, to a
greater extent, to the restricted dexterity of the welder. Therefore,
the prerequisite for open-air welding at any outdoor temperatures Appendix: Processing instructions (short versions)
Re. 4.1 Heated tool butt welding of pipes, piping parts,
influences. In this respect, it is necessary to pay attention to the
fittings and panels
information from the manufacturers and to the dew point curve.
The parts to be joined must exhibit an identical temperature level. Processing instructions (short version)
547
1. Create permissible working conditions, e. g. welding tent. 7. Simultaneously push the fitting and the pipe on to the heated
2. Connect the welding device to the mains or to the alternating spigot or into the heated bush as far as the stop or the mark.
current generator and check its function. Do not bump the pipe end into the end of the heated bush.
3. Align and clamp the parts to be welded, e. g. with dollies. 8. Comply with the heating-up time according to Table 4, Col-
4. Close the pipe ends against draughts. umn 3.
5. Clean the joining faces beyond the welding area with a 9. Pull the fitting and the pipe off the heated tools with a jolt,
cleaning agent according to Sections 3.2.1 and 3.2.3 with immediately push them together as far as the mark or the
unused, absorbent, non-fraying and non-dyed paper. stop (for max. changeover time: see Table 4, Column 4) and
fix them in this position (see Table 4, Column 5).
6. Machine the joining faces, in the case of pipes using a plane
(for example). 10. Let the joint cool down. Only subject the welded joint to me-
7. Take out the plane in the case of a pipe welding machine. chanical loads when the cooling time according to Table 4,
Column 6 has elapsed.
8. Remove the chips from the welding area without touching
the joining faces. 11. Complete the welding record sheet.
9. Check the plane parallelism by moving the joining faces to-
gether (max. gap width according to Table 1). Re. 6 Testing of the welded joints
10. Check the misalignment (max. 0.1 x wall thickness). The torsion shear test and the radial peeling test are suitable for
11. Check the heated tool temperature (240 � 8°C). quick checking of the welding quality of PVDF pipe joints.
12. Clean the heated tool with a cleaning agent according to The wall thickness of the pipe should be  3 mm.
Sections 3.2.1 and 3.2.2 with unused, absorbent, non-fray-
ing and non-dyed paper and ensure extraction.
13. Determine the movement pressure or the movement force
welding record sheet.
14. Determine the setting values for the alignment, heating-up
15. Stipulate the guide values according to Table 2.
17. Align the faces to the heated tool until a bead arises accord-
ing to Table 2, Column 2.
18. Heating-up at a reduced pressure  0.01 N/mm², heating-up
welded from the heated tool and move this out of the weld-
ing position.
Figure 6. Preparation of a test specimen from a heated-tool-butt-welded
20. Within the changeover time (Table 2, Column 4), quickly joint.
touch. The faces must come into contact at a speed of Four test pieces are removed by means of slitting, uniformly
nearly zero. Immediately afterwards, build up the joining distributed around the circumference. The dimensions are:
pressure with a linear rise in the build-up time (Table 2, Col-
umn 5). Test piece length
21. A bead must exist after the joining at a pressure of 0.10 N/ = sleeve length + 2 x 200 mm pipe length
mm². According to Fig. 3, K must be > 0 at every point. Test specimen length
22. Cooling under the joining pressure according to Table 2, = sleeve length + 2 x approx. 10 mm pipe length
Column 5.
Test specimen width
23. Unclamping of the welded parts when the cooling time has b = 3 - 6 mm with a pipe wall thickness  10 mm
elapsed. b = 5 - 6 mm with a pipe wall thickness > 10 mm
24. Complete the welding record sheet.
Torsion shear test: The torsion shear test serves to evaluate the
Re. 5 Heated tool sleeve welding fracture behaviour and the fracture pattern of the weld. For this
purpose, one part (e. g. the sleeve cross-section) of the test
Processing instructions (short version) specimen (see Fig. 6) is completely clamped in a vice. The other
1. Create permissible working conditions, e. g. welding tent. part (e. g. the pipe cross-section) is gripped with a suitable tool
2. Connect the welding device to the mains or to the alternating and is then twisted by 90° in the welding plane (see Fig. 7). The
current generator and check its function. rotating speed is very low in order to largely exclude its influence
on the fracture behaviour of the test specimen. The clamping
3. Clean the heated tools with a cleaning agent according to faces should have a slight undercut in order to be able to input
Sections 3.2.1 and 3.2.2 with unused, absorbent, non-fray- the torsional moment into the weld plane in a targeted way.
ing and non-dyed paper.
4. Check the welding temperature (250 - 270°C).
5. Clean all the non-machined joining faces with a cleaning
agent according to Sections 3.2.1 and 3.2.3 with unused,
absorbent, non-fraying and non-dyed paper and ensure ex-
traction. Figure 7.
Force introduction during the
6. Bevel the pipe end cut off as a rectangle according to Fig. 5 torsion shear test.
and Table 3 or machine it according to the information from
the fitting manufacturer. If necessary, mark the insert depth. The evaluation is made according to Table 6.
548
Table 6. Evaluation criteria for the torsion shear and radial peeling tests.
Separation behaviour Appearance and characteristics Evaluation
High separating forces, tough fracture, over 80 % Extremely structured fracture pattern with plastic deformation and stretching No or slight defects
of the welding face (ductile)
Welding face melted partially or totally but welded Isolated detachments, soiling and insufficient surface removal Impermissible defects
together at certain points only
Separating point with coarse pores, finely structured, interspersed with a lot of
small shrinkage cavities, partially burnt and overheating of the weld
Brittle fracture
Pipe surface not melted, weld too cold and welding gap too wide
Radial peeling test: In the case of this test, the pipe cross-section
of the test specimen (see Fig. 6) which is clamped in a vice with
the sleeve cross-section is peeled radially at the lowest possible
speed with the aid of suitable pliers or another clamping jig (see
Fig. 8).
The evaluation is made according to Table 6.
Figure 8. Force introduction during the radial peeling test.
549
550
Record sheet for the heated tool butt welding Material Sheet Of
of panels
Type:
No. of the order Name and company of the welding supervisor Machine no.:
Weld no. Date Panel Measured heated tool Setting values2) Heating-up Change- Joining Cooling time Ambient Remarks
thickness temperature1) time3) over time3) pressure under joi- temperature
build-up time3) ning pres-
min. max. Alignment Heating-up Joining sure
[mm] [oC] [oC] [bar] [bar] [bar] [s] [s] [s] [min] [oC]

1) From the control interval, frequency according to Section.

2) According to information from the manufacture of the welding machine or from the machine test.
Record sheet for the heated tool butt welding  Overground Material Sheet Of
of piping parts  Underground
Weathering: Protective measures:
1 = Sunny 1 = None
2 = Dry 2 = Screen
Type:
3 = Rain or snowfall 3 = Tent
No. of the order Name and company of the welding super- Machine no.:
visor 4 = Wind 4 = Heating
In the case of multiple designations, sequence of the numbers as above
Weld no. Date Pipe data Measured heated Movement Joining pressure Setting values2) Heating-up Change- Joining Cooling Ambient Code-no.
dxs tool temperature1) pressure (machine table) time3) over time3) pressure time under temperature
build-up time3) joining
min. max. Alignment Heating-up Joining pressure Weathering Protection
[mm] [oC] [oC] [bar] [bar] [bar] [bar] [bar] [s] [s] [s] [min] [oC]
1) From the control interval, frequency according to Section.

2) According to information from the manufacture of the welding machine or from the machine test plus movement pressure or force.
551
552
Record sheet for the heated tool sleeve  Overground Material Sheet Of
welding of piping parts  Underground
Weathering: Protective measures:
1 = Sunny 1 = None

2 = Dry 2 = Screen
Type:
3 = Rain or snowfall 3 = Tent
No. of the order Name and company of the welding Machine no.:
supervisor 4 = Wind 4 = Heating
Weld no. Date Pipe data Fitting data1) Measured temperature Heated-up Change- Cooling time2) Ambient Code no. Remarks
dxs time2) over time2) temperature
A B Serial no. Heated spigot Heated bush Fixed Total Weathering Protection
[mm] [oC] [oC] [s] [s] [s] [min] [oC]
1) If necessary, entries according to the utilised system A = Manufacturer’s code 1 = Sleeve 2 = Angle 3 = T-piece 4 = Reducer
2) The measured values must be entered B = Fitting code no. 5 = Saddle 6 = Cap 7 = Transition piece
July 2010

FÜR SCHWEISSEN UND Heated tool welding of pipes and piping parts Technical Code
VERWANDTE VERFAHREN E.V. made of Polyamide 12 DVS 2207-16
Contents: Every welder must be trained and must possess a valid qualifica-
tion certificate. The planned area of application may determine
1 Scope of application the type of the qualification. DVS 2212-1 applies to heated tool
2 General requirements butt welding and sleeve welding with an incorporated heating
3 Measures before the welding element in pipeline construction.
3.2 Cleaning The machines and jigs used for the welding must comply with the
3.2.1 Cleaning agents requirements in DVS 2208-1.
3.2.2 Cleaning of the heated tools
4.1 Heated tool butt welding of pipes, piping parts and fittings 3 Measures before the welding
4.1.2 Preparation for the welding 3.1 Prerequisites for the welding
4.1.3 Execution of the welding
5 Sleeve welding with an incorporated heating element The immediate welding area must be protected from unfavourable
weathering influences (e. g. wind or the action of moisture). If

5.2 Welding device suitable measures (e. g. preheating, tenting or heating) ensure
5.3 Preparation for the welding conditions permissible for the welding, the work may be carried
5.4 Execution of the welding out at any outdoor temperature – provided that the dexterity of
6 Testing of the welded joints the welder is not hindered (see the explanations). If necessary,
7 Standards, technical codes and guidelines which are also additional evidence must be provided by manufacturing trial
applicable welds in the specified conditions (see Table 2).
8 Explanations
Appendix: If the semi-finished product is heated non-uniformly due to solar
Processing instructions (short versions) radiation, the temperatures must be equalised by covering the
Welding record sheets area of the welding point in good time. It is necessary to avoid
any cooling during the welding operation, e. g. due to draughts.
When pipes are welded, the pipe ends must be closed in addi-
1 Scope of application tion.
PA 12 pipes from the ring coil are oval and curved immediately
This technical code applies to the heated tool butt welding and after the unrolling. The pipe end to be welded must be straight-
sleeve welding with an incorporated heating element of pipes and ened before the welding, e. g. by means of careful heating-up
fittings which are made of Polyamide 12 (PA 12) according to ISO and/or using a suitable clamping or round pressing jig.
22621-5 (under preparation) with a density of 1,000 -1,040 kg/m3
and serve to transport gases, liquids and solids. The joining faces of the parts to be welded must not be damaged
In normal storage conditions, the semi-finished product absorbs and must be free from contaminations (e. g. dirt, grease and
up to max. 0.8% moisture. The weldability up to this moisture chips).
content has been proven on the basis of tests.
3.2 Cleaning
2 General requirements For the manufacture of flawless welded joints, it is decisively

important that not only the joining faces but also the tools and the
The quality of the welded joints is dependent on the qualification heated tools are clean and free from grease.
of the welders, on the suitability of the utilised machines and jigs
as well as on the compliance with the technical codes and the 3.2.1 Cleaning agents
guidelines for the welding. The weld can be tested using non-
destructive and/or destructive procedures. The cleaning fluid or cloths which have already been moistened
The welding work must be monitored. The contracting parties with it in the factory and are kept in a lockable plastic box must
must reach agreement on the type and scope of the monitoring. It consist of a solvent with 100% vaporisation, e. g. of 99 parts
is recommended to document the process data on welding ethanol with a degree of purity of 99.8% and one part MEK
record sheets (for a specimen, see the appendix) or on data (methyl ethyl ketone, denaturation). Agents tested according to
carriers. DVGW VP 603 comply with this stipulation. The use of spirit
leads to a quality reduction because of the water contained in it.
to manufacture and test trial welds in the given working condi- The paper for the cleaning must be clean, unused, absorbent,
tions before commencing and during the welding work. non-fraying and undyed. Ensure subsequent extraction.
DVS, Technical Committee, Working Group “Fügen von Kunststoffen”
553
3.2.2 Cleaning of the heated tools read the movement force or movement pressure arising during
The heated tools must be cleaned with paper before every weld-
ing operation. No residues of plastic, cleaning agent or paper
may remain on the heated tool.
given to electronically controlled machines – if at all possible,
with recording.
The nominal wall thicknesses of the parts to be welded must
Before the chip-producing machining of the joining faces, it must
match in the joining area.
be ensured that the utilised tools and the workpieces are clean
and free from grease beyond the welding area. If necessary, the Pipes and fittings must be aligned axially before they are
cleaning must be carried out with a cleaning agent. clamped in the welding machine. The easy longitudinal mobility
of the part to be welded on must be ensured, for example, using
The joining faces must be machined immediately before the
adjustable dollies or a swinging suspension.
beginning of the welding.
Any chips must be removed without touching the joining faces.
subjected to chip-producing machining with a clean and grease-
If the surface is soiled after the chip-producing machining (e. g. free tool so that they have parallel faces in the clamped condition.
because of contact with the welder's hands), the welding areas The permissible gap width under the alignment pressure is 0.5 mm.
must be treated with a cleaning agent if an additional chip-pro-
ducing machining operation is not possible for process-related
reasons.
thickness on the outside of the pipe. A larger misalignment
results in a reduction in quality which restricts the load-bearing
capacity of the joint. In this case, an evaluation may be carried
out according to the DVS 2202-1 technical code taking account
4.1 Heated tool butt welding of pipes, piping parts and of the requirements on the joint.
fittings
The machined welding areas must not be either soiled or touched
4.1.1 Process description by the welder's hands since another chip-producing machining
operation would otherwise be necessary. An additional clean-
In the case of heated tool butt welding, the joining faces of the ing operation is not required and does not give rise to any
parts to be welded are aligned at the heated tool under pressure improvement in quality. Any chips which have fallen into the
(alignment), are subsequently heated up to the welding tempera- pipe must be removed.
ture at a reduced pressure (heating-up) and, when the heated
tool has been removed (changeover), are joined together under
4.1.3 Execution of the welding
pressure (joining). Fig. 1 shows the principle of the process.
In the case of heated tool butt welding, the faces to be joined are
Preparation heated up to the welding temperature using a heated tool and,
under pressure. The heated tool temperature is 230 ± 10°C. The
step-by-step sequence of the welding operation is illustrated on
Fig. 2.
Pipe Pipe
Heated tool
Pressure
Heating-up
Joining pressure
Alignment pressure
Heating-up pressure
Finished joint
Time
Changeover time
Heating-up time Cooling time
Figure 1. Principle of heated tool butt welding using the example of pipes. Alignment Joining pressure build-up
time Total joining time time
4.1.2 Preparation for the welding
The heated tool temperature necessary for the welding must be Total welding time
out, for example, with a quick-display temperature gauge for sur- Figure 2. Process steps in the case of heated tool butt welding.
face measurements with a contact area covering a diameter of
approx. 10 mm. The control measurement must be taken within Alignment
the heated tool area corresponding to the semi-finished product. In this respect, the joining faces to be welded are pressed on to
So that a thermal equilibrium can occur, the heated tool may be the heated tool until the entire joining faces are in contact with the
used, at the earliest, ten minutes after the nominal temperature heated tool with parallel faces. This can be recognised by the
has been reached. formation of the beads. The alignment is finished when the bead
For optimum welds, it is necessary to clean the heated tool heights around the entire pipe circumference have reached the
according to Section 3.2.2 before every welding operation. The values specified in Table 1, Column 2. The bead heights are
anti-adhesive coating of the heated tool must be undamaged in regarded as an indicator that the whole area of the joining faces
the working area. is in contact with the heated tool. The alignment pressure of
0.25 N/mm2 is effective throughout the alignment operation.
The respective joining forces or joining pressures must be stipu-
lated for the machines to be used. These may refer, for example, Heating-up
to information from the manufacturer or to calculated or mea- For the heating-up, the faces must be in contact with the heated
sured values. In the case of pipe welding, it is also necessary to tool at a low pressure. To this end, the pressure is reduced to
554
nearly zero (≤ 0.01 N/mm2). During the heating-up, the heat 5 Sleeve welding with an incorporated heating element
welding temperature. The heating-up times are shown in Table 1, 5.1 Process description
Column 3.
The joining faces (i. e. the surface of the pipe and the inside of
Changeover
the fitting) overlap, are heated up to the welding temperature by
After the heating-up, the joining faces must be detached from the electrical energy with the aid of resistance wires positioned in the
heated tool which must be taken out without damaging or soiling fitting (heater spiral) and are welded in this way (see Fig. 4).
together quickly until they almost touch. The changeover time Chip-producing machining
Joining face
exert a detrimental influence on the weld quality.
Joining
The faces to be welded should come into contact at a speed of Fitting Insert
nearly zero. The required joining pressure is applied, if at all depth Pipe
possible, with a linear rise. The joining pressure build-up time
necessary for this purpose is shown in Table 1, Column 5. The
joining pressure is 0.25 ± 0.05 N/mm2.
the end of the cooling process. For this purpose, the full joining Joining plane
pressure must be maintained during the cooling time at the
ambient temperature (see Table 1, Column 5). Figure 4. Sleeve welding with an incorporated heating element (principle).
An uniform double bead must exist after the joining. The bead
formation provides orientation with regard to the uniformity of the 5.2 Welding device
welds with each other. Different bead formations may be caused
by the various types of flow behaviour of the joined materials. It is only allowed to use welding devices which are adapted to the
K must always be > 0 (see Fig. 3). A rough uneven surface of the parts to be welded. Preference should be given to automatic
bead is permissible. welding devices – if at all possible, with recording. The welding
device must supply the welding parameters required for the fitting
Pipe wall surface Bead notch to be welded in each case, e. g. welding time, amperage and
on the outside voltage. The device must be switched off automatically as soon
as the necessary heat quantity has been supplied to the welding
zone.
Dimension
For the manufacture of flawless welded joints, decisive signifi-
cance is attached to clean surfaces and to stress-free installation.
For axial pipe joints, the pipe ends must, if necessary, be cut off
Figure 3. Bead formation in the case of heated tool butt welding at a right angle with a suitable tool. In the case of conical collaps-
(principle using the example of a pipe). ing of the cut edge of the pipe, the unmachined pipe must exhibit
the nominal diameter d at the planned insert depth, at least in the
For a short version of the processing instructions, see the appen- area of the heater spiral (Fig. 5). If necessary, the pipe end must
dix. be shortened correspondingly immediately before the welding.
Table 1. Guide values for the heated tool butt welding of pipes and fittings made of PA 12 at an outdoor temperature of approx. 20°C with
moderate air movement (intermediate values must be interpolated).
1 2 3 4 5
thickness
s Joining Cooling time under
Heated tool temperature 230 ± 10°C Changeover time
pressure joining pressure
build-up time
Bead height at (Heating-up time (maximum time) (minimum values)
the heated tool at the end p ≤ 0.01 N/mm2) p = 0.25 N/mm2 ± 0.05
of the alignment time 12 x wall thick-
(minimum values) ness s
(alignment
p = 0.25 N/mm2)
[mm] [mm] [s] [s] [s] [min]
up to 4.5 0.5 up to 54 5 5 6
4.5 ... 7 1.0 54 ... 84 5 ... 6 5 ... 6 6 ...10
7 ... 12 1.5 84 ... 144 6 ... 8 6 ... 8 10 ...16
12 ... 19 2.0 144 ... 228 8 ... 10 8 ... 11 16 ... 24
555
The fitting and the pipe must be at the same temperature level
before the welding. In the case of welding devices with automatic
temperature compensation, it must be ensured that the recorded
ambient temperature corresponds to the conditions at the loca-
tion of the welding. If necessary, the welding device as well as
the pipe and the fitting must be protected from (for example)
direct solar radiation.
Still permissible Wrong
The correct insert depth must be checked on the basis of the
mark. If necessary, suitable measures or jigs must be used in
order to prevent any changes in the positions of the components
to be welded.
Cables serve to connect the welding device with the fitting to be
Cold zone
Cold zone
Cold zone
Cold zone
Heater Heater welded. The welding cables must be attached in a weight-
spiral spiral relieved form. The contact faces must be clean. As a rule, the
zone zone welding device acquires the fitting data required for the welding
by reading in a component-specific bar code. The displayed data
(e. g. dimensions) must coincide with the component data. After
Figure 5. Conical collapsing of the pipe end or insufficient pipe insertion
before the welding (principle).
the welding operation has started, this proceeds automatically.
The welding duration is usually displayed by the welding device.
The out-of-roundness of the pipe must not exceed 1.5% of the Just like the other data displayed by the device, it must also be
outside diameter, max. 3 mm, in the welding zone. Correspond- indicated on the welding record sheet unless the data is stored.
ing round pressing clamps must be used if necessary. Pay attention to error messages! For example if the power supply
Beyond the area of the insert depth or the length of the saddle is interrupted, a prematurely terminated welding operation can be
fitting, the complete surface of the pipe or of the pipe spigot on repeated on one occasion in so far as there are no defects on the
the fitting must be subjected to chip-producing machining. A fitting or on the welding device (error message) and the fitting
rotating peeling device with constant wall thickness removal of manufacturer permits this. It is necessary to wait for the entire
approx. 0.2 mm must be used. Attention must be paid to the cooling time before carrying out the welding once again (fire
formation of a small annular gap! hazard).
The pipe end must be deburred on the inside and outside. Chips The cables can be removed when the device has been switched
must be removed without touching the joining face. off. If there are any welding indicators on the fitting, these must
be checked. The joint may only be moved after the cooling. Infor-
The fitting may only be removed from the protective packaging mation about this is provided by the fitting manufacturer.
immediately before the assembly.
If the manufacturer provides any information about additional
If the machined pipe surface is contaminated after the chip-pro- cooling times (e. g. until the pressure test), attention must be paid
ducing machining, it must be cleaned according to Section 3.2.3. to this.
In this respect, it must be ensured that no contamination is intro-
duced into the welding zone. The joining face of the fitting must For a short version of the processing instructions, see the appen-
be cleaned according to Section 3.2.3. dix.
It must be possible to check the insert depth of the pipe either on
the basis of a mark to be applied or using a suitable jig. The fitting 6 Testing of the welded joints
must not be tilted or pushed on to the pipe end with force (low-
stress assembly). The saddle piece must be tightly clamped on
the pipe with the aid of a suitable jig according to the information
from the manufacturer.
destructive test procedures. They are listed in Table 2. Depend-
The contact bushes for the connection of the welding cable must ing on the agreement, checking and sampling operations should
be easily accessible. be carried out on a random basis during the welding work.
Test procedure Heated tool butt welding Sleeve welding with an incorporated heating element
Pipes and fittings Fittings and saddle fittings
Visual inspection DVS 2202-1, Table 1 DVS 2202-1, Table 3
The machining of the pipe surface must be visible beyond
the welding area; check the insert depth on the basis of
the mark.
Radiographic and DVS 2206 applicable to a limited extent
ultrasonic tests
Statements possible, for example, about voids and the position of the heater spiral, not about the quality.
Tensile test DVS 2203-2; Not applicable
Short-time tensile welding factor ≥ 0.9
Tensile creep test DVS 2203-4; With reference to DVS 2203-4, Supplement 1
Tensile creep welding factor ≥ 0.8 The test parameters must be determined in preliminary
DVS 2203-1, Supplement 2 tests.
556
Table 2. Continuation.
Test procedure Heated tool butt welding Sleeve welding with an incorporated heating element
Pipes and fittings Fittings and saddle fittings
Technological bending DVS 2203-5; Not applicable
test Minimum bending angle according to
Minimum bending path according to
Internal pressure creep Test parameters according to ISO 22621; not meaningful for long-time welding factor > 0.5
test
Torsion shear test Not applicable DVS 2203-6, Supplement 1
Also as a site test for pipe wall thicknesses ≥ 4 mm
Radial peeling test Not applicable DVS 2203-6, Supplement 1
Site test for pipe wall thicknesses ≥ 4 mm
Compression test Not applicable DIN EN 12814-4, Section 8
Peeling decohesion Not applicable DIN EN 12814-4, Section 7
test
7 Standards, technical codes and guidelines which are DVS 2208-1 Welding of thermoplastics; machines and
also applicable devices for the heated tool welding of pipes,
piping parts and panels
ISO 22621-5 Plastic piping systems for gas supply for a Supplement 1 –, requirements on tools and devices (under
(under maximum permissible operating pressure of preparation)
preparation) 2 MPa (20 bar) – Polyamide (PA)
DVS 2212-1 Qualification testing of plastics welders; Quali-
DIN EN ISO Plastics; determination of the water content,
fication Test Groups I and II
15512 Method B
DIN EN 12814-4 Testing of welded joints between thermoplastics;
Part 4: Peeling test
DVGW VP 603 Test basis for cleaning agents and their recep-
8 Explanations
tacles for the preparation of welded joints
between polyethylene pipes
The welding of thermoplastics at ambient temperatures < 5°C is
DVS 2202-1 Defects in welded joints between thermoplastics; generally considered to be problematical. This relates not so
characteristics, description and evaluation much to the material-specific properties of the plastic but, to a
DVS 2203-1 Testing of welded joints between thermoplastics; greater extent, to the restricted dexterity of the welder. Therefore,
test procedures – requirements the prerequisite for open-air welding at any outdoor temperatures
Supplement 2 Requirements in the tensile creep test influences. In this respect, it is necessary to pay attention to the
Supplement 3 Requirements in the technological bending information from the manufacturers and to the dew point curve
test, bending angle / bending path (formation of moisture on the workpiece). The parts to be joined
must exhibit an identical temperature level. Trial welds must be
Supplement 4 Requirements on shear and peeling tests for produced and tested.
sleeve welding with an incorporated heating
element (HM) and heated tool sleeve welding It must be ensured that, within the framework of the welding
(HD) on pipes and fittings preparations, any white frost, ice and moisture are removed from
the welding area by supplying heat (e. g. a hot gas device but not
DVS 2203-2 Testing of welded joints between thermoplastics;
test procedures – tensile test a naked flame). Any damage must be avoided.
DVS 2203-4 Testing of welded joints between thermoplastics; Fittings must be stored in closed, frost-free and dry rooms and
test procedures – tensile creep test may only be transported to the welding location in the number
required in each case.
Supplement 1 Testing of sleeve-welded joints between pipes
In the event of water storage over a lengthy period, the semi-
Supplement 3 Testing of the resistance to slow crack growth finished product may absorb up to max. 1.5% moisture (measured
in the full-notch creep test (FNCT)
according to DIN EN ISO 15512, Method B).
DVS 2203-5 Testing of welded joints between thermoplastics;
Attention must be paid to this, for example, in the case of repairs
test procedures – technological bending test
to piping which has been used for a lengthy period. If necessary,
DVS 2203-6 Testing of welded joints between thermoplastics; trial welds must be produced in order to ensure the weldability.
test procedures – testing of joints between
polymeric materials
Supplement 1 Torsion shear and radial peeling tests for
joints manufactured by means of sleeve weld-
ing with an incorporated heating element and
heated tool sleeve welding
557
Re. 4.1 Re. 5

Heated tool butt welding of pipes, piping parts and fittings Sleeve welding with an incorporated heating element
Processing instructions (short version) Processing instructions (short version)

1. Create permissible working conditions, e. g. welding tent. 1. Create permissible working conditions, e. g. welding tent.
2. Connect the welding device to the mains or to the alternating 2. Connect the welding device to the mains or to the alternating
current generator and check its function. current generator and check its function.
3. Align and clamp the parts to be welded, e. g. with dollies. 3. Deburr the outside of the pipe cut off at a right angle. In the
case of excessively pronounced collapsing of the pipe end,
4. Close the pipe ends against draughts. shorten the pipe. See Fig. 5.
5. Clean the joining faces beyond the welding area with a clean- 4. Guarantee the roundness of the pipes using round pressing
ing agent according to Sections 3.2.1 and 3.2.3 with unused, clamps, permissible out-of-roundness: ≤ 1.5%, max. 3 mm.
absorbent, non-fraying and non-dyed paper. Machine the
joining faces, in the case of pipes using a plane (for exam- 5. Clean the joining faces beyond the welding area with a clean-
ple). ing agent according to Sections 3.2.1 and 3.2.3 with unused,
absorbent, non-fraying and non-dyed paper. Machine the
6. Take out the plane in the case of a pipe welding machine. pipe surface in the welding area, if at all possible with a
rotating peeling device and wall thickness removal of approx.
7. Remove the chips from the welding area without touching the
0.2 mm. Remove the chips without touching the pipe surface.
joining faces.
6. Clean the machined pipe surface (in so far as it is contami-
8. Check the plane parallelism by moving the joining faces
nated subsequently) and, if necessary, also the inside of the
fitting according to the information from the manufacturer
9. Check the misalignment (max. 0.1 x wall thickness). with a cleaning agent according to Sections 3.2.1 and 3.2.3
with unused, absorbent, non-fraying and non-dyed paper and
10. Check the heated tool temperature (230 ± 10°C). ensure extraction.
11. Clean the heated tool with a cleaning agent according to 7. Push the pipes into the fitting and check the insert depth on
Sections 3.2.1 and 3.2.2 with unused, absorbent, non-fraying the basis of a previously applied mark. Fasten the saddle
and non-dyed paper and ensure extraction. fitting to the pipe. Pay attention to low-stress assembly.
12. Determine the movement pressure or the movement force Prevent any change in the position of the pipe, if necessary
before every welding operation and make a note of it on the with a holding jig.
welding record sheet. 8. Connect the cables to the fitting in a weight-relieved form.
13. Determine the setting values for the alignment, heating-up 9. Input the welding data (e. g. using a bar code reading pen),
and joining pressures. check the displays on the device and start the welding
14. Stipulate the guide values according to Table 1. process.
15. Move the heated tool into the welding position. 10. Check the correct welding sequence on the welding device
(e. g. by checking the display and, if present, the welding
16. Align the faces to the heated tool until a bead arises (accord- indicators). Pay attention to error messages!
ing to Table 1, Column 2).
11. Detach the cables from the fitting.
17. Heating-up at a reduced pressure ≤ 0.01 N/mm2, heating-up
12. Unclamping of the welded parts when the cooling time
according to the information from the manufacturer has
18. At the end of the heating-up, detach the joining faces to be elapsed. Remove the utilised holding jigs.
welded from the heated tool and move this out of the welding 13. Complete the welding record sheet unless there was any
position. automatic recording.
19. Within the changeover time (Table 1, Column 4), quickly
move together the faces to be welded until they almost touch.
The faces must come into contact at a speed of nearly zero.
Immediately afterwards, build up the joining pressure with a
linear rise in the build-up time (Table 1, Column 5).
20. A bead must exist after the joining at a pressure of
0.25 ± 0.05 N/mm2. According to Fig. 4, K must be > 0 at
every point.
21. Cooling under the joining pressure according to Table 1,
Column 5.
22. Unclamping of the welded parts when the cooling time has
elapsed.
23. Complete the welding record sheet.
558
Record sheet for the heated tool butt welding Overground Material Sheet of
of piping parts Underground
Weather: Protective measures:
Title of the order Name of the welder Code no. Make: 1 = sunny 1 = none
Type: 2 = dry 2 = screen
No. of the order Name and company of welding supervisor Machine no.: 3 = rain or snowfall 3 = tent
Year of construction: 4 = wind 4 = heating
Weld Date Pipe data Measured heated tool Movement Joining Setting values2) Heating-up Changeover Joining pres- Cooling time Ambient Code no.
1) 3)
no. dxs temperature pressure pressure (ma- Alignment Heating-up Joining time3) time sure build- under joining temperature3 Weather Protec-
3) 3)
min. max. chine table) up time pressure tion
1)
From the control interval, frequency according to Section 4.1.2.
2)
According to information from the manufacturer of the welding machine or from the machine test plus the movement pressure or force.
3)
The measured values must be entered.
559
560
Record sheet for the sleeve welding of piping parts Overground Material Sheet of
with an incorporated heating element Underground
Weather: Protective measures:

Title of the order Name of the welder Code no. Make: 1 = sunny 1 = none
Type: 2 = dry 2 = screen
No. of the order Name and company of welding supervisor Machine no.: 3 = rain or snowfall 3 = tent
Year of construction: 4 = wind 4 = heating
Weld Date Pipe data Fitting data Device setting Fitting Secondary Welding times 2) Ambient Code no. Operating mode
1)
no. dxs A B Serial no. Manual Automatic resistance voltage1) Heating Cooling temperature2 Weather Protective Mains Gener-
[mm] [ohm] [volt] [s] [min] [°C] measures ator
1)
If necessary, entries according to the system used. A = manufacturer's code 1 = sleeve 2 = angle 3 = T-piece 4 = reducer
2)
The measured values must be entered. B = fitting code no. 5 = saddle 6 = cap 7 = adapter

C:\DVS Merkblätter\2207\2207-25\e2207-25.fm
DVS – DEUTSCHER VERBAND Welding of Thermoplastics Directive D

Heated Tool Butt Welding DVS 2207-25
VERWANDTE VERFAHREN E.V. Welding of Casements sections made from PVC-U (October 1989) S 
Contents: 3 General requirements
1 Range of application The sections to be joined together are to be conditioned of at

2 Terminology least 24 hours until the temperature reaches at last 15 °C over
3 General requirements the entire section.
4 Welding processes
5 Welding machines During this time, the sections should be stored in such a way that
no impermissible deformation takes place.
6 Preparing the machine
7 Preparing the components to be jointed The sections must be dry and their surfaces must be clean. In
8 Producing welded joints connection with this, it is advisable to open the packaging at the
9 After-treatment of welded joints front faces or, if necessary, to remove it completely. Any moisture
10 Testing welded joints which may be adhering to the sections must be removed by
11 Other standards and directives applying means of suitable measures (for example using an air jet).
12 Clarifications
The connecting surfaces of the sections to be welded must not
13 Appendix: Operating symbols for welding machines
be damaged and must be free from impurities (for example dirt,

14 Appendix: Guidelines on safety at work and accident pre-
grease, swarf) and moisture (condensation of water vapour due
vention
to variations in temperature).
The working area, and the welding area in particular, should be
1 Range of application protected against the effects of draughts, moisture and
impurities. Before the welding operation commences, the set-up
These directives apply to the production of joints on extruded should be checked to make sure that it coincides with the pre-set
sections, made from unplasticised polyvinyl. chloride (PVC-U1)), welding parameters. If necessary, some test pieces should be
for the manufacture of windows, doors, frames and other welded and the results checked. Test corners welded may not
structural elements, by heated tool butt welding, for example undershoot the minimum breaking loads laid down in the section
casement sections made from PVC-U (predominantly PVC HI) in manufacturer's system description (see Section 10, 'Testing
accordance with RAL-RG 716/1. Welded Joints').
The directives also apply to extruded sections made from PVC-U Welding operations should be carried out by specialist personnel
with coated surfaces, where the coating may consist of other who are familiar with the work and have adequate experience2).
thermoplastic plastics.
4 Welding processes
2 Terminology
The welded joints made from extruded PVC-U sections covered
Matching Section 4 and Fig. 1 by these directives, are produced by means of heated tool butt
Matching time Fig. 1 welding. Welding machines, as per Section 5 of these directives,
Heating cycle Fig. 1 are to be used for this. The connecting surfaces of the sections to
Heating time Fig. 1 be welded are matched on the heated tool under pressure
Heating pressure Fig. 1 and Section 5.5.1 (matching) until their entire surfaces are in contact. This has
Working pressure Section 5.2. been achieved if a clearly visible bead has formed over the entire
Adjustment plates Section 5.2. periphery of the section.
Jointing Section 4 and Fig 1
Components to be jointed Section 7 Matching is completed by a stop or by control of the working table
Jointing path Section 4 and Fig 1 movement, and passes directly into the heating process. Here
Jointing time Section 4 and Fig 1 the connecting surfaces are heated to the welding temperature
Jointing pressure Section 4 and Fig 1 and a sufficiently deep molten layer is formed. The heating
Heated tool butt welding (HS) Sections 4 and 8 process is controlled on a time basis, and the pressure in the joint
Bead limitation Section 5.3. surface corresponding to Fig, 1 must be reduced to the heating
pressure, PAW. When the warning-up time is over, the sections
Burn-off Section 7
are released by the heated tool and the heated tool is removed
Gap width Section 5.3.
from the welding plane (repositioning).
Clamping pressure Section 5.2.
Repositioning Section 4 and Fig 1 Directly after this, the two welding surfaces of the section are
Repositioning time Section 4, Fig. 1 and joined under the jointing pressure (jointing). The jointing path is
Section 5.5.2. limited by a stop or by control of the working table movement.
1) The internationally used term PVC-U, standing for 'unplasticised polyvinyl chloride' corresponds to the term 'rigid PVC' formerly in use.
2) Training courses on machining plastic casement sections are provided by the Plastics Processing Institute at the Aachen University of Technology (tel.:
+49 241/80 38 12), and in the associated course workshops, and by the South German Plastics Centre in Würzburg (tel.: +94 931/4104-0).
DVS, Technical Committee, Working Group W 4 "Plastics, Welding and Adhesive Bonding"
and Plastic Casement Section Quality Group of Plastics Products Quality Association
561
The jointing time should be selected in such a way that the joint b) It must. be possible to set. the clamping pressure, matching
weld is sufficiently cooled. The jointing pressure should be pressure and jointing pressure separately and externally, and
selected in such a way that the stop is not reached until the the settings must be repeatable and easily read off
second half of the jointing time (0.3 to 0.7 N/mm²) and the fusion
c) The control and display elements must be clearly indicated3)
viscosity of the material and the jointing surface of the section
should be taken into account. When the stop has been reached, d) Rapid clamping devices must be stable, adjustable and
the jointing pressure in the jointing area is reduced. The jointing replaceable
pressure then decreases further as a result of the cooling e) The clamping elements must open sufficiently widely for the
process. Fig. 1 gives a schematic outline of the individual stages workpiece to be removed without difficulty
in the process.
f) Clamping devices should be designed in such a way that
injury to the operators is avoided
g) The sequence of operations for the welding process must be
extensively mechanised, in order to guarantee good
reproduceability
h) It must not be possible to bring the heated tool into the
operating position unless the clamping table is in the initial
position
i) The welding slides must be guided without any play but so
that they move easily, in order to obtain good reproduceability
j) Unintentional activation of the operating process must be
prevented by a safety device
k) An interruption in the power supply must not trigger any
uncontrolled phenomena of movement
l) The exhaust air from the pneumatic valves must not be
directed onto the heated tool.
5.2 Removal of workpiece and clamping device

High standards are set for the surface quality of the components
to be welded. The seats and clamping devices must therefore be
designed in such a way that they
– fix the sections securely
– transmit the forces required for welding without damaging or
deforming the section surface
– avoid any impermissible mismatch in the weld.
The sections should be supported in the vicinity of the jointing
Figure 1. Sequence of operations for heated tool butt welding of zone, in such a way that deflection and deformation during
sections with jointing path limitation – path-time and pressure- warning-up and jointing are avoided. Depending on the type of
time diagrams (schematic). section in question, 'adjustment plates' are to be provided to
support the sections, so that the working pressures or clamping
sAG Matching path tF Jointing time pressures required for welding can be accepted by the sections
sF Jointing path tS Welding time (total) without any deformation. The clamping elements must exercise a
sS Welding path (overlength) PAG Matching pressure uniform pressure on the clamping surface, in order to clamp the
tAG Matching time PAW Warming-up pressure
section securely and without deformation.
tAW Warming-up time PF Jointing pressure
tU Repositioning time
5.3 Bead limitation
Should the thickness of the bead be limited by a heated device,
its temperature in the jointing area must be controllable to within
5 Welding machines
± 5 °C. (The usual temperatures for bead limitation lie in the
range between 45 and 50 °C.). The range of the limitation
Section welding machines are intended exclusively for stationary influences the strength of the welded joint. Reducing the gap
workshop operation. They must meet the safety regulations width reduces the strength.
applicable. They are used for welding sections, for example
window and door profiles, to frames, T-connections, double 5.4 Heated tool design
junctions or various angles can also be welded, depending on the
construction and equipment of the welding machines. The mounting brackets and guidance of the heated tool must be
designed in such a way that it can be matched to the joint
The welding machine must be set up in a dry area on a level surfaces or can be centred, and can easily be moved. The
load-bearing base support. It must also be in a place free from release and removal of the heated tool from the joint surfaces
draughts. after the heating process must take place as quickly as possible,
so that the permissible repositioning time of max. 2 s is not
5.1 Structure of machine and safety in use. exceeded. Special measures are usually adopted to make it
easier to release the heated tool from the plasticised joint
To meet the requirements for design and construction, the surfaces (for example PTFE covering).
following points should be. taken Into account in the structure of
the machine: 5.5 Control and adjustment for pressure. time and path
a) The structure must be stable and the table construction The control and adjustment of the welding machine must be
torsion-proof designed in such a way that the welding parameters are
3) See Appendix, Section 13: Operating Symbols for Welding Machines.
562
maintained, the strength and viscosity of the welds meet the Table 2. Permissible angular deflection on V-form heated tools.
requirements, and the pre-set dimensions of the window are
maintained. Fig. 1 gives schematic diagrams for the pressure- Length of a side mm permissible deflection mm
time progression and the path-time progression. It must be l a
possible to calibrate the control and adjustment equipment, and it ≤ 100 0.3
must be tested at regular intervals and readjusted if necessary. > 100 ... 150 0.4
> 150 ... 200 0.6
5.5.1 Pressure control > 200 0.8
The matching pressure, heating pressure and jointing pressure
must be separately adjustable. The heating pressure must be The useful area here is taken as being the part of the heated tool
close to 0 (see Fig. 1). Pressure gauges of accuracy class ≤ 1.6, in which the temperature and the amount of heat delivered can
as per DIN 16 005 and 16 063 must be provided for the matching be adjusted over the required range. The manufacturer must
pressure and jointing pressure, and the graduation of scale used display the dimensions of the useful area on the heated tool in
must be 0.2 bar. The minimum and maximum machine pressure permanent form.
which can be set, together with the effective piston surface of the
5.6.2 Surface finish
main cylinder, must be stated in the machine documents. The
pressure in the welding surface can be calculated from these The surface finish of heated tools in the useful area must be such
data and from the cross-section of the profile. as to avoid any plastic material residues remaining behind. It
must be possible to clean heated tools without damaging them.
5.5.2 Time-control
Coatings or coverings, for example PTFE, are recommended to
The heating time and jointing time must be separately adjustable make it easier to keep the surface clean and to reduce the
in stages. The repeatability of the heating and jointing time must adhesion when the components being jointed are removed.
be within an accuracy of ± 0.5 s. The repositioning time is Coverings must remain in contact with the heated tool at the
specified by the equipment. It must not exceed 2 s and must be welding temperature.
repeatable within ≤ 0,2 s.
PTFE spray acts as a parting agent and must not be used
since it is removed from the heated tool along with the
5.5.3 Path control
jointed components and transferred into the weld!
Path control must ensure that the pre-set dimensions of the Heated tools newly covered or newly coated with PTFE must be
window are maintained. In conjunction with the placing stop, the heated for at least 0.5 hours to a temperature of 280 °C, when
matching path and the jointing path must display a repeatability first put into operation.
of ≤ 0.1 mm.
The roughness depth value, Rt, (the roughness class as per DIN/
5.6 Heated tool ISO 1302 is given in brackets) is as follows, depending on the
version of heated tool used:
– Heated tool with indirect heat release through a heat conductor
(DVS 2208, Part 1) – – With PTFE covering or coating, Rt ≤ 16 µm (17). Usual coating
depths are 30 to 50 µm, and PTFE/fibreglass tissues in
The heat is transmitted from embedded electrical heaters to the thicknesses of 100 to 300 µm.
surface of the heated tool through a material which is a good
conductor and resistant to corrosion. Cast heated tools must be The covering or coating material must withstand a temperature
free of shrinkholes. stress of 300 °C for an hour without any significant change in its
anti-adhesive properties or its adhesive strength. In continuous
5.6.1 Design use the temperature should not exceed 270 °C.
Heated tools must be suitable for the jointing surfaces in terms of 5.6.3 Useful area of heated tool
form and dimensions. If laminar heated tools are used on both
sides, they must be plane parallel within their useful areas. The external dimensions of a heated tool should exceed the
Permissible deviations from plane parallelism are given in Table length of the sides of the useful area by at least 5% all the way
1 and are based on room temperature. round. The useful area AN is then obtained from the external
dimensions of the heated tool, aH and bH, for example as in Fig.
3:
Table 1. Plane parallelism of laminar heated tools.
AN = aN x bN in cm², where aN = 0. 9 aH, bN = 0.9 bH
Useful area cm² Permissible deviation mm
Plane paralellism Heated tool thickness
≤ 250 ≤ 0.2 ± 0.1
> 250 ... 400 ≤ 0.4 ± 0.15
> 400 ≤ 0.5 ± 0.2
The data in Table 2 apply to the permissible angular deflections

on V-form heated tools (Fig. 2).
Figure 3. Example for the position of the useful area.
The entire welding surface must lie within the useful area.
5.6.4 Minimum heated tool power

The minimum heated tool power is dependent on the conditions
of use and the type of model. The electrical power, based on the
Figure 2. Representation of angular deflection on V-form heated tools. heater area (aH, bH,), must be at least 2 W/cm².
563
5.6.5 Minimum temperature range are to be set or checked. The heated tool temperature in the
The heated tool must be continuously adjustable over the useful area should be measured using a suitable gauge (see
required temperature range within the useful area, at least Section 5.6.7). The average standard interval should not deviate
between 200 °C and 300 °C. from the nominal value by more than the amounts listed in Table
3.
5.6.6 Temperature precision
6.3 Commissioning the welding machine
The temperature precision should correspond to the welding
temperature differences listed in Table 3. These welding Good welded joints can not be obtained unless the welding
temperature differences correspond to the temperature machine has reached a constant operating condition. It takes
variations: about 0.5 hours to achieve this because of the heating of the
heated tool and the clamping devices. The welding machine must
a) over. the useful area therefore be switched on at least 0.5 hours before production
b) through the standard interval starts.
c) on the two sides.
Table 3 shows the resulting maximum permissible total 6.4 Functional testing
temperature differences in the effective area. The effective area Before production starts, and after any long interruptions, a
is the surface within the periphery of the profile section. functional test is to be carried out. At least one welded joint is to
be produced for this. Apart from the maintaining of the welding
Table 3. Maximum permissible temperature differences. parameters, special attention is to be paid to satisfactory
useful area area of temperature differences °C clamping of the section and the regular formation of the bead.
cm² a b c total
7 Preparation of components for jointing
≤ 150 4 2 2 6
> 150 ... 250 5 3 3 8 The profile sections which are intended to weld should be
> 250 ... 400 7 3 3 10 checked with regard to their geometric form and usability before
> 400 9 3 3 12 being cut to size. In the case of main profiles special attention
should be paid to mismatch and to the flatness of the surfaces
These values are to be maintained after a build-up time of app. which are visible after jointing.
30 min., at room temperature, in an environment protected from
draughts, in the working position, within the useful area and at a The burn-off – the difference between the component cut to size
reference temperature of 250 °C. for jointing in the unwelded condition and the finished size in the
welded condition – is to be taken into account when cutting to
5.6.7 Temperature control size takes place. It comes about in connection with the formation
of a bead of plasticised material during matching, heating and
The temperature control must guarantee the characteristic
jointing. (The burn-off was also previously known as the
temperature values required under Sections 5.6.5 and 5.6.6.
'consumption'.)
From the initial contact of the jointed surfaces to repositioning,
the temperature must not fall by more than 4 °C. The heated tool The cutting equipment used (preferably circular saws) must be
temperature must return to the nominal value during the jointing manufactured in such a way that the jointing surfaces do not
time of the welded component. deviate from the nominal values by more than 0.5 mm.
An additional check on the heated tool surface temperature is Deviation includes
required. Suitable equipment for this consists of (for example) – angular deflection
rapid-indicating contacting electrical surface temperature gauges – flatness
with appropriate mass-impregnated and drained probes or – roughness of jointing surface.
contactless radiation meters 4).
The cutting tools must be manufactured in such a way that the
jointing surfaces can be produced without difficulty and without
6 Preparation of machine impermissible heating, Swarf which impedes the jointing process
should be removed (for example by suction or blow-off).
6.1 Visual assessment of function capability of welding machine
The jointing surfaces must be kept free from damage and
The functional capability of the welding machine is to be impurities (for example dust, grease, hand sweat, protective foil,
evaluated before commissioning. The welding machine and the etc.). Moreover, the components cut to size for jointing are to be
leads must be in a condition allowing for a satisfactory sequence stored in a constant climate.
of operations. The machine's service units must be inspected
and maintained at the intervals laid down by the machine
manufacturer. 8 Production of welded joints
The condition of the heated tool surface is of special importance. – Place the jointing components to be welded, cut askew (on the
In the welding area, the surface coating of the heated tool must median) to size, into the machine.
be clean, free from faults and free of damage (for example,
pimples, cracks, etc,). No residues must be present. A stretched – Press the sections against the stops and the adjustment plates
PTFE/fibreglass tissue must be in uniform contact with the unless this part of the work has been taken over by the
heated tool at the welding temperature. machine.
When a new PTFE/fibreglass tissue has been fitted, the heated – Hold the jointing components in this position and release the
tool should be operated for 0,5 hours at 280 °C, in order to clamping devices.
harden the surface. The first three welded joints produced using – Activate the welding process.
this new PTFE/ fibreglass tissue are of inferior strength and
should therefore not be used. – The welding of the jointing components is carried out by the
welding machine automatically in accordance with the welding
6.2 Setting welding parameters parameters to which the welding machine is set.
The welding parameters laid down for the section to be welded – – The welding process is completed when the clamping device
working pressures, temperatures, times and bead limitations – opens.
4) .
Information can be obtained from the Casement Sections Quality Group, 2, Dyroffstraße, 5300 Bonn 1, W.Germany (tel 02 28/22 35 7M.).
564
– Do not release the welded jointing components from the The maximum force values for corner welds depend on the
clamping devices and remove them from the machine until the profile geometry and the test rig. The maximum corner weld
welded joints have cooled down sufficiently. values measured, F, must not be less than the calculated limiting
values for the breaking force, Fsoll. Fsoll is calculated as follows,
– Since the weld has not yet cooled completely, as little stress as
with a failure stress of σ = 35 N/mm²:
possible must be put on the joint.
F soll = 2 ⋅ W ⋅ σ-
--------------------
--a- – ------
e-
9 After-treatment of welded joints 2 2
The welding bead should be taken off as soon as possible, once = σ F ⋅ h-
----------
enough cooling has taken place, so as to avoid any impairment of 2W
the weld strength and appearance. Accelerated cooling, for l
example using compressed air, is not permissible and can lead to W= ---
e
stress cracking.
a e-
--- – ------
Welding beads should be removed manually or mechanically h =
2 2
using suitable means. The process can have a significant
influence on the strength of the welded joint.
Some examples of factors which can reduce the strength are:
– notches in inside corner
– grooves in the visible surfaces
– streaking of surfaces.
Using polishing and cleansing agents which dissolve PVC is not
permissible, as can lead to stress cracks and discolouration.
Consult the profile manufacturer's instructions for the after-
treatment of welded joints Involving co-extruded surfaces, coated
surfaces, or surfaces laminated with foil.
10 Testing welded joints
The welded joints are tested using corner samples of (90 ± 1)° or Figure 5. Representation of parameters for calculation of Fsoll.
T-connections from which one side of the continuous section is
out off. The welding bead should not be removed. In this context is:
The sides of the corner under test are cut to length, at an angle of F Maximum force
(45 ± 1)°, in such a way that the neutral fibres (approximately at Fsoll Breaking force limiting value
the centre of the main chamber of the section) lie above the axis I Axial angular impulse
of rotation of the test chassis. W Section modulus in direction of stress (inside corner)
The side lengths on the internal sides (Li) can be derived from the σ Failure stress (see DIN 16 830, Part 2 (at present draft)
lengths of the neutral fibres (Ln = 283 mm), minus twice the a Distance between axes of rotation; a = (400 ± 2) mm
distance of the section's internal sides from the neutral fibre (e): e Distance between critical fibre and neutral fibre
Li therefore equals 283 mm – 2e. Ln Length of neutral fibre; Ln = 283 mm.
Li Side length on internal side; Li = 283 mm – 2 ∙ e
For corners from sections with articulated asymmetrical external
h Lever arm
sides, the pressure stamp is to be adjusted to impose a uniform
stress on the profile section of the form of the external section
flank at the point of the corner (using adjustment plates as well,
for example).
Figure 4. Test rig with movable supporting (a = 400 mm).
In a suitable test rig, as in Fig. 4, which has movable supporting

chassis which can rotate around the transverse axis, the corners
are deformed in a pressure test, with a testing speed of (50 ± 5)
mm/min at room temperature (18 to 28 °C) without jolting, until Figure 6. Example of a minimum failure curve Fsoll as a function of the
they break, and the maximum forces arising are measured. section modulus with e = 40 mm and σ = 35 N/mm2.
565
11 Standards and directives also applying

Start
DIN 1910, Welding; welding plastics, processes
Part 3
DIN 7728, Plastics; Code letters and abbreviations for
Release, normal position
Part 1 polymers and their special properties
DIN 16 005 Excess pressure gauges with flexible error detector
for general use, requirements and testing Setting up
DIN 16 063 Excess pressure gauges with bourdon tube,
housing diameters 40, 50 and 63 mm, precision
class 1.6, 2.5 and 4.0 – dimensions and Indicating Clamping off
ranges
DIN 16 830, Draft Casement sections made from polyvinyl
Part 1 chloride of high impact strength (PVC-HI) – Test Clamping, clamping pressure
process
DIN 16 830, Draft Casement sections made from polyvinyl
Part 2 chloride of high impact strength (PVC-HI) – Brake
Requirements
DIN 32 502 Faults in welded joints made from plastics;
classification, terms, clarifications Matching pressure
DVS 2206 Testing of structural elements and structures made
from thermoplastic plastics
Heating-up time
DVS 2208, Machines and equipment for welding thermoplastic
Part 1 plastics – Heated tool welding
RAL-RG Plastic windows, quality assessment. (Quality and Jointing pressure
716/1 test regulations for plastic windows)
VDE 0100 Regulations for the erection of power plants with
rated voltages of up to 1,000 Volts Jointing time
VDE 0105, Regulations for the operation of power plants –
Part 1 General regulations
Check machine settings (weld strength risk)
VDE 0250 Regulations for insulated power lines
VDE 0551 Regulations for safety transformers
VDE 0612 Regulations for power distribution on building sites Temperature monitoring on
for rated voltages of up to 380 Volts AC and
currents of up to 630 A
VDE 0720 Regulations for electrical heating units for domestic Heated tool
use and similar purposes (apply by analogy)
Heated tool cleaning

12 Clarifications
These directives were drawn up by the GWEA/PCSQG Joint

Working Party. This consists of members of GWEA Working 14 Appendix: Guidelines on safety at work and accident
Party W4, representatives of the Plastic Casement Section prevention
Quality Group, and representatives of manufacturers of welding
machines for casement sections. The directives are intended to The 'Law on Technical Means of Operation' (Equipment Safety
allow window producers to optimise welded joints in window Law) of 24th June, 1968 lays down that technical. means of
manufacture and to keep them constant, and thus to ensure operation may be brought into use only if they correspond to the
welded joints of uniform quality. generally recognised rules of the art, as well as to the guidelines
on safety at work and accident prevention.
The results of long years of practical experience from the
manufacturers of profile sections and welding machines have Consequently, the generally accepted rules of the art, for
gone into these directives, together with the most recent example the relevant VDE guidelines, together with the
developments in machine technology. Special attention has been guidelines on safety at work and accident prevention, are to be
paid to the results of the research projects 'Welding PVC respected during the construction of plastic welding machines.
casement sections' and 'Welding corner joints on PVC casement
sections' of the South German Plastics Centre in Würzburg. 14.1 Electrical equipment
The following guidelines, in particular, apply as regards to the
construction and operation of welding equipment:
13 Appendix: Operating symbols for welding machines
VDE 0100 Regulations for the erection of power plants with
rated voltages of up to 1,000 V
On VDE 0105 Regulations for the operation of power plants –
Part 1 General regulations
VDE 0250 Regulations for insulated power lines
Off
VDE 0551 Regulations for safety transformers
VDE 0612 Regulations for power distribution on building rites
for rated voltages of up to 380 V AC and for
Placing, preparation currents, of up to 630 A
566
VDE 0720 Regulations for electrical heating units for domestic

use and similar purposes (apply by analogy)
14.2 Constructions and handling

General guidelines on safety at work and accident prevention
should be respected in the manufacture, handling and
maintenance of welding machines. Particular attention should be
paid to the chapter on 'Welding Machines and Welding
Equipment' in the guidelines of the Chemical Industry
Professional Trade Association on machines for processing and
converting plastics.
567
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Erstellt am:
24.10.2008
07.11.2014
January 2009

FÜR SCHWEISSEN UND Machines and devices for the heated tool Technical Code
VERWANDTE VERFAHREN E.V. welding of pipes, piping parts and panels
DVS 2208-1
Translation of the German edition from March 2007
Contents: 5.1.4 Input systems

5.1.5 Temperature measurement in order to compensate for
1 Scope of application the welding energy
2 General requirements on machines for heated tool butt 5.1.6 Transformers
welding and heated tool sleeve welding 5.2 Operating sequences
2.1 Clamping facilities 5.3 Device requirements
2.2 Guiding elements 5.3.1 Working range
2.3 Facility for the weld preparation 5.3.2 Energy supply
2.4 Arrangement of the heated tool 5.3.3 Measurement of the fitting resistance
2.5 Control and regulation facilities 5.3.4 Energy output
2.5.1 Force control
5.3.5 Welding time
2.5.2 Time control
5.3.6 Safety facilities
2.5.3 Displacement control
5.3.7 Proof of the loading
2.5.4 Record sheet printout
2.6 Structure and identification of the machines 5.4 Identification
2.7 Operational safety 5.5 Record sheet printout

2.8 Inspection and maintenance 5.6 Inspection and maintenance
2.9 General requirements on heated tools 6 Standards, technical codes, directives and guidelines
2.9.1 Designing 6.1 Standards
2.9.2 Materials 6.2 Technical codes and guidelines
2.9.3 Surface condition 7 Explanations
2.9.4 Minimum power of the heated tool Appendix: Specimens for inspection record sheets
2.9.5 Minimum temperature range
2.9.6 Temperature accuracy
3 Machines for heated tool butt welding 1 Scope of application
3.1 Welding machines for pipes
3.1.1 Clamping facilities In this technical code, the processors of semi-finished products
3.1.2 Guiding elements and clamping facilities and the machine manufacturers are given an overview of the
3.1.3 Heated tools requirements which must be set on devices and machines for the
3.1.4 Facility for the weld preparation heated tool welding and sleeve welding with an incorporated
3.1.5 Control and regulation facility for the force, the time, the electric heating element of thermoplastics. On the basis of the
temperature and the displacement highlighted characteristics, the processor can check with which
3.1.6 Structure of the machine and safety in utilisation devices or machines his welding tasks can be performed in a
3.2 Welding machines for panels safe way suitable for the material.
3.2.1 Clamping facilities
The technical code relates to the processes and the various
3.2.2 Guiding elements
execution types of heated tool welding in which the joining faces
3.2.3 Heated tools
are heated by direct contact with the heated tools as are
3.2.4 Control and regulation facilities
described, for example, in DVS 2207-1, DVS 2207-11 and
3.2.5 Structure of the machine and safety in utilisation
DVS 2207-15. In the case of heater spiral fittings, the heated tool
4 Machines for heated tool sleeve welding
is already integrated into the component in the form of an
4.1 Designs
electrical conductor and remains there after the joining process.
4.2 Technological variants
4.3 Welding machines and devices The content of the technical code relates, in particular, to devices
4.3.1 Heated tools for the welding of polyolefins (PE, PE-X, PP and PB) as well as of
4.3.2 Clamping facilities PVDF, PVC-U and PVC-C.
In the case of devices for the welding of other thermoplastics, it
4.3.4 Control and regulation facilities for the force and the
must be checked in each individual case whether the material or
displacement
the process necessitates the consideration of any requirements
5 Devices for sleeve welding with an incorporated electric
deviating from those stipulated in this technical code.
heating element
5.1 Structural designing This technical code does not deal with special machines, the
5.1.1 General whole field of film and sealing sheet welding, the infrared welding
5.1.2 Electrical safety technology or devices for high-frequency, vibration or friction
5.1.3 Operator guidance welding etc.
568
2 General requirements on machines for heated tool butt In the case of machines with spring force, the scale graduation of
welding and heated tool sleeve welding the display device must be adapted to the maximum display
value:
The requirements to be set on machines and devices for heated Range  100 N: 10 N
tool welding are so diverse and so closely linked to the welding
Range > 100 ...  500 N: 20 N
task to be performed in each case that it is not advisable to
Range > 500 N: 50 N
manufacture universal machines which can be modified for all the
welding tasks. For this reason, the generally applicable The required working pressure of the machine must be preselect-
requirements are described first of all below and then the able. The difference between the desired and actual joining forc-
particular features of the individual machine groups. es must not be more than ± 10 %. In the event of a greater devia-
tion, it is necessary to elaborate a correction table.
The manufacturer must prove in a suitable form that his product
fulfils the requirements described in this technical code. The operating forces must not exceed 250 N.
2.1 Clamping facilities 2.5.2 Time control

The clamping facilities must be designed in such a way that the For a safe welded joint, the time sequence must be controlled
parts to be welded are clamped in a precise, quick and safe way exactly. The times must be monitored.
and the forces necessary for the welding are transferred without
changing the positions of the workpieces. The clamping facilities 2.5.3 Displacement control
must not exert any detrimental influence on the workpiece
A total tolerance of  0.5 mm must be complied with during the
surface. For pipes and piping parts, they must be structurally
joining operation.
designed in such a way that round forming is obtained in the weld
area.
2.5.4 Record sheet printout
2.2 Guiding elements In the case of machines with recording or controlled machines, it
is necessary to print out record sheets whose content must fulfil
The guiding elements must be able to accommodate the resulting the following minimum requirements:
forces and must guarantee that the forces required for the
welding are transferred to the workpieces in a safe and precise Devices for heated tool butt welding:
way. The guides must be easy-running in all the operating – machine type and machine number
conditions. This is achieved, for example, by good continuous
lubrication. – date and time
– record sheet number and welder number
In the case of manual lubrication, the lubricating points must be
marked, readily visible and easily accessible. Corresponding – building site or order number and weld number
remarks must be included in the operating instructions. – dimensions of the semi-finished product and material
– outdoor temperature
2.3 Facility for the weld preparation
– nominal temperature and actual temperature of the heated tool
In the case of welding operations which require the machining of – heating-up time, changeover time and joining pressure build-
the joining faces while the workpieces are in the clamped up time
condition, provision must be made for a facility for chip-producing
– movement pressure, nominal pressure, actual pressure and
machining. This facility must not hinder any other operations of
cooling time
the machine.
– all the disturbances during the course of the welding must be
2.4 Arrangement of the heated tool recorded
– date of the last or next inspection
In the case of heated tool butt and sleeve welding, the
suspension and the guide of the heated tool must be designed in
2.6 Structure and identification of the machines
such a way that they are parallel to the joining faces. One
possibility to this end is a self-centring suspension for The structural designing of the welding machine must be adapted
displacement within certain limits without any resistance. After to the utilisation conditions and ambient influences of the welding
the heating-up operation, it must be possible to release and tasks.
remove the heated tool from the joining faces as quickly as
The operating instructions must include:
possible so that the permissible changeover time is not
exceeded. If necessary, provision must be made for special – the characteristic values of the machine
facilities for the detachment of the heated tool from the – functional descriptions
workpiece.
– maintenance instructions
2.5 Control and regulation facilities Any information which is indispensable for safe operation, i. e.:
In order to ensure reproducible results, it must be possible to – CE symbol
adjust the pressure and/or the time to the material to be welded – manufacturer
as well as to the other welding conditions. Requirements on the
temperature regulation are dealt with in Section 2.9.6. The – type
nominal and actual values must be recorded in a suitable form. – year of construction
– characteristic data (according to DIN)
2.5.1 Force control
must be affixed to every machine in a clearly recognisable and
For process-related reasons, the forces are not recorded by the permanent form.
devices in the case of heated tool sleeve welding. With regard to
heated tool butt welding, see Section 3.1.5.1 on this subject. 2.7 Operational safety
The pressures must be easy and clear to set and read off. In the The accident prevention regulations must be complied with and
case of hydraulic machines, the manometer must have a scale attention must be paid to the safety provisions according to VDE
graduation of  1 % of the final value. The display accuracy is and the Operational Safety Ordinance, particularly if any work is
± 0.5 bar (Quality Class 0.5). carried out with electrical voltage over 50 V.
569
2.8 Inspection and maintenance Moreover, attention must be paid to the following:
According to the information from the manufacturer but at least – In the case of a PTFE coating, Roughness Class N9 according
once per year, the welding device or machine must be inspected to DIN ISO 1302 (Ra 6.3 µm, Rt 16 µm). Customary coating
by an expert with the experience necessary for this purpose and thicknesses are between 30 µm and 50 µm. PTFE coatings
with proof of the qualification by the manufacturer concerned. must be dyed in such a way that any damage and residues
The inspection cycle must be shortened in the case of machines from the welding operation are easily recognisable.
and devices which are subjected to above-average loads. In the – In the case of electrodeposited coats, it is not allowed to use
operating instructions, reference must be made to the cycles and any copper primers or any electrodeposited coats containing
scope of the maintenance. copper.
Specimens for inspection record sheets are included in the
appendix. 2.9.4 Minimum power of the heated tool
2.9 General requirements on heated tools Irrespective of the type of the temperature regulation, of the
regulation behaviour connected with this and of the temperature
Embedded electric heating elements or heat carriers transfer the profile on the usable heated tool area, the temperature drop in
heat to the surface of the heated tool through a thermally the region of the workpiece supporting block must have balanced
conductive material. out to a value < 5°C by the end of the alignment time. An
The heated tool must be constructed in such a way that it is no adequate thermal capacity of the heated tool and a sufficient
problem to heat the joining faces up to the welding temperature in heating power are required for this purpose.
operating conditions. The handling of the heated tool must not
exert any negative influence on the changeover time. During the 2.9.5 Minimum temperature range
alignment time and the heating-up time, the operating personnel The heated tool must be infinitely adjustable across the required
must be able to observe the bead formation at the heated tool. temperature range within the useful areas:
It must be possible to move the heated tool into a position in
– in the case of heated tool butt welding from 180°C to 260°C
which it can be cleaned safely without any problems. The
maximum nominal temperatures which can be set on the – in the case of heated tool sleeve welding from 230°C to 270°C
machine must not lead to any destruction of or change in the The measurements are taken with the heated tool in the working
surface coating. position, after an operating duration of min. 30 minutes, with
The particular features of sleeve welding with an incorporated slight air movement and at an ambient temperature of 23 ± 2°C.
electric heating element are described in Section 5.
2.9.6 Temperature accuracy
2.9.1 Designing The temperature deviations measured at a heated tool result
The whole welding area of the workpieces must be located within from technically induced inaccuracies (regulator deviation and
the useful area of the heated tool. In this respect, the region in temperature distribution across the useful area), from the
which the temperature and the heat to be emitted can be installation position of the tool (e. g. natural convection and
regulated within the demanded tolerance field is regarded as the shielding effects) and from ambient influences (e. g. draughts).
useful area. The dimensions of the useful area must be indicated The temperature difference between the highest and lowest
permanently on the heated tool. temperatures at any position on the useful area of the tool is
designated as a regulator deviation. The temperature distribution
2.9.2 Materials across the area results from the difference between the highest
The heated tools are made of a corrosion-resistant material with and lowest mean temperatures within the useful area.
adequate thermal conduction and without any shrinkage cavities. Optimum testing conditions which exclude any ambient
influences such as natural convection to the largest possible
2.9.3 Surface condition extent are necessary for the exact determination of the
In the useful area, the surface of a heated tool must be in such a technically induced temperature deviation.
condition that no residues of the plastic material remain and the In the case of measurements in practical conditions, disturbing
cleaning can be carried out without any damage. Coatings are variables (e. g. draughts) exert a serious influence on the
recommended in order to make it easier to keep the surface measured results. Therefore, greater temperature deviations
clean and to reduce the adhesive forces when the joining parts than the values listed in Table 1 for the technically induced total
are detached. deviations do not directly suggest an impermissible heated tool.
Anti-adhesive spray acts like a separating agent and must not be If the temperature deviation measured with the heated tool in the
used. When the joining parts are lifted off the heated tool, it is working position (vertical position) is greater than the permissible
also lifted off and is transferred into the weld. temperature deviations according to Table 1, Line 3, the
In order to check the coating quality, heated tools newly coated measurement must be repeated in the horizontal position. If the
with PTFE must be preheated up to the working temperature of temperature deviation is impermissible once again, further
260°C for at least one hour before the first commissioning. measures must be taken, in so far as they promise success, in
Temperatures over 270°C destroy the PTFE coating and the order to optimise the measuring conditions (e. g. measurement in
heated tools must then be coated anew. laboratory conditions).
Table 1. Maximum permissible technically induced temperature deviations.
Heated tools for pipes and fittings Heated tools for panels
Useful area [cm2] < 250  250 ...  2,000 > 2,000 ...  5,000 > 5,000 ...  12,000 > 12,000
Regulator deviation [°C] 3 3 3 3 3 3
Temperature 5 7 11 13 14 8
distribution across the
useful area [°C]
Technically induced 8 10 14 16 17 11
total deviation [°C]
570
In the case of heated tools for pipes, the measurement is taken at Table 2. Difference between the gap dimensions in the case of
four points 90° apart around the external boundary circle of the joining pressure depending on the pipe diameter (inter-
useful area. With tools for the welding of panels, the tool is mediate values must be interpolated).
moved into the cleaning position and the measurements are Pipe diameter d Difference between the gap
taken on the useful area after a waiting time of eight minutes dimensions = 0.8 %o x d
(draught-free surroundings), i. e. from the centre, beginning [mm] [mm]
50 cm away, and at/underneath the fastening points / supports.
The measuring time must be chosen in such a way that the  315 0.25
values are displayed in a stable way. In order to form the
difference, reference is made to the lowest and highest 315 ... 630 0.25 ... 0.50
measured values. 630 ... 800 0.50 ... 0.65
The measurements are taken at an ambient temperature of
800 ... 1,000 0.65 ... 0.80
23 ± 2°C and a reference temperature of 210°C or, in the case of
tools for heated tool sleeve welding, at 260°C. Quick-display 1,000 ... 1,200 0.80 ... 0.95
temperature gauges which are suitable for surface
measurements on a contact area with an edge length of approx. 1,200 ... 1,600 0.95 ... 1.30
10 mm and permit good area contact and rapid reaction times
should be preferred for this purpose.
The temperature regulator must be integrated into the machine
controller in an appropriate way in order to display any major
deviations between the heated tool temperature and the nominal
temperature and to block the welding sequence.
3 Machines for heated tool butt welding
Due to the different sets of problems in the various areas of

d – s  
application of heated tool butt welding, different requirements are b  ---------------- , min. 10 mm
set on the welding machines concerned. 100
3.1 Welding machines for pipes

Pipe welding machines may preferably be designed for building
site or workshop operation. As a rule, workshop machines permit
a higher degree of mechanisation because of their stationary
installation.

In order to avoid high local stresses in the pipe and deformations,
the clamping facilities must enclose min. 80 % of the pipe shell
parallel to the welding plane. They must be so stable that the
geometrical circular shape of the pipes can be preserved with
them. Even when subjected to the highest working forces, they
1/2 at a 90° angle to the guiding elements, e. g. horizontally arranged
must not change their positions in relation to the guides. clamping pieces if guiding from below
The clamping tools must be structurally designed in such a way b width of the clamping pieces
that no sharp-edged damage arises in the pipe shell. It is Sp 1 upper measuring point
recommended to put a maximum of two clamping shells in each Sp 2 lower measuring point
other for adjustment to different pipe diameters. If more clamping d outer pipe diameter
shells are put in each other, the manufacturer must take this into s pipe wall thickness
consideration during the designing. Figure 1. Measurement of the gap dimension (differential dimension).
For fittings, provision may be made for special clamping facilities
with which height and side adjustability is possible if necessary. If, during the test, the measured gap remains within the
permissible tolerance range depending on the pipe dimensions to
3.1.2 Guiding elements and clamping facilities be welded, the joining pressure is also complied with according
to the technical code.
The guiding elements and the clamping facilities must guarantee
that the maximum gap according to Table 2 (measured at the
cold joining faces at the room temperature) is not exceeded at 3.1.3 Heated tools
the most unfavourable position in the respective working area of The faces of the heated tool used must be as parallel as possible
the machine at the maximum working pressure and with the within its useful area. For the permissible deviations, see Table 3.
largest pipe diameter due to bending and rising.
The measurements are taken when the pipes have been Table 3. Permissible deviation of the heated tool from the plane
clamped and processed to a plane condition in the machine. The parallelism.
alignment of the pipes and the planing operation must be carried
out carefully since no (or only a small) residual gap may arise Diameter or edge Permissible deviation from the plane
between the pipe ends. Thereafter, the machine is moved apart length parallelism
and two opposite reference clamping pieces are put on to the [mm] [mm]
pipe ends. The clamping pieces must be manufactured with an  250  0.2
accuracy of ± 0.025 mm in the measured thickness. The pipe
ends are subsequently moved against each other once again at > 250 ... 500  0.4
the joining pressure necessary for the clamped pipe. The
> 500 ... 800  0.8
differential dimension in the resulting gap must not exceed the
dimension from Table 2. A measuring wedge or a feeler gauge > 800 ... 1,200  1.2
must be utilised in order to determine the differential gap width
according to Figure 1. > 1,200  1.5
571
The measurements are taken at 23 ± 2°C when the heated tool of the machine must be indicated by the manufacturer. The force
has been heated up to the maximum operating temperature of range of the machine must be designed in such a way that there
260°C on one occasion for a short time. For workshop operation, is a pressure reserve of  20 % which is required for the
the heated tool is firmly assembled on the machine in general maximum welding cross-section and in order to overcome the
(floating suspension). In the case of heated tools which are not friction forces of the machine.
firmly attached, corresponding fixtures must be present for
It must be possible to control the heating-up pressure towards
incorporation and fixing purposes (e. g. handles, hooks and
zero after the alignment and to check it (for example) with a
lugs).
pressure cell. When the joining faces meet, the joining force,
If the size and condition of the heated tool require mechanical beginning from zero, is increased linearly and uniformly up to the
detachment from the joining faces, provision must also be made final value which must be held during the cooling time.
for corresponding jigs to this end.
The power supply must be protected against thermal damage in 3.1.5.2 Time control
the area of the heated tool and the useful area of the heated tool Exact time control guarantees the correct interaction between the
against mechanical damage. Any heated tools which are not machine functions and the forces, particularly evident during the
connected with the machine must be placed in protective jigs linearly rising force build-up for the alignment and the joining.
between the welding operations.
3.1.5.3 Displacement control
3.1.4 Facility for the weld preparation
In a sensible way, the machine controller must record the
In order to be able to machine parallel joining faces while the positions of the guiding elements and thus of the workpieces in
pipes are in the clamped condition, provision must be made for a relation to each other and must process these positions. Time-
corresponding chip-producing tool. The cutting facility must bring optimised engaging movements are initiated in this case. It must
the chips to the outside diameter of the pipe. The operating be possible to implement the demanded changeover times using
personnel must be able to see the resulting chips during the a suitable machine design.
planing operation and to end the planing operation when the
parallel faces have been achieved. The maximum permissible 3.1.6 Structure of the machine and safety in utilisation
deviations from the plane parallelism of the joining faces are
Machines for workshop operation must fulfil the following
included in Table 4.
requirements:
Table 4. Permissible deviation of the joining faces from the plane – sturdy design
parallelism after the planing. – universal basic set-up (auxiliary tools and clamping jaws which
can be swivelled in or retracted)
Pipe diameter d Permissible deviation from the plane
parallelism – quick-clamping jig
[mm] [mm] – highest possible degree of mechanisation (welding sequence)
– indication of the pressure intensification (hydraulic pressure /
 355  0.5
joining force)
400 ... < 630  1.0 While fulfilling the specified requirements, machines for building
630 ... < 800  1.3 site operation must be constructed as light as possible:
800 ... < 1,000  1.5 – sturdy design

– they must have corresponding fixtures for transport,
> 1,000  2.0 introduction and alignment in the pipe trench (e. g. handles or
lugs)
3.1.5 Control and regulation facility for the force, the time, – indication of the pressure intensification (hydraulic pressure /
the temperature and the displacement joining force)
Control and regulation systems must be adjustable and must During the construction and operation of the machines, attention
guarantee reproducible welding. must be paid to the corresponding safety provisions, see Section 6.
The alignment begins when the joining faces touch the heated
3.2 Welding machines for panels
tool and ends when the whole area of this (including the bead
height) is in contact. The welding machines are preferably intended for stationary
operation. They serve to weld panels or workpieces which have
The heating-up time begins after the alignment and ends with the
been formed from panels and have a weld path in a straight line.
separation from the heated tool.
A high degree of automation should be an objective in order to be
The changeover time begins with the separation of the joining able to manufacture high-quality and, in particular, reproducible
faces from the heated tool and ends when they touch. It results welds.
from the total of various machine functions and must be as short
as possible. 3.2.1 Clamping facilties
The joining time begins when the joining faces touch and ends The clamping force to be exerted on the workpiece via the
when the weld has cooled down. This includes the build-up time clamping facilities is the product of the machine force and the
for the joining pressure during which the joining force, beginning friction between the clamping jaws and the workpiece surface.
from zero, is linearly increased to the final value. The necessary clamping force can be provided either via the
clamping facilities alone or with an additional clamping facility.
3.1.5.1 Force control The clamped workpieces must not make any movement relative
to the clamping elements, i. e. slipping-through.
In the case of heated tool butt welding, the alignment, heating-up
and joining forces must be infinitely adjustable in the range from Clamping facilities basically consist of supporting tables and
the smallest welding cross-section to the largest, taking account clamping beams. They must permit the exact clamping of the
of the various specific forces for the weldable plastics. Losses workpieces. The misalignment of the table supports in relation to
due to friction in the drive and in the guiding elements at a low each other must not exceed 0.2 mm at the plate support. In
travel speed must be recorded in a suitable way, e. g. using a particular, it must be ensured that the supporting tables are
pressure or force display. The working forces must be increased guided exactly and that suitable reinforcements and bearings
by this zero force. The adjustable minimum and maximum forces prevent any sagging or tilting.
572
The section shape chosen for the clamping facilties is directly form as a line diagram over the time. The changeover time as
connected with the smallest hollow section which can be well as the force ramps of the alignment and joining phases must
manufactured in a round or rectangular design and whose be stretched over the time.
dimensions must be indicated by the machine manufacturer.
An interruption in the energy supply for the machine must not
trigger any uncontrolled movement operations.
The guiding elements must guarantee that the clamped parts are
flush and do not change their positions when they are subjected 4 Machines for heated tool sleeve welding
to the maximum working force. Workpieces must be placed and
clamped in the centre of the table in order to apply a uniform load
4.1 Designs
to the guides. This must be pointed out in the operating instruc-
tions. A distinction must be made between sleeve welding devices in
which the force for the joining process is applied by hand and
3.2.3 Heated tools sleeve welding machines in which the force is applied
The heights and lengths of the faces of the heated tool used must mechanically, pneumatically or hydraulically. The manual
be parallel within its useful area. For the permissible deviations, welding devices have been developed for the welding of
see Table 5. There is no length-specific distinction in this respect. diameters  50 mm. Preference should be given to the choice of
devices or machines with forced guiding.
Table 5. Permissible deviation of the heated tool from the plane All the types of devices and machines are suitable for building
parallelism. site and workshop utilisation.
Height of the useful area Permissible deviation from the
4.2 Technological variants
plane parallelism
[mm] [mm] Heated tool sleeve welding can be carried out with the processes
described below.
 30  0.3
In the case of Process A, there is no surface machining in the
> 30  0.5 weld area of the pipe.
Process B is characterised by the fact that the surface of the
The measurements are taken at 23 ± 2°C when the heated tool pipes is subjected to machining in the weld area before the
has been heated up to the maximum operating temperature of welding process. It can be carried out using calibration tools with
260°C on one occasion for a short time. dimensions according to Table 6.
3.2.4 Control and regulation facilties
Table 6. Calibration diameters and lengths for the chip-producing
It is advantageous to automate the welding sequence by machining of the pipe ends (Process B).
regulating the force, the time, the displacement and the
temperature. The controllers must be adjustable and guarantee Pipe diameter d Calibration Calibration length l
reproducible welding. The adjustable minimum and maximum diameter d1 (minimum dimensions)
forces must be indicated by the machine manufacturer. [mm] [mm] [mm]
As far as possible, the measured process data of the heated tool 16 15.90 ± 0.05 13
temperature, the table force and the table displacement must be
recorded and monitored at sufficiently small intervals throughout 20 19.90 ± 0.05 14
the welding sequence. The regulation system must be designed 25 24.90 ± 0.05 16
in such a way that operating errors are prevented if at all possible
or are indicated to the operator. 32 31.90 ± 0.05 18
40 39.85 ± 0.10 20
3.2.5 Structure of the machine and safety in utilisation
Machines must fulfil the following requirements: 50 49.85 ± 0.10 23
– sturdy design 63 62.80 ± 0.15 27
– torsionally stiff frame and table structures 75 74.80 ± 0.15 31
– clamping forces must be introduced into the machine frame
90 89.80 ± 0.15 35
– prevent the tables from sagging using multiple anti-friction
bearings 110 109.75 ± 0.20 41
– low-friction table movements 125 124.75 ± 0.20 44
In order to improve the transport of the workpieces (also in the
case of engaging movements), provision must be made for The dimensional requirements on the piping parts for heated tool
sturdy table extension elements which also permit the sleeve welding are stipulated in the corresponding standards,
subsequent attachment of workpiece holders. see Section 6.1.
The safe and problem-free removal of welded hollow sections is
made considerably easier by quick-release devices on the 4.3 Welding machines and devices
clamping beams.
4.3.1 Heated tools
The heated tool must be thermally insulated during the joining
operation so that neither radiant heat nor convection heat exerts The whole mass of the heated tool must have a sufficient heat
any effect on the bottom side of the workpieces and thus leads to capacity. The temperature drop after the heating-up operation
different cooling rates. Thermal insulation of the heated tool is must not be greater than 5°C.
advantageous whenever it is not located in the working position.
A plane contact over the entire area must be ensured for the best
Both measures contribute to saving energy.
possible heat transmission from the heated tool to the heating
For the quality assurance in the welding operation, it must be tools. The heating tools for heated tool sleeve welding (heating
possible to print out the important data of the heated tool bush and heating socket) are shown on Figure 2 and their
temperature, the table force and the table stroke in an indelible dimensions in Table 7 and Table 8.
573
Table 7. Dimensions of the heating tools for Process A without any pipe machining.
Pipe diameter d D1 1) D2 1) D3 1) D4 1) L1 L2 L3 R
[mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm]
16 16.15 15.92 15.43 15.65 11.0 4 13.0 2.5
20 20.15 19.94 19.40 19.65 12.0 4 14.0 2.5
25 25.25 24.92 24.37 24.65 13.0 4 15.0 2.5
32 32.15 31.90 31.34 31.65 14.5 5 16.5 3.0
40 40.15 39.88 39.31 39.65 16.0 5 18.0 3.0
50 50.20 49.84 49.27 49.65 18.0 5 20.0 3.0
63 63.20 62.78 62.22 62.70 24.0 6 24.0 4.0
75 75.25 74.57 73.67 74.70 26.0 6 26.0 4.0
90 90.30 89.54 88.61 89.75 29.0 6 29.0 4.0
110 110.30 109.45 108.48 109.75 32.5 6 32.5 4.0
125 125.30 124.38 123.36 124.75 35.0 6 35.0 4.0
1) Dimensional data applies to 260 + 10°C
Diameter tolerance:  40 mm ± 0.04 mm
 50 mm ± 0.06 mm
Table 8. Dimensions of the heating tools for Process B with pipe machining.
Pipe diameter d D1 1) D2 1) D3 1) D4 1) L1 L2 L3 R
[mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm] [mm]
16 15.90 15.76 15.37 15.50 14.0 4 13 2.5
20 19.85 19.70 19.31 19.45 15.0 4 14 2.5
25 24.85 24.68 24.24 24.40 17.0 4 16 2.5
32 31.85 31.65 31.17 31.35 19.5 5 18 3.0
40 39.80 39.58 39.10 39.30 21.5 5 20 3.0
50 49.80 49.55 49.07 49.30 24.5 5 23 3.0
63 62.75 62.46 61.93 62.20 29.0 6 27 4.0
75 74.75 74.42 73.84 74.15 33.0 6 31 4.0
90 89.75 89.38 88.75 89.10 37.0 6 35 4.0
110 109.70 109.27 108.59 109.00 43.0 6 41 4.0
125 124.70 124.22 123.49 123.49 48.0 6 46 4.0
1) Dimensional data applies to 260 + 10°C
Diameter tolerance:  40 mm ± 0.04 mm
 50 mm ± 0.06 mm
If required, provision must be made for setting possibilities

(adjustments) for the centring.
4.3.4 Control and regulation facilities for the force and the
displacement
The force of the machines must be dimensioned in such a way
that the joining is carried out uniformly without any jerks.
According to the sleeve depth to be welded, provision must be
made for displacement limitation not only for the heating-up
a) heating bush b) heating socket process but also for the welding process.
Figure 2. Heating tools for sleeve welding. 5 Devices for sleeve welding with an incorporated electric
heating element
The devices are preferably utilised in mobile building site
The clamping facilities must guarantee that pipes and pipe fittings operation. The design must satisfy this application and must be
are held safely, are not deformed and are guided in a centred operated without any disturbances with the different power
position in relation to each other. generators (pay attention to the information from the
manufacturers).
4.3.3 Guiding elements The operating instructions must include:
The guiding elements must guarantee that the joining parts can – the characteristic values of the device
be guided and moved centrically in relation to the heated tools – functional descriptions
during the heating-up and welding processes. – maintenance instructions
574
5.1 Structural designing 5.1.6 Transformers
5.1.1 General All the transformers must comply with the DIN EN 60335 and
DIN EN/IEC 61558-1 to DIN EN/IEC 61558-6 standards.
The structural designing of the welding device must be adapted
to the utilisation conditions and ambient infuences of the welding
tasks. It must be easy to calibrate and maintain. For the 5.2 Operating sequences
connection to a generator, the manufacturer must indicate the
It is necessary to monitor the level and frequency of the input
connected load of the device including the reactive power.
voltage. If the measured values are outside the permitted limits,
The weight must be reduced to a minimum so that the device can this must be indicated acoustically and/or optically. The start of
be carried easily by one person. Including the frame and the the welding operation must then be blocked.
connecting cable, it should weigh no more than 25 kg.
The operator must check that the input data coincides with the
It must be possible to carry out the operation without any danger connected fitting. In the case of automatic data input, all the
in all the customary building site conditions. The device and the relevant data is displayed by the device. If any deviation of the
accessories must be designed in such a way that the operational verifiable fitting data is established, the start of the welding
safety and the efficiency are influenced neither by corrosion nor operation must be blocked and the reason displayed.
by mechanical effects during the transport or during the handling.
It must not be possible to start the welding operation if the input The operator must confirm the displayed information by pressing
parameters and/or the connection values are outside the the START push-button or another push-button. See also the
specified working range. operating instructions from the device manufacturer.
A completely new start to the welding operation must be made if

5.1.2 Electrical safety the primary or secondary circuit of the welding device is
The welding device must correspond at least to the IP 54 interrupted (pay attention to the data from the manufacturer). If
protection class according to IEC 529, DIN EN 60529 and the welding is interrupted due to an external or internal
DIN VDE 470-1. All the electrical parts must be protected against occurrence, the reason for the interruption must be displayed.
condensation. No water may accumulate in the switches and
push-buttons on the outside of the device. Important information about the welding operation (time, voltage,
current and resistance) must be displayed.
Safety extra-low voltage  50 V must be chosen as the output
voltage.
5.3 Device requirements
The device must withstand an insulation test according to
DIN EN 60335-1.
5.3.1 Working range
The output circuits must be galvanically uncoupled from the
mains input according to DIN EN 60335-1. It must be possible to operate the welding device at an ambient
temperature between - 10°C and 40°C without any restrictions.
In the case of a firmly assembled mains cable, the minimum
length must be 4 m. The flexibility must be adapted to the
operating and storage conditions of the welding device. 5.3.2 Energy supply
Provision must be made for the following operating elements in a The energy supply must be suitable for operation not only from
readily visible form: the mains but also from a generator. The device must be
designed, at least, for a frequency and voltage tolerance of
– START push-button in a green colour
± 15 %. It must not be damaged if the voltage or the frequency
–- STOP push-button in a red colour
exceeds the indicated range.
– on/off switch for the power supply
Provision must be made for short-circuit overload protection in 5.3.3 Measurement of the fitting resistance
the input circuit.
Devices with resistance measurement may exhibit a maximum
5.1.3 Operator guidance measuring accuracy of ± 5 %. The fitting is tested for continuity
before the welding operation is started. The testing voltage must
All the optical and/or acoustic signals must be easily perceptible
not heat the heater spiral of the fitting.
in normal building site conditions.
The requirement relating to the open-circuit voltage must be
5.1.4 Input systems complied with according to DIN EN 60335-2-45.
The input can be effected manually using the keyboard or
preferably using a data carrier, e. g. a bar code according to 5.3.4 Energy output
ISO 13950 or a magnetic card. Then, the welding device must be
equipped with a facility for the reading and decoding of the The controller records either the voltage or the current within the
welding parameters. welding time or the welding energy.
It must not be possible to alter the data when the welding The maximum output power which can be taken from the welding
operation has started. device must be indicated at 23  2°C for a duty cycle (DC) of
100 %. An overload of 10 % for at least one minute must be
5.1.5 Temperature measurement in order to compensate for possible.
the welding energy
The welding device may be equipped with an element for 5.3.4.1 Voltage regulation
measuring the ambient temperature. The measurement must
exhibit a temperature accuracy of  2°C and a resolution of 1°C. The output voltage is stabilised within a range of ± 1.5 % of the
The temperature sensor (response time: < 3 minutes) must be nominal welding voltage, max.  0.5 V. The voltage to be
attached in such a way that the temperature is measured at a regulated is measured at the fitting or at the adapter plug.
distance up to 1 m away from the weld. The influences exerted Voltage-regulated welding devices must be capable of outputting
by the inherent heating must not be greater than the temperature up to 110 A. The nominal variable of the voltage or the current
accuracy. must be reached in at least three stages (see Table 9).
575
Table 9. Rise time depending on the nominal power. must be affixed to every device in a clearly recognisable and
permanent form. Furthermore, the technical data sheet must
Nominal power of the fitting Max. rise time include information according to Table 10 and about the output
[kW] [s] voltage type.
 1.5 1
Table 10. Data sheet to be filled in by the manufacturer.
> 1.5 ...  2.5 3
Power output DC Switched-on Switched-off
> 2.5 5
duration duration
[kW] [%] [s] [s]
5.3.4.2 Current regulation
x 100 x x
The output current is stabilised in a range of ± 1.5 % of the
operating conditions. The stipulated nominal current must be x 60 x x
reached within three seconds at most. x 30 x x
5.3.4.3 Energy regulation x = information from the manufacturer

The energy input into the fitting must be regulated with an
accuracy of ± 5 % within the operating conditions, including the 5.5 Record sheet printout
ambient temperature correction.
In the case of devices with recording or controlled devices, it is
necessary to print out record sheets whose contents must fulfil
5.3.5 Welding time the following minimum requirements:
It is necessary to comply with the welding time with an accuracy Devices for sleeve welding with an incorporated electric heating
of ± 1 % in operating conditions. element:
5.3.6 Safety facilities – device number and operating mode (if several are possible)
The welding device must be equipped with safety facilities which – date and time
interrupt the welding operation. The triggering must be indicated – building site or order number
and, if there is a memory facility, recorded.
– welder number or name
The obligatory safety facilities include:
– consecutive record sheet or weld number
– Voltage and current monitoring
If the value of the regulated voltage or the current is outside – fitting manufacturer, design, diameter and dimensions of the
± 2 % of the stipulated value for more than 5 % of the welding semi-finished product
time (max. 3 s), the welding operation must be interrupted. – ambient temperature
– Interruption – nominal time and actual time
The device does not start with the welding operation if it – voltage and electrical resistance
measures a resistance > 200  at the connected fitting. The
monitoring for an interruption is carried out throughout the – all the disturbances during the course of the welding
welding operation. If an interruption occurs, the welding must – date of the last or next inspection
be interrupted within max. 1 s.
– Input voltage and frequency 5.6 Inspection and maintenance
If the input voltage is outside the working range for longer than According to the information from the manufacturer but at least
5 s, the welding operation must be terminated. If it is generally once per year, the welding device must be inspected
located outside the working range, it is not allowed to start any correspondingly by an expert with the experience necessary for
welding operation. this purpose and with proof of the qualification by the
manufacturer concerned. The inspection cycle must be
–- Short circuit
shortened in the case of devices which are subjected to above-
If the current in the fitting increases due to a short circuit, the average loads. In the operating instructions, reference must be
welding operation must be interrupted. made to the cycles and scope of the maintenance.
5.3.7 Proof of the loading Specimens for inspection record sheets are included in the
appendix.
The welding device is stored for 24 hours at an ambient
temperature of 23 ± 2°C according to ISO 12176-2. Thereafter,
the output power indicated by the manufacturer must be provided 6 Standards, technical codes, directives and guidelines
with a duty cycle (DC) of 60 % for the duration of one hour taking
account of the cycle duration applicable to the device according 6.1 Standards
to Section 5.3.4. The readiness for welding according to this
technical code must exist after this test. DIN EN ISO Plastic piping systems for industrial applica-
10931 tions – Polyvinylidene fluorides (PVDF) – Re-
The cycle durations (ratio of the switched-on time to the quirements on piping parts and the piping
switched-off time) must be min. 10 min for devices with an output system
power  2 kW and min. 15 min for devices  2 kW.
ISO 12176-2 Pipes and fittings made of plastics – Equip-
ment objects for welded joints between poly-
5.4 Identification
ethylenes – Part 2: Electric welding
Any information which is indispensable for safe operation, i. e.: ISO/TR 13950 Plastic pipes and fittings – Automatic recogni-
– CE symbol tion system for sleeve welding with an incor-
– manufacturer porated electric heating element
– type DIN EN ISO Safety of machines – Fundamental terms and
– year of construction 12100-1 general guiding designing principles – Part 1:
– characteristic data (according to DIN) Basic terminology and methodology
576
DIN EN ISO Safety of machines – Fundamental terms and 6.2 Technical codes and guidelines
12100-2 general guiding designing principles – Part 2: DVS 2207 Welding of thermoplastics
Guiding technical principles
Part 1 Heated tool welding of pipes, piping parts
DIN EN 294 Safety of machines; safety distances in order and panels made of PE-HD
to prevent the reaching of danger points with
upper limbs Part 1, Supplement 1 Sleeve welding with an incorporated elec-
tric heating element of pipes made of
DIN EN 418 Safety of machines; EMERGENCY-STOP fa- PE-X with piping parts made of PE-HD
cility, functional aspects; guiding designing
principles Part 6 Non-contact heated tool butt welding of
pipes, piping parts and panels – Process-
DIN EN 14883 Welding of thermoplastics; machines and de- es, machines and parameters
(draft) vices for the heated tool welding of thermo-
plastics Part 11 Heated tool welding of pipes, piping parts
and panels made of PP
DIN EN 60204-1 Safety of machines – Electrical equipment of
machines – Part 1: General requirements Part 15 Heated tool welding of pipes, piping parts
and panels made of PVDF
DIN EN 60335 Safety of electrical devices for domestic use
and similar purposes EC Machine Directive 89/392
(2nd Amendment 91/368/EEC, 3rd Amendment 93/44)
Part 1 General requirements
Part 2-45 Particular requirements for mobile electric Devices and Production Safety Act
heating tools and similar devices
BGV A 3 Accident prevention regulations; electrical
DIN EN 61558/ Safety of transformers, mains power packs installations and operating materials
VDE 0570 and similar items
VBG 5 Force-operated working materials (as
Part 1 General requirements and tests from January 1, 2004, only applicable to
Part 2-6 Particular requirements on safety transform- the stock of old machines); included in
ers for general applications the rules of the employers' liability insur-
DIN EN ISO Geometrical product specification (GPS) – In- ance association BGR 500
1302 dication of the surface condition in the techni- VBG 22 Working machines in the chemical, rub-
cal product documentation ber and plastics industries (as from Janu-
DIN 16831 Pipe joints and fittings for pressure pipelines ary 1, 2004, only applicable to the stock
made of polybutene (PB) – PB 125 of old machines); included in the rules of
the employers' liability insurance associa-
DIN 16962 Pipe joints and piping parts for pressure pipe- tion BGR 500, Chapter 2.11
lines made of polypropylene (PP), Types 1
and 2
DIN 16963 Pipe joints and piping parts for pressure pipe- 7 Explanations
lines made of high-density polyethylene
(HDPE), Types 1 and 2 DVS 2208-1, 12.97 edition was updated according to today's
DIN EN 60529/ Protection classes using housings (IP code) state of the art. That applies, in particular, to the machines for
VDE 0470-1 sleeve welding with an incorporated electric heating element.
DIN VDE 0100 Provisions for setting up heavy-current instal- Devices for non-contact heated tool welding are dealt with in
lations with nominal voltages up to 1,000 V DVS 2207-6.
DIN EN 50110-1/ Operation of electrical installations
VDE 0105-1
DIN VDE 0281-1 Heavy-current lines with a thermoplastic insu-
lating covering for nominal voltages up to
450/750 V – Part 1: General requirements
DIN EN 60519 Safety in electric heating installations
577
Appendix: Specimens for inspection record sheets
Inspection record sheet for heated tool butt welding machines (piping parts)
Make/manufacturer Type
Machine/device no. Dimension range*
Heated tool device no. * (also applies to the heated tools required for this purpose)
Date of the last inspection
 Personal and operational safety Inspection result Assessment

Power supply cables including plugs
Tools and operating elements
Condition and leak tightness of the hydraulic system
Optical and acoustic monitoring facilities
Emergency stop funcion
 Clamping facility and guiding elements

Gap measurement Gap difference mm
Condition of the clamping elements and surfaces

Condition of the guiding elements
Condition of the sliding surfaces
 Clip-producing tools
Condition of the cutting elements
Chip assessment Chip thickness mm
Plane parallelism of the joining faces after the processing

Finish of the joining faces after the processing
 Heated tool Set temperature oC
Plane parallelism Deviation* mm

Temperature distribution Deviation* oC
Temperature accuracy in relation to the set value Deviation* oC
Surface finish and condition
 Functional inspection (for the specified dimension range)

Joning force control Deviation* %
Reading-off accuracy of the joining force (manometric pressure) Deviation* %
Joining force build-up time Deviation* %
Effective joining force time Deviation* %
* (Deviation from the reference variable) Reference variables according to DVS
 Operating instructions (if these are not available, please enter 0)
Assessment of the overall condition (for remarks about the overall condition, please use an additional sheet)
Assessment key for the inspections and the condition Assessment key for the measurements
1 = No complaints 1 = Within permissible tolerances
2 = Minor complaints 2 = Deviation with a slight influence
3 = Complaints which restrict the use 3 = Deviation which restricts the use
4 = Further use not permissible 4 = Impermissible deviation
Date of inspection: Inspection agency with stamp and signature:
Inspector:
578
Inspection record sheet for heated tool butt welding machines (panels)
Heated tool device no. * (also applies to the heated tools required for this purpose)
 Personal and operational safety Inspection result Assessment

Condition and leak tightness of the hydraulic system / pneumatic system
Condition of the maintenance unit

Table misalignment mm
 Direction spar
Plane parallelism
Straightness and alignment
Height setting
 Heated tool Set temperature oC
Plane parallelism Deviation* mm
Height setting in the working position

oC
Temperature distribution Deviation*
oC
Temperature accuracy in relation to the set value Deviation*
 Functional inspection (for the specified dimension range)

Joning force control Deviation* %
Reading-off accuracy of the joining force (manometric pressure) Deviation* %
Joining force build-up time Deviation* %
Effective joining force time Deviation* %
Inspector:
579
Inspection record sheet for heated tool sleeve welding machines
Heated tool device no. * (also applies to the heated tools and, if necessary, peeling tools required for this purpose)
 Personal and operating safety Inspection result Assessment


Condition of the toothed bar
 Chip-producing tools (Procedure B)

Condition of the peeling tool
Condition of the peeling elements
Finish of the surfaces after the processing
 Heated tool (bush and mandrel) Set temperature oC
Dimensional accurancy (when the set temperature has been reached) Deviation* mm
oC
Temperature distribution Deviation*
oC
Temperature accuracy in relation to the set value Deviation*
 Functional inspection
Movement control
Fixing jig
Effectiveness of the push in limitation
Inspector:
580
Inspection record sheet for devices for sleeve welding with an incorporated electric heating
Device no. Date of the last inspection
 Personal and operating safety Inspection result Assessment

Short circuit and overload safety devices
Insulation resistances
 Welding device, visual inspection

Housings
Keys and sensors
Display
Adapters
Welding cables
 Welding device, functional inspection in the case of mains operation

Start and stop
Keyboard / reading pen / scanner
Input of welding data
Recording
 Checking of the welding voltage

(using a digital measuring device with a crest factor > 3.0) Actual value Deviation
Load case: 0.3  / inspection voltage 20 V ( 2 V) V %
Load case: 15  / inspection voltage 40 V ( 2 V) V %
 Temperature recording
(using an inspection thermometer with a permissible deviation of  3oC) Value at 40oC Value at 40oC
oC oC
Actual value
Deviation from the limiting value % %
 Checking of the resistances and the welding time

Deviation Deviation
(using a measuring device with a digital display and a stopwatch) at 0.3  at 15 
Resistance comparison with the reference value % %
(permissible deviation =  5 %)
Welding time comparisation with the reference value % %

(permissible deviation at > 100 s =  1 %)
Yes No
 Passing of the maintenance dates
Note: the inspection documented here does not replace the device maintenance by the manufacturer
Inspector:
581
February 2012

FÜR SCHWEISSEN UND
Tools and devices Technical Code
for the heated tool welding DVS 2208-1
of pipes and piping parts Supplement 1
Contents: – The operating elements must be formed and arranged in such

a way that any unintentional adjustment is prevented.
1 Scope of application – A low weight of the device must be striven for.
2 General requirements and criteria
3 Tools for sleeve welding with an incorporated heating – Subject to correct utilisation, the devices must offer the user
element safety from injuries of all kinds. Sharp edges on devices and
3.1 Rotational peeling devices (mechanical peeling devices) accessories which may lead to injuries are not permissible.
3.2 Holding jigs – The statutory regulations for the execution of the devices must
3.3 Round pressing jigs be complied with, e.g. the Machine Directive.
4 Tools for heated tool sleeve welding – The utilisation field must be taken into account according to the
4.1 Peeling and chamfering devices information from the manufacturers.
5 Tools for heated tool butt welding
5.1 Dollies
6 Additional tools and devices 3 Tools for sleeve welding with an incorporated heating
6.1 Pipe cutting devices element
6.2 Hand-held scrapers and deburrers

6.3 Welding bead removers 3.1 Rotational peeling devices (mechanical peeling devices)
6.4 Temperature measuring devices
7 Service, maintenance and care Rotational peeling devices serve exclusively to properly remove
8 Literature the oxide coat from the circumference of pipes as a preparatory
measure for the welding. A distinction is made between universal
and dimension-bound peeling devices.
1 Scope of application The devices must be designed in such a way that flawless con-
centricity and a uniform chip of approx. 0.2 mm all around are
This supplement to the DVS 2208-1 technical code is intended to guaranteed for the stipulated dimension range. The information
give the user of the technical codes for the heated tool welding of from the fitting manufacturer must be observed.
the PE, PE-X, PP, PVC, PVDF, PB and PA materials an overview
Ovalities within stipulated tolerances must not affect the function of
of the requirements on tools, on necessary accessories and on
the device.
devices.
Requirements:
The tools and devices addressed here are used for the following
welding processes: sleeve welding with an incorporated heating – Quick dimension change in the case of devices covering various
element (HM), heated tool sleeve welding (HD) and heated tool butt dimensions.
welding (HS and IR). The processes for this purpose are described – Flexible knife holder in order to compensate for any unevenness.
in the following technical codes: DVS 2207-1, DVS 2207-1 (Supple-
ment 1), DVS 2207-6, DVS 2207-11, DVS 2207-12, DVS 2207-13, – Easy-running rollers and mechanical feed equipment.
DVS 2207-15 and DVS 2207-16. – Oil-free and grease-free in the working area.
Special devices for particular applications are not addressed with- – Operating instructions with care and maintenance indications
in the framework of this supplement. (see Section 7).
– The device must permit processing beyond the area of the in-
sertion depth and the length of the saddle fitting.
2 General requirements and criteria
3.2 Holding jigs
The quality of the welded joints is dependent on the qualification
of the welders, on the suitability of the utilised machines and jigs, Holding jigs allow the user to carry out the assembly with low
on the compliance with the technical codes for welding and the stresses. They must be designed for the corresponding application,
stipulations from the manufacturers as well as on the suitable e.g. whether rod or ring coil products are being processed.
tools and devices for the weld preparation and the welding exe- Requirements:
cution.
– Guarantee of the firm positioning of the pipe.
In general, the following points must be fulfilled by the utilised – No impermissible damage to the pipe surface.
tools and resources:
– Exact alignment of the pipe ends in order to assemble the fitting
– The devices must be appropriate for the workshop or the building with low stresses.
site.
– The functioning capacity must be guaranteed from –10°C to 3.3 Round pressing jigs
+ 45°C. Pipes (e.g. from the ring coil) whose ovality is located outside the
– The devices must be service-friendly and repair-friendly. In permissible tolerance according to the DVS 2207 technical code
particular, wear parts should be easy to replace. must be rounded in the welding area with the aid of round pressing
582
jigs. These must correspond to the diameter in question, must be 6.3 Welding bead removers
able to apply the force for the round pressing and must not damage As a rule, it is not necessary to remove the welding bead for
the pipe impermissibly while doing so. hydraulic or strength-related reasons. Moreover, the removal of
Requirements: the welding bead makes it more difficult to evaluate the weld.
– The welding area must be oil-free and grease-free. Special applications (e.g. transport of extrapure media or relining
– Large round pressing jigs must be executed with handles or processes) demand the removal of the external and/or internal
lugs. welding bead on butt-welded piping. With regard to these tools
(bead removers), it must be ensured that, during the removal of
the bead, the pipe is not damaged (notches) and the wall thick-
4 Tools for heated tool sleeve welding ness of the pipe in the area of the weld is not lower than the nom-
inal wall thickness of the pipe. That can only be guaranteed with
4.1 Peeling and chamfering devices suitable devices specially developed for this purpose. The indica-
tions from the device manufacturer must be observed.
Peeling and chamfering devices serve to properly calibrate the
pipe end and to remove the oxide coat from the pipe circumference 6.4 Temperature measuring devices
as a preparatory measure for the welding.
Calibrated surface measuring devices with a spring-mounted ele-
Ovalities within stipulated tolerances must not affect the function of ment and a contact area with a diameter of min. 10 mm must be
the device. utilised for measuring the temperature on the heated tool.
Requirements:
– Oil-free and grease-free in the working area. 7 Service, maintenance and care
– Operating instructions with care and maintenance indications
(see Section 7). Tools and devices are also subject to maintenance and checking
– The device must permit processing in the area of the insertion intervals.
depth. For example, rotational peeling devices which are subject to con-
stant use must be checked and, if necessary, repaired at least
once per year by a specialist with the experience necessary for
5 Tools for heated tool butt welding this purpose.
The checking cycles must be shortened in the case of high
5.1 Dollies
stresses.
Dollies serve to improve the alignment of the pipes and to keep
the movement forces low during the heated tool butt welding.
Dollies must be chosen or designed in such a way that: 8 Literature
– They do not damage the pipe surface.
DVS 2207-1 Welding of thermoplastics; Heated tool welding of
– They are suitable for the pipe diameter in question. pipes, piping parts and panels made of PE-HD
– They include an indication of the load-bearing capacity. DVS 2207-1 Welding of thermoplastics; Heated tool welding
– They guarantee a stable standing position. Supplement 1 of pipes made of PE-X with piping parts made of
– The rollers are easy to move – even when subjected to the PE-HD
maximum specified load-bearing capacity. DVS 2207-6 Welding of thermoplastics; Non-contact heated
– If necessary, they are provided with grab handles or lugs for tool butt welding of pipes, piping parts and pan-
changing the position quickly. els – Processes, machines and parameters
DVS 2207-11 Welding of thermoplastics; Heated tool welding
of pipes, piping parts and panels made of PP
6 Additional tools and devices DVS 2207-12 Welding of thermoplastics; Heated tool welding
of pipes, piping parts and panels made of
In principle, small tools and devices which are needed for the PVC-U
processing on the building site or in the workshop must be selected
in such a way that an application appropriate for plastics is ensured. DVS 2207-13 Welding of thermoplastics; Heated tool welding of
pipes, piping parts and panels made of PVC-C
6.1 Pipe cutting devices DVS 2207-15 Welding of thermoplastics; Heated tool welding
of pipes, piping parts and panels made of PVDF
With regard to pipe cutters, pipe shears or saws (manual or driven),
it must be guaranteed that: DVS 2207-16 Welding of thermoplastics; Heated tool welding
of pipes and piping parts made of Polyamide 12
– They permit cuts at a right angle.
DVS 2208-1 Welding of thermoplastics; Machines and devices
– They do not deform the pipe impermissibly. for the heated tool welding of pipes, piping parts
– Cutting devices do not cause any material damage (e.g. hairline and panels
cracks). Operational safety ordinance (BetrSichV)
– Cutting appropriate for plastics is possible (if at all possible, no
smearing or cracking of the material).
– If at all possible, no oil or grease enters the welding zone.
– Electric devices comply with the statutory rules and regulations.
6.2 Hand-held scrapers and deburrers

These resources are utilised for the chamfering and deburring of
pipe ends as well as for the machining-off or retouching of
scratches and grooves. The blades of the scrapers must have a
stable shape and be in a flawless condition (e.g. no notches).
583
File:
D:\Eigene Daten\Kunden\DVS\Ri+Me\2210\englisch_2210-1\e2210-1.fm
April 1997

Industrial Pipelines
FÜR SCHWEISSEN UND
Made of Thermoplastics
Planning and Execution Technical Code
VERWANDTE VERFAHREN E.V. DVS 2210-1
Above-Ground Pipe Systems
Content: 5.7 Pipe Brackets

5.7.1 Slide Bearing (GL)
1 Scope 5.7.2 Guide Bearing (FL)
1.1 Areas of Application 5.7.3 Fixed Point (FP)
1.2 Materials 5.7.4 Vertical Support (VL)
2 General Remarks 5.7.5 Hanging Bearing (HL)
3 Planning 5.7.6 Mounting Bracket (AH)
3.1 Fundamentals 5.7.7 General Design Guidelines for Pipe Brackets
3.2 Influencing Variables 5.8 Marking of the Pipelines
3.2.1 Loads Caused by Internal Overpressure 6 Fabrication and Assembly
3.2.2 Loads Caused by External Overpressure 6.1 Requirements on the Fabrication and Assembly of
3.2.3 Temperature Loads Pipelines
3.2.4 Loads Caused by the Transported Substance 6.1.1 Requirements on the Manufacturer
3.3 Material Characteristics 6.1.2 Personnel-Related Requirements
3.3.1 Fire Behaviour 6.1.3 Requirements on Machines and Devices
3.3.2 Hygienic and Toxicological Behaviour 6.1.4 Supervision of the Fabrication and of the Laying Work
3.3.3 Behaviour with Regard to Electrostatic Charging
6.2 Prefabrication of Pipeline Parts

3.3.4 Behaviour when Subjected to the Effect of High-Energy 6.3 Transport and Storage of Pipeline Parts
Beams 6.4 Welding, Adhesive Bonding and Laying
3.3.5 Behaviour when Subjected to the Effect of UV Radiation
6.4.1 Joining of Pipeline Parts by Means of Welding and
3.3.6 Behaviour in the Case of Abrasive Transported Adhesive Bonding
Substances
6.4.2 Manufacture of Flange Joints
3.3.7 Paintwork and Marking
6.4.3 Joining of Pipeline Parts Using a Union
4 Calculations
6.4.4 Installation of Mountings and Devices
4.1 Hydraulic Calculations
7 Tests and Approvals
4.1.1 Determination of the Clear Pipe Diameter
7.1 Testing of the Devices and Machines
4.1.2 Determination of the Flow Rate
4.1.3 Hydraulic Parameters 7.2 Visual Inspections
4.1.4 Determination of the Hydraulic Losses 7.3 Non-Destructive Tests
4.2 Strength Calculations 7.4 Destructive Tests
4.2.1 Determination of the Pipe Wall Thickness 7.5 Internal Pressure Test
4.2.2 Determination of the Fitting Wall Thicknesses 7.6 Periodic Tests
4.2.3 Stress Analysis 8 Quality Assurance
4.2.4 Strain Analysis 8.1 Incoming Tests
4.3 Calculations for Pipe Laying 8.2 Intermediate Tests
4.3.1 Determination of Changes in Length 8.3 Final Tests and Outgoing Inspections
4.3.2 Compensation for Changes in Length 8.4 Records
4.3.3 Fixed Point Loads 8.5 Training
4.3.4 Determination of the Pipe Spans 8.6 Quality Assurance System
4.3.5 Determination of the Guiding Distances in the Case of 9 Documentation
Axially Clamped Pipe Sections 10 Standards, Directives and Regulations that are also
5 Installation Planning Applicable
5.1 Pipes 10.1 DIN and EN Standards
5.2 Pipe Fittings 10.2 Directives, Leaflets and Work Sheets
5.3 Pipe Joints 10.2.1 Directives and Leaflets of Deutscher Verband für
5.3.1 Welding of PE, PP and PVDF Pipeline Parts Schweißen und verwandte Verfahren e.V.
5.3.2 Adhesive Bonding of Pipeline Parts Made of PVC 10.2.2 Directives of Deutscher Verein des Gas- und Wasser-
5.3.3 Joining of Pipeline Parts Using Flanges faches e.V.
5.3.4 Unions 10.2.3 Laying Instructions of Kunststoffrohrverband e.V.
5.3.5 Clamped Joints 10.3 Regulations, Ordinances and Miscellaneous Directives
5.3.6 Couplings 11 Explanation of the Symbols and Abbreviations
5.3.7 Push-Fit Fittings 12 Appendix
5.3.8 Threaded Connections Table 9
5.4 Mountings Coefficients of Hydraulic Resistance of Pipe Fittings
5.4.1 Selection of Mountings Table 10
5.4.2 Use of Butterfly Valves Coefficients of Hydraulic Resistance of Mountings
5.5 Safety-Related Devices Table 11
5.6 Expansion Joints and Sliding Sockets Criteria for the Selection of Mountings
584
Table 12 2 General Remarks

Guideline Values for Bolt Tightening Torques on Flange
Joints Pipelines that are used in installations for the storage or
Tables 13 to 19 transportation of water-polluting substances must be handled
Spans for Pipelines according to the construction and testing principles stipulated by
Table 20 Deutsches Institut für Bautechnik (DIBt).
Guiding Distances for Axially Clamped Pipe Sections
Figures 1 to 7 Pipelines that have an outside diameter > 32 mm and an
Graphic Determination of L-Shaped Bends operating overpressure of more than 0.1 bar and are used to
Figures 8 to 10 transport combustible, corrosive or poisonous gases, vapours
Instructions about the Execution of Expansion Bends and liquids are governed by the Pressure Vessel Ordinance
Figures 11 to 17 (DruckbehV). The pipelines also include their equipment parts.
Examples of Pipe Brackets All the mountings, measuring and regulating devices and other
Examples of Applications devices that may exert an influence on the safety of the pipeline
must be regarded as equipment parts.
In connection with the provisions stipulated in DruckbehV, it is
1 Scope necessary to comply with the Technical Rules (TRR 120) for
pipelines made of thermoplastics.
This directive includes fundamentals for the planning, calculation,
prefabrication and assembly of industrial pipelines that are made
of thermoplastics and are laid above ground. Prerequisites for the 3 Planning
application of the directive are not only experience in general
pipeline construction but also extensive knowledge about the 3.1 Fundamentals
materials specified in Section 1.2. As far as the planning of thermoplastic pipelines is concerned,
The pipelines referred to in the directive can be used in order to consideration must be given to the particular material character-
transport liquid and gaseous substances. The pipelines may be istics with regard to their behaviour when subjected to operation-
laid either inside buildings, ducts and shafts or outdoors. induced and external influences. These include mechanical,
Pipelines for heating, sanitary and ventilation installations are not thermal and chemical stress types. The mathematical design of
dealt with in this directive. the pipeline must correspond to the loads arising in the testing,
assembly and operating states. The essential material character-
This directive must be considered for the specified area of
istics are described in Section 3.3.
application. Particularly in the case of pipelines for the transport
of environmentally hazardous or toxic substances, there is no
3.2 Influencing Variables
need for any additional agreements between the customer and
the company performing the work with regard to the application The expected service life of the pipeline is influenced by the
of the directive. operating loads. It must therefore be ensured that, during the
Separate attention must be paid to any laws, regulations or planning phase, the influencing variables from all of the operating
official requirements that demand, extend or restrict the states are defined carefully and that the approach for the design
application of this directive. Remarks about this subject are is based on these influencing variables.
included in Section 2. The fundamental loads on thermoplastic pipelines and their effect
on the operational safety are described below.
1.1 Areas of Application
Typical areas of application are: 3.2.1 Loads Caused by Internal Overpressure
– Waste water installations As a rule, the internal pressure of a pipeline must not exceed the
– Electroplating installations operating overpressure stipulated in the generic standards for
– Semi-conductor industry pipes. Persistent overstressing caused by internal pressure leads
– Industrial and chemical installations to the accumulative expansion of the pipe until it fractures.
– Cooling and service water supply It must be borne is mind that the operating overpressures speci-
– Food and beverage industries fied in the pipe standards are not generally applicable to all pipe
– Water treatment installations fittings. Particularly in the case of fittings manufactured from pipe,
This directive may also be valid for areas of application that are geometrical influences and fabrication-induced imperfections
not specified. may result in a necessary reduction in the internal pressure loads
permissible according to the pipe standard.
1.2 Materials* Another restriction on the internal pressure resistance of
The directive applies to the following materials: pipelines in comparison with the data in the pipe standards
results from bending and thermal stresses whose effect may be
– Polyethylene(HDPE) superimposed on the stresses caused by the internal pressure.
– Polypropylene, Types 1 to 3(PP-H), (PP-B) and (PP-R) Therefore, the overall stress condition inside a pipe system must
– Polyvinyl chloride(CPVC) and (UPVC) always be defined mathematically and must be used as a
– Polyvinylidene fluoride(PVDF) measure for assessing the permissible operating overpressure.
The selection of the material is influenced by the application in It must be taken into consideration that the pipeline is frequently
question and by the operating conditions to be expected. The exposed to an intermittent operating overpressure rather than a
directive may also be applied to thermoplastics that are not stationary operating overpressure. The levels and durations of
specified here. the loads in question must be the subject of a separate
examination. Over time, the individual load sections result in the
definitive stresses that allow a statement to be made about the
* The material designations must be understood as generic terms for one expected service life of the pipeline.
group of thermoplastics in each case. The information corresponds to
Pressure surge loads may also arise, and these must be
the current status of the standardisation. Thermoplastics with code desi-
gnations according to DIN, EN and ISO standards must be assigned to investigated mathematically and their effect on the operational
the respective material groups according to their characteristics (e.g. safety of the pipeline must be assessed. Pressure surges must
HDPE includes the PE 63, PE 80 and PE 100 types and UPVC the HI, be reduced or avoided primarily by taking design-related
NI and RI types). measures.
585
Example: Pipe systems that are operated using pumps should – Calculation of the compressive or buckling stresses and of the
not include any quick-acting shut-off devices. fixed point loads according to Sections 4.2.3.1 and 4.3.3,
taking account of the characteristic strength values, which are
3.2.2 Loads Caused by External Overpressure reduced by swelling.
The permissible external overpressure or internal negative – Design of the pipe brackets, paying attention to the increase in
pressure is dependent on the wall thickness / diameter ratio of a the length and diameter of pipes and fittings as a result of
pipeline. Thin-walled pipes in particular are at risk from indenting. swelling.
If an internal negative pressure can arise in the pipe system, the – Do not leave assembly details exclusively to the installation per-
critical indenting pressure of the pipe must be determined and sonnel. Instead, specify expert execution planning beforehand.
compared with the negative pressure that occurs in service
– Have pipeline work carried out by a recognised specialist
(stability analysis). The critical indenting pressure must exhibit a
company and have it supervised by an expert.
reasonable safety margin in relation to the actual negative
pressure experienced. The stability analysis must be made with a 3.3 Material Characteristics
safety factor S  2.0.
The fundamental characteristics of the plastics specified in
For example, even large-diameter pipelines that are not filled and Section 1.2 are described below. For special applications, it is
are located outdoors and are unprotected are at risk from necessary to take account of the information provided by the
negative pressure when wind suction occurs. manufacturers and relevant literature.
3.2.3 Temperature Loads 3.3.1 Fire Behaviour

With regard to the pipe dimensioning, it is necessary to take In order to assess the fire behaviour of plastics, attention must be
account of the level and duration of the temperature loads. As the paid to DIN 4102. For pipelines that may be subjected to fire, the
temperature increases, the permissible internal or external relevant information in the above standard as well as country-
overpressure of a thermoplastic pipeline decreases as a result of specific requirements must be taken into consideration. Planning
the temperature-dependent strength behaviour. Temperature decisions must be taken on the basis of the applicable fire
changes in axially-mobile pipelines make the pipe sections in protection provisions.
question either longer or shorter. The changes in length are more
pronounced than in the case of metallic pipelines and therefore 3.3.2 Hygienic and Toxicological Behaviour
necessitate particular attention when expansion joint elements When plastic pipelines are used, for example in the food and bev-
are chosen. erage industries, no constituents that may be harmful to human
Apart from the compensation, it is possible to prevent changes in health or have a permanent influence on the composition of the
length by incorporating fixed points into a pipe train. This results transported substance may be released from the pipeline.
in an axially clamped pipe section and is associated with Furthermore, the formation of algae or the growth of bacteria
compression of the pipe and the risk of buckling. should not occur. With regard to the construction of drinking
water pipes, it is necessary to comply not only with the general
The application limits of the axially clamped pipeline are defined regulations but also with the Plastics / Drinking Water Recom-
by the permissible tensile or compressive stress and by the mendations (KTW).
critical expansion or compression. In addition to the stress
analysis, a stability analysis must be made with regard to 3.3.3 Behaviour with Regard to Electrostatic Charging
buckling. The buckling safety factor must be Sk  2.0. When thermoplastic pipelines are operated, static charges may
be generated by the flow of liquids or dusts. Positive and
3.2.4 Loads Caused by the Transported Substance negative charges arise during static charging. While the positive
In comparison with metallic materials, thermoplastics are more charges remain bound where they are formed, negative charges
resistant to a large number of transported substances, e.g. are brought away, for example, along with the liquid (spatial
chemicals. However, some of these transported substances may separation).
give rise to changes in the material characteristics of Electrostatic charges can be dangerous, in particular they may,
thermoplastics. This is shown, for example, by a reduction in under certain circumstances, give rise to ignitions. In order to
strength in the case of swelling or oxidation. prevent or eliminate charges, it is necessary to pay attention to
The supplements to the pipe standard in question provide an the following:
initial indication of the resistance of the material to the – All the conductive parts of the pipeline must be earthed. Any
transported substances. However, for the dimensioning of a objects that are made of conductive materials and whose
plastic pipeline, the designer requires a term that takes account discharge resistance is  106 ohm must be electrostatically
of the effect on the strength behaviour of the material (reduction earthed. The earthing may be carried out individually or by
factor). Detailed information about this is included in the means of conductive joining all of the parts and a single dis-
DVS 2205-1 directive and in DIN EN 1778. charge point.
– If the pipelines end in vessels or apparatus parts, it is
3.2.4.1 Loads Caused by Solvents necessary to comply with the directives that are stipulated by
Subject to certain prerequisites, thermoplastic pipelines are also the employers' liability insurance association in order to avoid
suitable for the transport of substances containing solvents (e.g. ignition risks caused by electrostatic charging. It is considered
chemical waste water). In order to ensure that the pipelines oper- that solid substances with a surface resistance < 109 ohm and
ate without any problems, the following approach is necessary: liquid substances with a specific resistance < 108 ohm cannot
be statically charged.
– Within the framework of immersion tests, determination of the
Standard pipeline parts made of thermoplastics exhibit a surface
solvent absorption of the plastic and of the swelling caused by
resistance > 109 ohm and thus do not satisfy the requirements
this. Otherwise, assumption of a load type according to
specified in the explosion protection directives. The use of
Equation (31) in Section 4.3.3.
electrically conductive plastic pipes makes it possible to reduce
– Decision as to whether the pipeline can be clamped axially the static charges or to eliminate them altogether. The measures
taking account of its geometry and of the construction-related that lead to an improvement in the conductivity include surface
conditions. If this is the case, the supporting and pipe guiding coating with conductive materials or the incorporation of
distances must be determined according to Sections 4.3.4 and conductive substances into the plastics. In most cases, the
4.3.5. In this respect, attention must be paid to the creep conductivity is achieved by mixing particles of special carbon
modulus, which is reduced by swelling. blacks.
586
3.3.4 Behaviour when Subjected to the Effect of High- 4 Calculations

Energy Beams
4.1 Hydraulic Calculations
In general, plastic pipelines are not resistant to high-energy
beams in the long term. The resistance to radiation is lower than Flow processes in liquid pipelines are defined using the continuity
that of most metallic and ceramic materials. equation.
The effect of high-energy beams on thermoplastics may lead to V = A i  w = const. (1)
the cross-linking of the molecular structure, resulting in an
increase in strength. However, if the radiation persists, this may Although the following relations apply to liquids. However, they
break the molecular chains and thus damage the material, with a can also be used for gases.
corresponding substantial reduction in strength.
4.1.1 Determination of the Clear Pipe Diameter
The above behaviour can be taken into consideration using a
reduction factor whose level must be determined experimentally. V' V''
d i = 18,8  = =
----- or d i 35.7  ------ (2)
Thermoplastic pipelines can be used at dose rates < 106 rad if a w w
slight reduction in strength is taken into account. The limit of the
radiation resistance of the thermoplastic is given in the material 4.1.2 Determination of the Flow Rate
sheets provided by the manufacturers.
V' V''
w = 354  ------- =
or w =
1275  ------- (3)
2 2
3.3.5 Behaviour when Subjected to the Effect of UV di di
Radiation
Guideline values for typical flow rates are:
Pipelines made of thermoplastics with stabilising additives may
be used outdoors without any lasting effects due to ultraviolet Liquids: w = 0.5 - 1.0 m/s for suction pipelines
radiation. In spite of the thermoplastics being provided with light- w = 1.0 - 3.0 m/s for pressure pipelines
stable pigments, long-term irradiation with intensive UV light may Gases: w = 10 - 30 m/s
lead to discoloration (fading of the original colour). A reduction in The symbols in Equations (1) to (3) have the following meanings:
the impact resistance may also occur.
Ai = clear pipe cross-section (mm²)
Most pipelines made of PP are not stabilised against UV di = pipe inside diameter (mm)
radiation and must therefore be protected. If effective protection V' = flow volume (m³/h)
against direct sunlight is not possible (e.g. protective coat of paint V" = flow volume (l/s)
or insulation), an alternative plastic (e.g. PE, PVC or PVDF) may w = flow rate (m/s)
be used.
4.1.3 Hydraulic Parameters
Although the outdoor service duration of pipelines made of PP is
limited to < 10 years, the oxide coat formation occurring when
4.1.3.1 Reynolds' Number
they are subjected to UV radiation may be counterbalanced by a
mathematically-derived increase to the wall thickness. Depend- The Reynolds' number (Re) gives a measure of the ratio of
ing on the UV radiation intensity and the duration of the expo- inertial forces to viscous forces for given flow conditions. It can be
sure, the increase to the wall thickness must be stipulated as determined as follows:
 2 mm.
wd
The creep rupture behaviour of PP pipeline parts when they are = Re ----------------i-
3
(4)
subjected to internal pressure is not necessarily affected by the 10  v
UV radiation. Circular pipelines have a laminar flow below the critical Reynolds'
Because PP loses toughness as a result of exposure to UV number Recrit = 2320. If the Reynolds' number is above the
radiation, it may only be used outdoors without protection critical value, this indicates turbulent flow.
provided that the pipe wall temperature does not drop below 5 °C In practice, a laminar flow occurs, in particular, during the
when loads are applied. transport of viscous substances, e.g. lubricating oils. Most
applications (including aqueous substances) relate to turbulent
3.3.6 Behaviour in the Case of Abrasive Transported flows with a considerably more uniform flow distribution across
Substances the pipe cross-section than in the case of laminar flow.
Thermoplastic pipelines are suitable for the transport of dry 4.1.3.2 Pipe Friction Coefficient
substances with an abrasive effect to a limited extent only. In
each individual case, the applicability of a material must be The dimensionless pipe friction coefficient  is required in order
established by experimentally. to determine hydraulic losses in pipelines. The following applies
to laminar flows in circular pipes (Re < 2320):
Positive experience with thermoplastic pipelines is available with
regard to the transport of liquid/solid mixtures. The service life is 64
 = -------- (5)
comparatively long in the case of solid contents up to 700 g/l, Re
grain sizes < 10 mm and flow rates below 3 m/s. In general, it For turbulent flows (Re > 2320),  can be established using
must be ensured that the pipe cross-section is completely filled Figure 1 (Appendix). In order to determine the pipe friction
by the transported medium otherwise the bottom of the pipe will coefficient, the roughness coefficient must be inserted as
be worn away relatively quickly (so-called channel wear). k = 0.01 although k = 0.007 is specified for plastic pipelines in the
literature. For approximate calculations, it is sufficient to establish
3.3.7 Paintwork and Marking the hydraulic losses of pipeline sections with  = 0.02.
Paintwork may be applied as protection against UV radiation in The symbols in Equations (4) and (5) have the following
the case of PP pipelines or for the purpose of marking plastic meanings:
pipelines. Only those pigments that do not have a detrimental
di = pipe inside diameter (mm)
influence on the material behaviour (e.g. solvent-free emulsion
Re = Reynolds' number (–)
paints) may be used.
w = flow rate (m/s)
It is recommended to use self-adhesive marking tapes that can  = pipe friction coefficient (–)
be secured to the pipe in a reliable and permanent way. The  = kinematic viscosity (m²/s)
same prerequisites apply to the adhesives as to the pigments. (for water at 20 °C = 1.0 ∙ 10-6)
587
4.1.4 Determination of the Hydraulic Losses 15 % compared with the pressure loss of a straight pipe section
pR and of the fittings pRF.
The flow of a substance in a pipeline causes friction and thus
energy losses, which results in a decrease in pressure. The
4.1.4.4 Pressure Loss in Mountings
following factors are relevant to the level of the losses:
The pressure loss in mountings can be established as follows:
– The length of the pipeline.
– The cross-sectional shape of the pipe.  2
p RA =  RA  -----------------  w (10)
– The pipe roughness. 5
2  10
– The geometry of the fittings, mountings and pipe joints.
– The viscosity and density of the transported substance. The symbols in Equation (10) have the following meanings:
– The type of the flow (laminar or turbulent). pRA = pressure loss in the mounting (bar)
The overall pressure loss in a pipe system results from the total RA = resistance coefficient of the mounting (–)
of the following individual losses:  = density of the transported substance (kg/m³)
w = flow rate (m/s)
p ges = p R + p RF + p RA + p RV (6)
Note: Table 10 in the appendix includes mounting resistance
The symbols in Equation (6) have the following meanings: coefficients, which are intended for approximate calcula-
pR = pressure loss of the straight pipe sections (bar) tions. For any particular application, it is necessary to
take account of the data provided by the manufacturer of
pRF = pressure loss of the fittings (bar)
the mounting concerned.
pRA = pressure loss of the mountings (bar)
pRV = pressure loss of the joints (bar)
4.1.4.5 Pressure Surges in Pipelines
4.1.4.1 Pressure Loss in the Straight Pipe Section A change to the stationary conditions in a pipe system (e.g. when
a quick-acting mounting is actuated or when pumps are switched
The pressure loss in a straight pipe section is inversely
on) produces a pressure wave. Reflection at positions where
proportional to the pipe diameter.
there are changes in direction or cross-section leads to an
On this basis: increase in pressure, which may amount to many times the
 operating pressure (pressure surge). In order to roughly estimate
L 2
p R =   ----  -----------------  w (7) whether a pipeline is at risk from pressure surges, it is possible to
d i 2  10 2 apply the following empirical relation:
The symbols in Equation (7) have the following meanings: LR  w
K = --------------- (11)
pR = pressure loss in the straight pipe section (bar) Hp
 = pipe friction coefficient (–)
L = length of the straight pipe section (m) The symbols in Relation (11) have the following meanings:
di = inside diameter of the pipeline (mm)
K = pressure surge parameter (–)
 = density of the transported substance (kg/m³)
LR = length of the pipeline (m)
w = flow rate (m/s)
w = flow rate (m/s)
Hp = delivery head of the pump (m)
4.1.4.2 Pressure Loss in Pipe Fittings
Note: For K > 70 and with the simultaneous use of quick-acting
Considerable friction, deflection and unbonding losses occur in
mountings, it is recommended to calculate the pressure
fittings.
surges separately.
The pressure loss is determined as follows:
 2
4.2 Strength Calculations
p RF =  RF  -----------------  w (8)
5 In principle, strength calculations relating to thermoplastic
2  10
pipelines must be made on the basis of long-term parameters for
Note: Table 9 in the appendix includes a selection of a design life of 25 years. The strength parameters may,
resistance coefficients for different pipe fittings. depending on the operating temperature, be taken from the creep
rupture curves provided by the manufacturers, from the generic
4.1.4.3 Pressure Loss at Pipe Joints pipe standards, from the DVS 2205-1 directive or from DIN EN
No exact data can be given about pressure losses at the pipe 1778.
joints because the geometrical dimensions (e.g. weld beads) are In special cases, the strength may be calculated for a service life
not constant. It is recommended that the calculation of the < 25 years provided this has been expressly agreed between the
pressure loss should be based on a resistance coefficient of customer and the manufacturer of the pipeline or with the
planning body. The permissible stress must be determined
 RV = 0.1 (–)
according to the DVS 2205-1 directive or according to DIN EN
for each joint in the plastic pipe system, such as butt welds and 1778.
socket-fusion joint assemblies as well as for flanges.
4.2.1 Determination of the Pipe Wall Thickness
On this basis:
The minimum wall thickness is given by:
 2
p RV =  RV  -----------------  w (9)
5 p  da
2  10 s min = ------------------------------
- (12)
20   zul + p
The symbols in Equations (8) and (9) have the following
meanings: The symbols in Equation (12) have the following meanings:
pRF, pRV = pressure loss in the fitting or joint (bar) smin = mathematical pipe wall thickness (mm)
RF = resistance coefficient of the fitting (–) p = internal overpressure (bar)
RV = resistance coefficient of the joint (–) da = pipe outside diameter (mm)
 = density of the transported substance (kg/m³) zul = permissible stress (N/mm²)
w = flow rate (m/s)
When the mathematical pipe wall thickness has been
In order to determine the approximate pressure loss at the joints established, the actual wall thickness used must be determined
of a pipeline, it is sufficient to assume an increase of approx. taking account of the nominal pressure stage of the series of the
588
pipe standard in question. Consideration must be given to according to Equations (16) to (20). The direction of the stress
required wall thickness increases (e.g. when PP pipelines are concerned is defined as follows:
used outdoors without any UV protection or when abrasive
X axis: parallel to the pipe longitudinal axis (vertical to the pipe
substances are transported).
cross-section)
Y axis: tangential to the pipe cross-section
4.2.2 Determination of the Fitting Wall Thicknesses
Z axis: radial to the pipe cross-section
4.2.2.1 Minimum Wall Thickness at Pipe Bends All the stresses acting in the same direction must be added
together taking account of their preceding signs (+ or -). These
For pipe bends that are formed from pipe or are composed of
can be compared directly with strength parameters established in
segments, the minimum wall thickness must be determined
the case of uniaxial loading.
according to Equations (13) and (14). In the case of injection-
moulded pipe bends, the manufacturer must prove an adequate Stresses that do not act in the same direction must be converted
wall thickness by means of appropriate tests. into a comparative stress (v) by applying a strength hypothesis.
The following applies to the wall thickness on the inside of a When the existing stresses are compared with the permissible
bend: stresses, attention must be paid to whether these are uniaxial or
multiaxial. Details about the different strength hypotheses can be
p  da taken from the specialist literature.
s min = -------------------------------  f Bi (13)
20   zul + p For the scope of this directive, the comparative stresses from the
internal pressure stresses on pipes are available in the form of
The following applies to the wall thickness on the outside of a
creep rupture curves. Therefore, it is possible to establish a direct
bend:
relation to the determined stresses.
p  da
s min = -------------------------------  f Ba (14) 4.2.3.1 Determination of the Stress Components
20   zul + p
Stress in the longitudinal direction (X axis) caused by
The symbols in Equations (13) and (14) have the following internal overpressure:
meanings:
p 1
smin = mathematical bend wall thickness (mm)  i = ------  ------------------------------ =  x (16)
10 2
p = internal overpressure (bar)  d a /d i  – 1
da = bend outside diameter (mm)
zul = permissible stress (N/mm²) Stress in the circumferential direction (Y axis) caused by
fBi = factor for the inside of the bend according to Table 1 (–) internal overpressure:
fBa = factor for the outside of the bend according to Table 1 (–) 2
p  d a /d i  + 1
 u = ------  ------------------------------
- = y (17)
Table 1. Factors for the Determination of Bend Wall Thicknesses. 10  d /d 2 – 1
a i
Bend radius R 1.0 ∙ da 1.5 ∙ da 2.0 ∙ da 2.5 ∙ da Stress in the radial direction (Z axis) caused by internal
Seamless fBi 1.27 1.22 1.15 1.12 overpressure:
bends fBa 0.92 0.93 0.95 0.96 p
Segment fBi 1.59 1.50 1.44 1.40 r =– ------ =z (18)
10
bends fBa 1.15 1.16 1.19 1.20
Stress in the longitudinal direction (X axis) caused by pipe
bending:
4.2.2.2 Minimum Wall Thickness at Pipe Branches
2
The cut-out for the branching spigot in the pipeline weakens the q  LA
----------------
b = -=x (19)
circular ring. This weakening must be compensated for by 8  WR
increasing the wall thickness at the cut-out edge of the base pipe.
Stress in the longitudinal direction (X axis) caused by
If the wall thickness at the cut-out edge cannot be increased for prevented thermal extension:
fabrication-related reasons, the permissible internal overpressure
(bar) for 20 °C / 50 years must be indicated on the fitting or in the   =      E c =  x (20)
relevant certificate (works certificate or acceptance certificate).
The symbols in Equations (16) to (20) have the following
In general, the following applies to the wall thickness at pipe meanings:
branches:
i,u,r,b = stress in the x, y and z directions (N/mm²)
p  da p = internal overpressure (bar)
s min = ---------------------------------------------------
- (15)
 20   zul + p   V RF da = pipe outside diameter (mm)
The symbols in Equation (15) have the following meanings: di = pipe inside diameter (mm)
WR = pipe resistance moment (mm³)
smin = mathematical bend wall thickness (mm) q = line load caused by pipe, filling and
p = internal overpressure (bar) additional weight (N/mm)
da = bend outside diameter (mm) LA = existing supporting distance (mm)
zul = permissible stress (N/mm²)  = coefficient of longitudinal thermal extension (1/K)
vRF = weakening factor of the fitting (–)
 = temperature difference (also dT) (K)
Details about the determination of the weakening factors as well Ec = creep modulus (N/mm²)
as values for the reinforcement of the cut-out are included in the
AD leaflets B 9 and N 1. 4.2.4 Strain Analysis
The loads in a pipe system lead not only to stresses but also to
4.2.3 Stress Analysis
strains, which must vary within material-dependent limits. If no
In order to establish the overall stress condition, it is necessary to attention is paid to this, those points of the pipe system that are
calculate the level and direction of all the stresses that take effect subjected to stresses may be damaged in the long term. For a
in a pipe system. The level of the stresses must be determined typical application, the strain in the pipe is calculated as follows:
589
Strain in the X direction: 4.3.1.2 Changes in Length Caused by Internal Pressure

Loads
100
 x = ----------    x –     y +  z   (21) The internal overpressure leads to the following longitudinal
Ec
extension in a closed pipe section mounted on frictionless
Strain in the Y direction: bearings:
100
 y = ----------    y –     x +  z   0.1  p   1 – 2 
Ec
(22) l p = --------------------------------------------  L (25)
2 2
Ec   d a / di – 1 
The symbols in Equations (21) and (22) have the following
meanings: The symbols in Equation (25) have the following meanings:
x, y = strain in the x and y stress directions (%) lp = change in length caused by internal
x, y, z = stress in the x, y and z directions (N/mm²) overpressure (mm)
 = Poisson's ratio = 0.38 for thermoplastics (–) L = length of the pipe section under consideration (mm)
Ec = creep modulus (N/mm²) p = internal overpressure (bar)
The greatest strain in each case must be determined according  = Poisson's ratio = 0.38 for thermoplastics (–)
to Equations (21) and (22) and must be compared with the grenz Ec = creep modulus (N/mm²)
limiting value. The safety margin results from the following: da = pipe outside diameter (mm)
di = pipe inside diameter (mm)
 grenz
S  = ---------------  1.3 (23)
 max 4.3.1.3 Changes in Length Caused by Chemical Effects
The symbols in Equation (23) have the following meanings: In the case of thermoplastic pipelines, certain transported
substances (e.g. solvents) may give rise to a greater length and a
S = safety margin in relation to the limiting strain (–) larger pipe diameter (swelling), as well as a reduction in the
grenz = limiting value on the strain according characteristic strength values. In order to ensure a satisfactory
to DVS 2205-1 (%) operation of thermoplastic pipelines exposed to solvents, it is
max = strain established according to Equations (21) recommended to dimension them with a factor of
and (22) (%)
fQ = 0.025 … 0.040 (mm/mm)
4.3 Calculations for Pipe Laying for the swelling load type.
Accordingly, the expected change in the length of a pipe section
4.3.1 Determination of Changes in Length subjected to the effect of solvents can be determined as follows:
Changes in the length of a plastic pipe system may be caused by
l Q = f Q  L (26)
testing or operating processes. A distinction must be made
between: The symbols in Relation (26) have the following meanings:
– Changes in length caused by temperature changes. lQ = change in length caused by swelling (mm)
– Changes in length caused by internal overpressure. L = length of the pipe section under
– Changes in length caused by chemical effects. consideration (mm)
fQ = factor for chemical effect (mm/mm)
4.3.1.1 Changes in Length Caused by Temperature Changes
Note: For application-related calculations of thermoplastic
If the pipeline is exposed to different temperatures (operating or pipelines exposed to solvents, the fQ factor must be
ambient temperatures), it changes its position according to the established by means of selective investigations.
movement possibilities of the individual pipe sections. The Particular measures with regard to the operational safety
distance between two fixed points is regarded as one pipe of pipelines at risk from swelling are described in Section
section. 3.2.4.1.
The following applies to the calculation of temperature-
dependent changes in length: 4.3.2 Compensation for Changes in Length
As a rule, pipelines made of thermoplastics must be laid in such a
l  =   L   (24) way that it is ensured that any changes in length are
The symbols in Equation (24) have the following meanings: compensated for. In most cases, reference may be made to
changes in the direction of the pipeline route for compensation
l = temperature-dependent change in purposes. If this is not possible, it is necessary to install
length (mm) additional expansion joint elements. The use of expansion joints
 = coefficient of linear extension and sliding sockets is dealt with in Section 5.6.
according to Table 2 (mm/m ∙ K or 1/K)
L = length of the pipe section under 4.3.2.1 Dimensioning of Expansion Bends
consideration (m or mm)
Changes in the length of thermoplastic pipelines can be
 = temperature difference
compensated for most easily using expansion bends in an L
[dT = max T – min T] (K)
shape (90° changes in direction), commonly called a bending leg.
With regard to the stipulation of , it is necessary to estimate The minimum dimensions of L-shaped expansion bends are
the lowest and highest pipe wall temperatures TR during the determined from the following equation:
assembly, operation or shut down of the installation.
3  d a  L 1.2    E cm
Table 2. Average Coefficients of Thermal Extension. LB = --------------------------------------------------- (27)
zul  b
Aerage  values mm/(m ∙ K) 1/K
The symbols in Equation (27) have the following meanings:
PE 0.18 1.8 ∙ 10–4
LB = necessary length of the bending leg in
PP 0.16 1.6 ∙ 10–4 question (mm)
PVDF 0.13 1.3 ∙ 10–4 L1,2 = system lengths of the expansion bend (mm)
da = pipe outside diameter (mm)
CPVC 0.07 0.7 ∙ 10–4
Ecm = average bending creep modulus
UPVC 0.08 0.8 ∙ 10–4 for t = 25 a (N/mm²)
590
zul  –  l = permissible bending stress proportion For the L-shaped expansion bend, the fixed point loads can be
for t = 25 a (N/mm²) approximately determined from the bend deformation without any
 = longitudinal extension according to friction in the slide bearings as follows:
Equations (29) to (31) (–)
12  l  E c  J R
Remarks about the Dimensioning of Expansion Bends: F LB = --------------------------------------
- (32)
3
The design of expansion bends in L, Z and U configurations are LB
given in Figures 8 to 10. According to Equation (27), the respec-
tive bending leg lengths LB are determined using the value for The symbols in Equation (32) have the following meanings:
Ecm at Tm = 0.5 ∙ (min T + max T). FLB = fixed point loads on the L-shaped
Figures 2 to 7 can be used to determine the bending leg using a expansion bend (N)
simplified method, where b > 0.15 v in Equation (27). LB = length of the bending leg (mm)
Attention: The determination of expansion bends in L, Z and U l = change in length according
shapes, using the above figures, does not replace to Equations (23) to (25) (mm)
the stress analysis. Ec = creep modulus for t = 100 min (N/mm²)
JR = pipe moment of inertia (mm4)
4.3.3 Fixed Point Loads
Note: Calculations for the exact determination of the fixed point
loads of two-dimensional systems such as expansion
4.3.3.1 Fixed Point Loads without any Compensation for the
bends in L, Z and U shapes as well as the loads in three-
Change in Length
dimensional systems must be dealt with in an elasticity
If the change in the length of a straight pipe section is prevented investigation. Reference is made to the corresponding
by installing fixed points, this results in an axially clamped literature and to PC calculation programs.
system. With regard to its dimensioning, the axially clamped
pipeline must be considered as a special case. The following 4.3.4 Determination of the Pipe Spans
system variables must be established mathematically:
The supporting distances of thermoplastic pipelines must be
– The fixed point loads, see Equation (28). established while paying attention to the permissible bending
– The necessary guiding distance of the pipe, see Equation (34). stress and to the limited deflection of the pipe train. LA/500 to
– The tensile/compressive stresses and strains, see Equations LA/750 may be assumed as a guideline value for the permissible
(20) and (21). deflection. Taking account of the above deflection of a pipe
The greatest fixed point loads occur on the straight, axially section between the supporting points, this results in a
clamped pipe train. In a general form, they are: permissible supporting distance of the pipeline of:
F FP = A R  E c   (28) Ec  JR
L A = f LA  3 ----------------- (33)
The symbols in Equation (28) have the following meanings: q
FFP = fixed point loads in the clamped pipe train (N) The symbols in Equation (33) have the following meanings:
AR = annular surface of the pipe wall (mm²)
LA = permissible supporting distance (mm)
Ec = creep modulus for t = 100 min (N/mm²)
 = prevented longitudinal extension (–) fLA = factor for the deflection (0.80 - 0.92) (–)
Ec = creep modulus for t = 25 a (N/mm²)
Taking account of the possible load types,  must be JR = pipe moment of inertia (mm4)
incorporated into Equation (28) as follows:
q = line load caused by pipe, filling and additional
Load type – thermal expansion:  =    (29) weight (N/mm)
0.1  p   1 – 2  Note: The factor fLA must be stipulated depending on the pipe
Load type – internal pressure:  = -------------------------------------------- (30) outside diameter da. The following relation is applicable in
2 2
Ec   d a / di – 1  this respect:
min  da  max
Load type - swelling:  = 0.025 ... 0.040 (31)
0.92  fLA  0.80
The symbols in Equations (29) to (31) have the following
meanings: Customary spans of thermoplastic pipelines are shown in Tables
13 to 17.
 = prevented longitudinal extension (–)
 = coefficient of thermal longitudinal extension (1/K) 4.3.5 Determination of the Guiding Distances in the Case of
 = temperature difference (K) Axially Clamped Pipe Sections
p = internal overpressure (bar)
da/di = pipe outside/inside diameter (mm) If pipelines are laid in such a way that no axial movement is
Ec = creep modulus for t = 100 min (N/mm²) possible, attention must be paid to the critical buckling length for
 = Poisson's ratio (–) the operational safety. The pipe guiding distances to be defined
must exhibit a buckling safety factor of at least SK = 2.0. If the
4.3.3.2 Fixed Point Loads with Compensation for the necessary guiding distance LF is smaller than the calculated
Change in Length supporting distance LA according to Equation (33), LA must be
reduced to LF.
The fixed point loads on expansion bends in L, Z and U shapes
are considerably lower than those on the straight, axially clamped If axially clamped pipelines are operated at an elevated
pipe section. The loads depend on the geometry of the temperature, the guiding distance determined according to
expansion bend in question. Equation (34) must be reduced by 20 %. The operating
temperatures which must be regarded as elevated are
In general, it is true: summarised in Table 3.
The "softer" the pipeline route between two fixed points is, the
lower are the reaction forces (fixed point loads) caused by the
deformation energy in the bending legs. In the case of long pipe Table 3. Elevated Operating Temperatures in Plastic Pipelines.
sections, it must be ensured that the friction of the pipe slide Material PE PP PVDF CPVC UPVC
bearings is taken into consideration with regard to the fixed point
loads. Temperature > 45 oC > 60 oC > 100 oC > 80 oC > 40 oC
591
For a minimum safety factor of SK = 2.0, the pipe guiding The releasable pipe joint permits, for example, the non-
distance is: destructive dismantling and simple reassembly of pipeline parts
and can also be used at positions with difficult accessibility. On
JR the other hand, a homogeneous and maintenance-free joint can
erf L F = 3.17  --------------  LA (34)
  AR be achieved by means of welding or adhesive bonding. This is
more important, in particular, in the case of transported
The symbols in Equation (34) have the following meanings: substances with a high risk potential. The decision as to which of
the specified critieria should have priority must be taken by the
erf LF = necessary distance of the pipe guide
pipeline manufacturer after appraising the risks to people and to
bearings (mm)
the environment.
JR = pipe moment of inertia (mm4)
AR = annular surface of the pipe wall (mm²)
5.3.1 Welding of PE, PP and PVDF Pipeline Parts
 = prevented extension according to
Equations (29) to (31) (–) PE, PP and PVDF pipeline parts must be joined by means of
The pipe guiding distances can be determined using a simplified welding in compliance with the standards, directives and
method with the aid of Table 20. regulations specified in Section 10. The individual welding
processes are described in detail and do not require any further
explanation with regard to their application.
5 Installation Planning
The welding processes customary in the construction of
The operational safety and service life of the thermoplastic thermoplastic pipelines are:
pipeline is fundamentally influenced by the characteristics of the – Heated tool butt welding (HS)
material in question and by the quality of the installation. The – Heated tool socket welding (HD)
installation planning that must be carried out by the pipeline – Electrofusion welding (HM)
manufacturer serves to prepare the delivery, fabrication and
assembly of pipeline parts. Heated tool butt welding can be used for all the available pipe
dimensions without restriction. The joint factor attainable guaran-
For this purpose, pipeline parts such as tees a high degree of operational safety and long-term use of the
– pipes, pipeline.
– fittings, The application of heated tool socket welding and electrofusion
– joint parts, welding is limited by the available fittings. The quality of these
– mountings, methods is equivalent to the heated tool butt welding process. If
– expansion joints and electrofusion welding is to be used for the joining of pipeline
– fastenings parts, the resistance of the heated coil material to the transported
must be harmonised with regard to their materials, design and substance must be checked.
fabrication. Hot gas welding with a high-speed nozzle (WZ) and hot gas
extrusion welding (WE) may only be used for the joining of
5.1 Pipes pipeline parts in exceptional cases. The joint factor using these
The dimensions of the pipes as well as the general quality processes in lower than that of the above welding processes.
requirements within the framework of the manufacture and
delivery are stipulated in the generic standards and do not 5.3.2 Adhesive Bonding of Pipeline Parts Made of PVC
require any further explanation. The compliance with the quality
requirements should be documented by means of the PVC pipeline parts must be joined by means of adhesive bonding
corresponding delivery certificate provided by the manufacturer in compliance with the standards, directives and regulations
according to DIN EN 10204. specified in Section 10. The sockets required for the adhesive-
bonded joint limit the area of application with regard to the
5.2 Pipe Fittings nominal pipe size. The quality of the adhesive-bonded joint is
equivalent to that using the welding processes customary in the
The sizes and connecting dimensions of the fittings are stan- construction of thermoplastic pipelines.
dardised to the greatest possible extent. Their outside diameters
and wall thicknesses correspond to the pipe series in question.
5.3.3 Joining of Pipeline Parts Using Flanges
Furthermore, the manufacturers have made their own dimen-
sional specifications for different fittings. These specifications As a rule, pipeline connections to vessels, pumps, mountings and
have not been incorporated into standards. similar equipment must be made using flange joints. In
With regard to the installation planning, it must be ensured that thermoplastic pipelines, welding necks or collars with backing
designs with an accumulation of joints should be avoided if at all flanges are predominantly used for this purpose. Fixed flange
possible. If such structures are unavoidable, they must be joints should only be used in special cases.
manufactured by a recognised specialist company. The compli-
ance with the quality requirements during the manufacture of 5.3.3.1 Welding Necks and Collars
fittings and special designs must be documented by means of the The dimensions of and quality requirements on the welding
corresponding delivery certificate provided by the manufacturer necks and collars are stipulated in the standards specified in
according to DIN EN 10204. Section 10. If non-standardised welding necks and collars are
used in pressure pipelines, the pipeline manufacturer must
5.3 Pipe Joints
provide appropriate proof of their operational safety.
Not only welding and adhesive bonding but also flanges, unions,
sockets and couplings are used to join thermoplastic pipelines. 5.3.3.2 Backing and Blind Flanges
With regard to the choice of the joint type concerned, it is
necessary to take particular account of the aspects specified The dimensions of the flanges are stipulated in the standards
below. specified in Section 10. With regard to the choice of material,
attention must be paid to the expected loads on the flange. In
Criteria for the selection of a pipe joint: principle, flanges must have a distortion-free design and may
– Operational safety. exhibit only minimal creep. The flange thickness may be adapted
– Degree of tightness. to the loads by means of strength calculations. With regard to the
– Influence of the transported substance. installation of the backing flanges, the regulations indicated by
– Expense. the manufacturers must be complied with.
592
5.3.3.3 Packings for Flange Joints pressures, combined with different operating temperatures, with
reference to the equivalent pipe standard for the material. There
Taking account of the operating conditions and the packing
are some standards available relating to unions, containing infor-
forces, the selection of suitable flange packings in thermoplastic
mation about the quality requirements.
pipelines is dependent on the following factors:
– Shape. 5.3.5 Clamped Joints
– Dimensions.
– Material. A clamped joint may be used in connection with a union and also
a flange joint. Its exclusive task is to join metallic pipeline parts
Shape of the Packing with thermoplastic pipes. The quality requirements on the metal/
The packing may be shaped as a flat ring, as a profiled flat ring or PE clamped joint are given in the relevant standards.
as an O ring. A gasket that is manufactured from 2 - 5 mm thick When clamped joints are used, it must be ensured that the type
plate material corresponding to the nominal size is adequate for test is certified by a recognised testing body. The proof of
many applications. This packing type can be manufactured on tightness of the clamped joint must be provided for the
site. permissible operating overpressures, combined with different
Profiled gaskets and O ring packing have proven to be suitable at operating temperatures, with reference to the equivalent pipe
increased operating and testing pressures. In contrast with the standard for the material.
gasket ring, the profiled gasket consists of two components –
firstly, of the spherical gasket part, which is also armoured with a 5.3.6 Couplings
steel insert and secondly, of the profiled packing part (O ring or
The use of couplings is basically limited to joints with hoses.
lip ring) on the inside of the packing.
Metallic shell couplings have also proven to be suitable for water
The stabilised profiled gasket and the O ring packing offer the supply field and for the temporary joining of applications pipes for
following advantages: the transport of non-hazardous substances at temperatures up to
– Reliable tightness with low bolt tightening torques. approx. 20 °C.
– Can be used at higher internal pressures and with internal The advantages of couplings are to be found in its simple
negative pressure. handling and in its reusability. Their disadvantages include a
– Easy installation even in vertical pipe trains. reduction in tightness over time during operation due to frequent
– Minor influence of the flange and collar surfaces. coupling and uncoupling and also soiling.
– Safety when pipelines made of different materials are joined.
Due to the lack of standards for couplings made of thermo-
Depending on their shape, packings can be used according to plastics, a particulary careful selection must be made with regard
Table 4. to their operational safety. The permissible pressures and tem-
peratures of the coupling must be specified by the manufacturer.
Table 4. Selection Criteria for the Packing Shape. When couplings are used, the provisions to be complied with
include the regulations stipulated by the employers' liability insur-
Packing Shape Recommended Flange or
ance associations (e.g. BG Chemie).
Application Limits Collar Design
Flat ring p up to 10 bar with packing grooves 5.3.7 Push-Fit Fittings
T up to 40 °C
In the case of joint manufactured using a push-fit fitting, the
Flat ring, profiled p up to 16 bar with or without tightness is basically brought about by the internal overpressure.
all temperatures packing grooves The customary push-fit fitting is not non-positive in the
O ring groove dimensions: longitudinal direction and requires corresponding fixed points in
general use DIN 8063/4 the pipeline route. However, there are variations that are non-
up to DN 200 positive in the longitudinal direction. The permissible axial loads
p = –1 to 16 bar DIN 16962/4 must be specified by the manufacturer.
all temperatures DIN 16963/4 If an internal negative pressure can occur in pipelines joined
using push-fit fittings, there is a risk of leaks due to the partial
Dimensions of the Packing detachment of the packing in the socket gap with simultaneous
unbonding caused by dirt particles. In most cases, slight pipe
The packing dimensions are stipulated in the generic standards bends in the socket are tolerable without affecting the tightness.
for pipe joining parts. In certain circumstances, dimensional
deviations of the inside or outside diameter of the packing in Longitudinal movements may be accommodated according to the
relation to the welding neck or collar lead to increased permissible distance between the inserted pipe end and the
mechanical loads on the flange joint, to accelerated wear on the packing. Attention must be paid to the corresponding information
inside of the packing and to deposits inside the pipe. provided by the manufacturers. During assembly, it must be
ensured that the resulting changes in length remain within the
Packing Material permissible sliding displacement.
The packing material to be chosen is determined by the
transported substance. Details about the suitability of the packing 5.3.8 Threaded Connections
material (i.e. its chemical resistance) are shown in the documents For measuring and testing purposes on a pipeline, threaded
provided by the packing manufacturers. connections are required for the corresponding devices. Here, it
The use of packing materials with a higher hardness (such as is necessary to use connection pieces with an internal thread
used in steel pipelines) may not be suitable for thermoplastic which are either joined with the pipe by means of heated tool butt
pipelines because the greater packing forces lead to deformation welding processes or, integrated in a fitting, are flanged into the
of the flange or collar. More suitable elastomer materials are pipeline.
EPDM, CSM or FPM with a Shore A hardness up to 70°.
In all cases, it must be ensured that the metallic threaded part is
joined with the thermoplastic part firmly and tightly. The joint must
5.3.4 Unions
not develop any leaks even when the measuring device has been
When unions are used in thermoplastic pipelines, it must be screwed in and out several times. The packing must be effected
ensured that the permissible pressures and temperatures are by means of a suitable gasket ring. With regard to exchangeabili-
specified by the manufacturer. The proof of the tightness of the ty, it is recommended to use fitting measuring connection pieces
union must be provided for the permissible operating over- that can be clamped between flanges.
593
There are currently no standards for threaded connections in expansion to be accommodated. Attention must be paid to the
thermoplastic pipelines. Therefore, it is left to the user to draw up following functional characteristics:
clear specifications with regard to the execution and quality – Axial expansion joints and expansion sockets serve to
requirements. accommodate changes in length in the pipe axis direction.
They do not transfer any longitudinal or transverse forces. In
5.4 Mountings order to be able to work without problems, they require exact
Mountings are components for the operation of pipeline guidance of the pipe axis. The distance to the next guide
installations. There are no restrictions with regard to the use of bearing may be up to three times the pipe diameter in both
commercially-available mountings in thermoplastic pipelines. For directions.
weight-related reasons and in order to provide equivalent If expansion sockets are used in pipelines that transport sub-
corrosion protection for the pipe, it is appropriate to use plastic stances that can cause swelling or that contain particulates,
mountings. attention must be paid to the impairment of the sliding function.
An extensive range of mountings with a housing and internal – Lateral expansion joints are suitable for accommodating
fittings made of different plastics is available. The operational changes in length transverse to the pipe axis. In combination
safety must be guaranteed by the internal pressure and tempera- with tie rod length limiters, they are a non-positive element in
ture limits specified by the manufacturer. the axial direction.
Mountings should be installed in the pipeline in such a way that – Angular expansion joints are equipped with hinges and, with
ease of operation and problem-free removal are ensured. a corresponding arrangement in the pipe system, permit greater
Additional support must be provided at those positions where the changes in length via angular adjustment.
weight of the mounting may lead to a detrimental load on the In general, it is true:
pipeline. Actuating forces during the opening or closing of the Only one expansion joint element may be arranged between two
mounting must not be transferred to the pipeline. fixed points.
5.4.1 Selection of Mountings In the case of a design that is not non-positive, the reaction force
results from the deformation of the expansion joint and from the
The following criteria are important with regard to the selection of longitudinal force caused by the internal pressure. The loads
mountings: resulting from this must be taken into consideration when the
– Permissible Operating Pressure and Temperature fixed points are dimensioned.
Attention must be paid to the temperature-dependent area of
application of plastic mountings. Details of this are shown in 5.7 Pipe Brackets
the documents provided by the manufacturers. Brackets have the tasks of safely accommodating all the loads on
– Type of Transported Substance a pipeline and transmitting them to a construction or substruc-
e.g. viscosity, solids content and chemical loads. ture. The restricted and temperature-dependent strength and
shape stability of thermoplastic pipelines lead to requirements
– Throughput that differ from those on metallic pipelines.
e.g. flow resistance and pressure loss.
The first step in the procedure for the laying of a pipeline consists
– Design of installing the bracket system that is intended to accommodate
e.g. overall length and opening and closing times. the pipeline trains. This approach avoids the use of unnecessary
– Actuation Type auxiliary structures and unsuitable provisional measures. Fur-
e.g. manual, electric or pneumatic. thermore, this constitutes a safe laying method which, to a great
extent, eliminates any impermissible loads on the pipeline during
Note: For common mountings, an assessment has been made the assembly.
in Table 11 on the basis of different selection criteria.
The opposite approach (i.e. the adaptation of brackets to pipe-
5.4.2 Use of Butterfly Valves lines that have already been laid and temporarily fastened) is on-
ly permissible in exceptional cases, especially because the sub-
It is difficult to adapt the nominal size of the mounting to the sequent installation of the planned brackets may result in con-
inside diameter of the thermoplastic pipeline in question, straints that may restrict the operational safety of the pipeline. If
particularly when butterfly valves with a short overall length are the provisional measures are not subjected to any strength
used. When such valves are installed, it must be ensured that the examination, larger pipelines will entail a higher risk of failure,
valve disc can be opened completely and does not impinge on together with all its consequences. Therefore, such a procedure
the inside of the pipe. is not allowed.
If the valve disc does impinge on the inside of the pipe, it is In principle, a pipe bracket must be classified according to the
recommended to install adapters on both sides of the butterfly function which it has to perform in the pipe system. Examples of
valve. It must be possible to adjust these adapters not only to the the different functions are shown in Figures 11 to 17.
pipe inside diameter but also to the nominal size of the valve.
Funnel-shaped chamfering of the welding necks is only 5.7.1 Slide Bearing (GL)
permissible when it does not have a detrimental effect on the
The slide bearing, Figure 11, in a horizontally laid pipeline can
flange joint. Particular proof of the operational safety of such
only accommodate vertical forces (loads). It is intended, mainly,
flange joints may be demanded by the customer.
to counteract the operational changes in the length of the pipeline
with the lowest possible resistance. The pipeline must be free to
5.5 Safety-Related Devices
move not only in the longitudinal direction but also transverse to
The design of any devices that ensure that the permissible the pipe axis.
operating overpressure or the permissible operating temperature
is not exceeded must be authorised. Attention must be paid to 5.7.2 Guide Bearing (FL)
the relevant mounting and installation guidelines.
The guide bearing must prevent any lateral deviation of the
pipeline. It is thus capable of accommodating transverse forces
5.6 Expansion Joints and Sliding Sockets
and is required, for example, in axially-clamped pipe sections in
If length differences cannot be fully compensated for using order to prevent buckling. Depending on its function, the guide
expansion bends, it is also possible to use expansion joints or bearing may be fixed or mobile in the pipe axis direction. Sliding
sliding sockets. The design and structure of the expansion joints the pipe in the clip, as a substitute for a guide bearing with a
or sliding sockets must be related to the size and direction of the sliding shoe, is unsafe and is therefore not permitted.
594
Types of Guide Bearing: 5.7.5 Hanging Bearing (HL)

Type A: Guide bearing with a sliding shoe, Figure 12, which The hanging, or self-aligning bearing, Figure 16, can, like the
permits movement in the axial direction. It is installed, slide bearing, only accommodate vertical loads and is mostly
for example, close to expansion joints or at the ends of used to fasten the pipeline to building ceilings. There are design
expansion bends. variations in the form of single and double hanging bearings. The
Type B: Guide bearing fastened on a substructure. It is in- pipeline secured in this way is sensitive to vibrations and, in most
stalled, for example, in pipe trains that have a fixed cases, requires intermediate bearings with a stabilising effect
point at each end. Axial movement is not necessary. (e.g. guide bearings).
Type C: Guide bearing in a vertical pipe train, Figure 13. This

5.7.6 Mounting Bracket (AH)
should be designed in such a way that movement is
possible in the axial direction while at the same time The mounting bracket, Figure 17, serves to accommodate loads
guaranteeing radial guidance. resulting from the mounting and filling weight of the pipeline. It
should be designed in such a way that even the loads caused by
5.7.3 Fixed Point (FP) the actuation of the mounting are not transmitted to the pipeline.
Fixed points are intended to prevent individual pipe sections from The fastening structure must be chosen in such a way that the
moving in any direction, Figure 14. Furthermore, they serve to mounting can be replaced without dismantling the surrounding
accommodate reaction forces when expansion joints, sliding equipment. If the mounting bracket corresponds to a fixed point,
sockets or push-fit fittings are used. Fixed points must be the effect of the restricted change in length must be taken into
installed in such a way that the size and direction of the changes consideration separately.
in the length of the pipe system can be accommodated by the
expansion joint elements.
5.7.7 General Design Guidelines for Pipe Brackets
Fixed points must be dimensioned for all the loads resulting from
the testing and operating conditions of the pipeline. Especially in With regard to the design of pipe brackets, attention must be paid
the case of axially-clamped pipe sections, the fixed point forces to the following:
may be significant and must be transferred safely from the pipe to
the surrounding structure. In vertical pipelines, a fixed point is – At the supporting point, pipelines should be equipped with a
subjected to additional stresses caused by dead weights and fastening design adapted to the plastic. In order to avoid any
dynamic loads (deflection forces). point or line loads, the pipe supports must match the outside
diameter. Sharp edges in the area of the pipe supports are not
The pipeline is fixed in the fixed point clip using suitable fittings, permitted.
which are incorporated into the pipeline by means of welding or
adhesive bonding. The dimensions of the fixed point ring should – The enclosing angle of the support must be at least 90°. The
be chosen such that commercially-available pipe clips can be recommended minimum widths are summarised in Table 5. If
used. With regard to the selection of the pipe clips, attention must provision is made for saddle supports, appropriate measures
be paid to a stable, torsionally-rigid design. must be taken to prevent the pipe from lifting off the supports.
The clamping of the pipe in a pipe clip, as a substitute for axial – Pipe brackets should enclose the pipe as tightly as possible
limitation using fixed point rings, is not permissible. With this without clamping it. For this purpose, the inside diameter of the
method, the function of the fixed point is inadequate. Moreover, pipe clips must match to the diameter of the pipe or fitting.
this frequently leads to the deformation of the pipe cross-section Most of the commercially-available pipe clips for metallic
or to damage of the pipe surface. pipelines have different dimensions and are therefore
Fixed point rings may only be joined to the pipe by means of a unsuitable. Since they are used for fixed point structures, they
fillet weld, using the hot gas extrusion welding process (WE), in must be finished (e.g. welding-in of a spacer ring).
exceptional cases (e.g. low axial loads). It is not permissible to – In order to compensate for the distance between the pipe
manufacture the fillet welds by means of hot gas welding with a outside diameter and the clip inside diameter, plastic or rubber
high-speed nozzle (WZ) or hot gas fan welding (WF). inserts may be provided, although it is not necessity to equip
– The ring to be fastened on the pipe by means of WE welding all the pipe clips with inserts in order to protect the surface of
must be closed. The use of split rings with a longitudinally the plastic pipe.
welded joint on the pipe is not permissible because of the
resulting stress concentration in the weld. The fixed point ring – Since the pipe is, in exceptional cases, allowed to slide in the
must be shaped in such a way that the loads are transmitted pipe clip, this must be taken into consideration by choosing a
exclusively via the circumferential weld. corresponding clip inside diameter. If the pipe slides in the clip,
the location of pipe clips close to pipe welds must be excluded
– It is not permissible to weld axial stiffening ribs on the pipe in because they might come into contact.
order to support the fixed point ring. The introduction of local
loads may lead to the failure of the pipeline at these points in – The sliding surfaces on pipe brackets must be permanently
extreme testing or operating conditions. corrosion-resistant and must exhibit a sufficient sliding dis-
placement. In certain circumstances, provision must be made
5.7.4 Vertical Support (VL) for end limitation.
If the weight of a vertical pipeline is to be borne, a supporting ring – The expansion of the pipe train in the case of axially mobile
similar to the fixed point ring must be provided in the pipe train in pipelines must not be impeded by the fastening. If a change in
order to accommodate the load via the pipe clip, Figure 15. This length results in the risk of the pipeline lifting off the bracket at
type of pipe bracket is also called a vertical stop. In certain the supporting point or if hanging bearings have to be arranged
circumstances, the vertical support must be shaped in such a in inclined pipe sections, it may be necessary to install
way that the pipe train can slide horizontally. additional spring elements.
Table 5. Minimum Widths of Pipe Supports.
Pipe diameter da 12 ... 20 25 ... 32 40 ... 63 75 ... 125 140 ... 180 200 ... 280 315 ... 400
Minimum width of the 12 15 20 25 30 35 45
supporting surface
595
– The supporting distances should be as according to Tables 13 satisfy the diverse requirements for the manufacture and assem-
to 17. If the specified distances are exceeded, this will lead to bly of thermoplastic pipelines.
an increase in the pipe deflection and bending stress.
In all cases where there has been no planning in relation to the
Furthermore, the cross-section of larger and thin-walled pipes
manufacture of the pipeline, the laying personnel must perform
may be ovalised at the supporting point.
the following tasks using standards, directives and assembly
– In the case of pipelines that are laid without any length regulations:
compensation, attention must be paid to the permissible
supporting distances LA according to Tables 13 to 17 and to – Determine the pipe fastening distances.
the necessary pipe guiding distances LF according to Table – Determine the dimensions of expansion bends.
20. During installation, consideration must be given to the – Establish forces at the pipe brackets.
smaller distance in each case. – Stipulate the bracket function in the pipe system.
– If the fastening distances for the pipe brackets are greater than By means of work instructions and suitable aids such as tables,
allowed as a result of construction-related conditions, continu- diagrams and forms, the pipe construction company must ensure
ous supporting profiles should be used. Particularly in the case that the work mentioned above can be carried out properly by the
of small pipelines, the supporting profile serves to guide the laying personnel.
pipe axis and prevents any unacceptable deflections due to
individual fastenings. 6.1.3 Requirements on Machines and Devices
– Pipelines with a vertical route and unimpeded longitudinal The machines and devices for plastics fabrication as well as for
mobility can be laid with a supporting distance that may be as carrying out the laying and joining work must be functioning
much as 30 % greater than the permissible values in Tables 13 correctly. Information about the requirements on machines and
to 17. devices for the welding of thermoplastic pipelines is included in
the DVS 2208-1 directive and in the directives for the welding or
5.8 Marking of the Pipelines adhesive bonding process in question.
The pipelines are marked according to the information provided The machine and device setting for the fabrication must be
by the customer or the installation operator. The marking must checked and calibrated at regular intervals. The calibration data
permit the clear identification of the pipeline according to the must be documented in a clear form and must be made
transported substance (in this respect, see DIN 2043). With accessible and comprehensible to the machine and device user
regard to the marking, attention must be paid to the information within the framework of work instructions or training courses.
provided in Section 3.3.7.
6.1.4 Supervision of the Fabrication and of the Laying Work
6 Fabrication and Assembly The pipeline manufacturer must ensure that the plastic-specific
and pipeline-related work is supervised at all times. The
6.1 Requirements on the Fabrication and Assembly of personnel must report to an expert supervisor who is responsible
Pipelines not only for matters relating to fabrication, joining technology,
assembly and quality assurance but also for the use of suitable
6.1.1 Requirements on the Manufacturer machines and devices. One possibility for this is offered by the
welding specialist with training according to the DVS 2213
Pipeline installations must be manufactured by qualified special- directive.
ist companies. Those companies that have specialised technical
facilities and have the necessary experience in the field of 6.2 Prefabrication of Pipeline Parts
plastics fabrication specific to pipelines are considered to be
specialist companies. The fabrication, welding and adhesive bonding of pipeline parts
in connection with prefabrication should be carried out in
Prerequisites are the employment of trained specialists as well as fabrication shops equipped especially for this purpose. The
knowledge of the materials specified in the scope according to requirements specified in Section 6.1 are also applicable to
Section 1.2. It is necessary to provide proof of qualification as a fabrication shops that are located outside the actual fabrication
specialist company, including the documents stipulated below. plant (e.g. on the site).
The following may constitute proof of qualification:
With regard to prefabrication, it must be ensured, by means of
– Certification document according to DIN EN ISO 9000. corresponding fabrication documents, that all materials, pipeline
– Authorisation document according to WHG, Section 19 I. parts and welding and adhesive bonding processes used are
– Supervisory contract with a recognised body (e.g. plastics suitable for the application. The requirements on the joint
institute or expert in plastics technology). between the pipeline parts must be specified in the fabrication
– Company organisation chart with an integrated synopsis of documents according to DVS 2202-1.
personnel. Reports must be prepared regarding the fabrication of the
– List of machines and devices (inventory list). pipeline parts as well as the welding and adhesive bonding work,
– Reference list of previous plastic pipeline installations manu- including the tests performed during or after prefabrication.
factured.
6.3 Transport and Storage of Pipeline Parts
The customer and the contractor must reach agreement on other
proof of qualification. Pipeline parts made of thermoplastics must be transported using
suitable vehicles. The surfaces must be protected to prevent
6.1.2 Personnel-Related Requirements scratches or notches. For this reason, pipeline parts must not be
dragged along the ground or over obstacles.
The fabrication and assembly personnel of the pipeline manufac-
turer must be capable of taking independent decisions in connec- Loading and unloading must be carried out with appropriate care.
tion with the activities to be carried out. One prerequisite for this If the loading operations are carried out using lifting equipment,
is plastics-specific training with basic knowledge of pipeline special attachment devices must be used. It is prohibited to throw
technology or many years of performing an equivalent activity the pipeline parts down from the loading level.
with intensive training in the plastic pipeline construction sector.
When pipes are transported, they must, if necessary, be
The training and examination to become a plastics welder or a separated using intermediate layers and must be secured
plastics adhesive bonder are a prerequisite for the reliable joining against shifting or sagging. They should be supported over their
of pipeline parts. However, training alone is not sufficient to entire length.
596
Abrupt loads must be avoided at all costs. This is applicable, in must be subjected to destructive testing. The scope of this
particular, where ambient temperatures are less than 0 °C since agreement should also include the prefabrication.
this leads to a substantial reduction in the impact resistance of If removal of the weld beads inside the pipeline is specified for
some plastics (e.g. UPVC). any reason (special case), this must be carried out using suitable
The pipeline parts should be stored in such a way that they are equipment and according to expert instructions (supervision).
not soiled unnecessarily. It is recommended that the pipe ends During the finishing of the joints, it is imperative that this opera-
are closed off using protective caps in order to prevent dirt tion does not generate any scratches or notches into the pipe. It
particles from entering the pipes. is only permissible to cut or peel off the weld bead if it is guaran-
It is imperative that the storage area for the pipes is stone-free teed that this does not affect the joint.
and flat. The support and the stacking height must be chosen in An adequate number of test pieces to provide evidence of the
such a way that no damage or permanent deformation can occur. reliability of the fabrication work must be manufactured before the
Pipes with larger diameters and a smaller wall thicknesses must pipe laying begins. If necessary, the quality of the joints can be
be provided with stiffening rings. Punctiform or linear supporting assured by means of appropriate testing procedures (e.g. tensile
of the pipes must not be used. creep test according to the DVS 2203-4 directive).
Recommendations about limiting the stacking height of pipes that All the joints in a pipeline must be marked for the duration of the
are not stored on pallets are summarised in Table 6. If pipes are assembly work. This must indicate not only consecutive
stacked on pallets and are secured against any lateral move- numbering but also the name of the person who has
ment, the stacking heights specified in Table 6 can be increased manufactured the joint. The marking must be entered in the
by 50 %. When thermoplastic pipes are stacked, attention must welding or adhesive bonding report. The reports must be
be paid not only to the possible cross-sectional deformation of presented to the construction supervisor at regular intervals so
the lower pipes due to the weight of the pipes above but also to that he/she can inspect and sign them.
the relevant accident prevention regulations (UVV). Upon completion of the laying work, an isometric drawing on
which the joints must be indicated with the corresponding
Table 6. Recommended Stacking Heights for Plastic Pipes. marking must be drafted for the entire pipe system.
Material HDPE PP PVDF PVC 6.4.2 Manufacture of Flange Joints
Permissible stacking 1.00 1.50 1.50 1.50 If pipeline parts made of the materials specified in the scope
height (m) according to Section 1.2 are joined to each other using flanges,
attention must be paid to the following rules:
The space for the storage of the pipeline parts should offer the – When packing is inserted between the flange joint, it must be
greatest possible protection. The storage location must be checked whether the packing dimensions coincide with the
selected carefully and must be set up expertly. It is imperative to outside and inside diameters of the welding neck and collar
prevent the effects of oils, solvents and other chemical respectively. If the inside diameter of the packing exhibits
substances during the storage duration. deviations >  10 mm, there is insufficient match. If the packing
The influence of the weather on the stored pipeline parts must be is nevertheless installed, this may lead to problems at the
reduced to a minimum. The measures to be taken to this end flange joint.
include preventing the exposure of pipes and fittings to direct – Before the bolt pretension is applied, the jointing faces must be
sunlight. aligned parallel with each other and must be in contact with the
packing. It is imperative to avoid additional tightening of the
Furthermore, it must be borne in mind that one-sided heat flange joint together and the associated tensile stresses.
absorption due to exposure to sunlight may lead to axial
deformation of the thermoplastic pipes. – The joint bolts must be tightened uniformly with the aid of a
torque spanner. Guideline values for bolt tightening torques
If the pipeline parts are stored outdoors for a long period in an are given in Table 12.
unprotected condition, attention must be paid to their behaviour
when they are subjected to UV radiation (Section 3.3.5). – The length of the bolts must be chosen such that the bolt
thread protrudes from the nut by no more than two to three
If it is intended to store pipeline parts made of unstabilised threads. Washers must be placed underneath both the bolt
plastics (e.g. PP) outdoors for more than 12 months, it is head and nut.
necessary to make provision for suitable covering measures
– In order to aid the smooth tightening of joint bolts and loosen-
(canvas, UV-stabilised PE film or similar materials) with good
ing after a being in service for a long time, the thread must be
ventilation.
coated, for example, with molybdenum sulphide.
In order to ensure an inventory turnover appropriate for the 6.4.3 Joining of Pipeline Parts Using a Union
plastic, pipeline parts must be used in the same order they are
manufactured or delivered. If pipeline parts made of the materials specified in the scope
according to Section 1.2 are joined with each other using a union,
6.4 Welding, Adhesive Bonding and Laying attention must be paid to the following rules:
– In order to avoid any impermissible loads during the assembly,
6.4.1 Joining of Pipeline Parts by Means of Welding and unions with a round packing ring should be used if at all
Adhesive Bonding possible.
Welding and adhesive bonding work should be carried out – The cap nut should be tightened manually or using special
according to the standards and directives specified in Section 10 pipe belt tongs. It is not permissible to use the pipe tongs used
as well as according to the regulations stipulated by the in the construction of steel pipelines.
manufacturers of the pipe parts. Before the welding and adhesive – The use of unions must be avoided at those positions in the
bonding work is started on site, the specialist personnel in pipeline that are subjected to bending stresses.
question must, taking account of the workplace conditions,
manufacture a specimen joint in the presence of the construction 6.4.4 Installation of Mountings and Devices
supervisor. In this respect, it is necessary for the specialist
Mountings and devices must be installed between the flanges in
personnel to draw up a report indicating all the data of the
such a way that negligible tensile stresses can arise in the flange
machine and device settings as well as the joining parameters.
joint when the joint bolts are tightened. It is recommended to
Within the framework of assembly-related quality assurance, the maintain the axial movement of at least one pipeline train until the
customer and the contractor may agree that the specimen joints mounting or device has been installed.
597
When the flange joint is manufactured on plastic mountings and parts. Any foreign substances must be removed and the areas to
devices, attention must be paid not only to the permissible bolt be welded/adhesive-bonded must be cleaned if necessary.
tightening torque according to Table 12 but also to that of the
Completed pipelines or pipeline sections must be inspected
mounting or device flange. The manufacturer is responsible for
visually by an independent expert supervisor. The inspection
the data relating to the maximum applied loads for mounting and
should include the following elements:
device flanges.
– The shape of the weld beads in the case of the HS process.
– The external beads and the socket transition in the case of the
7 Tests and Approvals HD process.
– The alignment of the sockets and fittings on the pipe with
The type and scope of the tests and approvals must be agreed additional checking of the fusion indicators in the case of the
between the customer and the contractor beforehand and must HM process.
be stipulated in a testing plan. Particular regulations such as the – The level of cleanliness of the adhesive-bonded joints.
Construction and Testing Principles of DIBt, DruckbehV or the – The shape of the groove on adhesive-bonded sockets.
Technical Rules for Thermoplastic Pipelines must be taken into – The condition of the pipe and fitting surfaces.
consideration.
– The suitability of the fastening elements.
Before the work is started, the customer and the contractor must – The compliance with the permissible fastening distances.
ensure that the respective tests can be performed and are – The sensitivity to vibrations.
suitable. The results of the test in question must be recorded in a – The connections to vessels and pumps.
report. – The dimensions of expansion bends.
An approval must be carried out by the operator upon completion Assessment criteria for the welded joints are given in the DVS
of the pipeline or, at least, prior to the initial commissioning. If 2202-1 directive.
necessary, functional tests must also be conducted within the
framework of the approval. 7.3 Non-Destructive Tests
For the approval, both the operating manual and the documenta- Details about the testing procedures are shown in the DVS 2206
tion must be handed over to the operator. During the approval, an leaflet. The execution of non-destructive tests on thermoplastic
actual/nominal comparison must be made with the design pipelines requires devices that are physically/technically adapted
documents. All deviations from the mathematical and design- to the materials specified in the scope according to Section 1.2.
related specifications as well as the results of the approval must Moreover, the person performing the test must have experience
be noted in a report. The drawing documents must be submitted in the handling of the devices and in the evaluation of the tests.
as a revised copy.
7.4 Destructive Tests
7.1 Testing of the Devices and Machines
Destructive tests must be carried out, to prove the strength
The machines and devices for the fabrication of the pipeline parts characteristics of the welded and adhesive-bonded joints. Details
as well as for the execution of the laying and joining work must of the requirements and the testing procedures to be applied are
satisfy the requirements of the fabrication method in question. given in the DVS 2203 ff. directives. Information about the testing
Information about this can be obtained, for example, from the of semi-finished products is provided in the DVS 2201 ff.
DVS 2208-1 directive. The assembly company or the pipeline directives.
manufacturer is responsible for the functional capability.
By means of records, the pipeline manufacturer must prove that 7.5 Internal Pressure Test
a machine or device test has been carried out at least once a The internal pressure test must be performed on the completed
year. If this is not the case, a test must take place in the presence pipe system. The stresses caused by the internal pressure must
of the customer or the construction supervisor before the work is be above the operating loads and should constitute experimental
started. The results of the test must be recorded in a report. proof of the operational safety. Only in exceptional cases may the
pipeline be tested at an internal pressure below the nominal
7.2 Visual Inspections pressure of the pipeline parts.
All the pipeline parts to be installed must be subjected to a visual The recommendations for carrying out of the internal pressure
inspection before they are laid or installed. As a minimum, it is test on thermoplastic pipelines are summarised in Table 7.
sufficient to check the integrity and external condition of the Supplementary details are included in DIN 4279 ff.
Table 7. Conditions for the Execution of the Internal Pressure Test for Thermoplastic Pipelines.
Subject Preliminary Test Main Test Short-term Test

Test pressure 1.5 ∙ PN 1.3 ∙ PN 1.5 ∙ PN
max. (PN + 5) bar max. (PN + 3) bar max. (PN + 5) bar
pipelines min. 3 h min. 3 h min. 1 h
without branches
total L  100 m
Test duration
pipelines min. 6 h min. 6 h min. 3 h
with branches
total L > 100 m
Checking during the test every 1 h every 1.5 h every 1 h
with restoration without restoration without restoration
of the test pressure of the test pressure of the test pressure
Material-specific pressure drop up to 0.8 bar/h up to 0.3 bar/h up to 0.8 bar/h
(reference values)
Remarks about the test in question special case (customer's
normal case
consent necessary)
598
The result of the internal pressure test must be recorded in a tion, arrangements must be made for an intermediate test before
report, including information about the boundary conditions. The the parts are delivered to the site. The following may be elements
pressure and the temperature must be recorded throughout the of the intermediate test:
test.
– Checking the conformance with the fabrication drawing.
– Inspection of the fabrication (e.g. joints).
7.6 Periodic Tests – Checking the conformity of the materials.
As components of installations for the storage, filling and handling
of water-polluting liquids, pipelines must be subjected to periodic 8.3 Final Tests and Outgoing Inspections
tests if these have been stipulated by regulations in commercial As part of the final tests, it must be ensured that the quality tests
or water laws. The type, scope and frequency of periodic tests required according to the rules of technology (including incoming
are indicated in the notice of approval for an installation. and intermediate tests) have been carried out and that the results
meet the quality requirements.
8 Quality Assurance In principle, outgoing inspections should be made on all ma-
chines and devices that are required to lay the pipelines on site.
The pipeline manufacturer must guarantee appropriate quality The results of the outgoing inspections must be enclosed with the
assurance, which should primarily include the assembly work. machine and device delivery in question.
Within the framework of the quality assurance, he/she is
responsible for ensuring that the pipeline parts procured from the 8.4 Records
ancillary supplier satisfy the requirements stipulated in the order The pipeline manufacturer must prepare, keep and store records.
and in the generic standards. The quality records must prove that the pipeline parts or the
Explanations about Table 7: pipeline that has been installed ready for operation have passed
the quality tests with regard to the stipulated acceptance criteria.
Preliminary Test: The preliminary test serves to prepare the All quality records must permit a precise allocation.
pipeline system for the actual test (main test).
During the course of the preliminary test, a 8.5 Training
stress-strain equilibrium occurs in the pipe
The pipeline manufacturer must guarantee the training of all
system due to an increase in volume. This
employees entrusted with any activities relevant to quality.
results in a material-dependent pressure drop,
Appropriate procedures must be introduced and maintained in
which requires not only repeated repressuris-
order to determine the need for training. Suitable records about
ing to the test pressure but also frequently
the type and scope of training must be kept.
retightening of the bolts of the flange joints.
Main Test: During the main test, a considerably lower 8.6 Quality Assurance System
pressure drop may be expected at approxi-
mately constant pipe wall temperatures. With regard to the setting-up of a quality assurance system,
Therefore, it is not necessary to restore the attention is drawn to DIN EN ISO 9000 to 9004. A quality
test pressure. The checking may simply con- assurance system may be based, on the one hand, on the
centrate on the tightness of the flange joints technical requirements stipulated in standards and directives and
and on any possible changes in the position of on the terms of delivery and, on the other hand, on the
the pipeline. manufacturing supervision with reference to DIN 18200. Table 8
provides an overview of quality assurance measures in the
Short-term Test: The short-term test constitutes a special case construction of thermoplastic pipelines.
since, according to general experience, no
stress-strain equilibrium occurs in the time
available. In certain circumstances, any faults 9 Documentation
that may exist at the joints may not be
detected when short-term loads are applied. The pipeline manufacturer must provide a set of documentation
This does not achieve the purpose of a test. when the construction has been completed. In principle, the
documentation should have the following constituents:
The ancillary supplier must guarantee that every pipeline part can
be traced back to the manufacturing origin. For this purpose, it is – Isometric drawings of the actual condition of the pipeline with
advisable to mark the pipeline parts and document them. The information about the joints and the consecutive numbering
documents may relate, for example, to the material certificates, according to the welding / adhesive bonding report.
specifications and drawings. The documents must include all the – Data sheets for the pipeline with information about the
information that allows the pipeline part concerned to be operating pressure, the operating temperature and the laying
recognised unambiguously. parameters.
– Calculations and static analyses.
8.1 Incoming Tests
– Material certificates and certificates of origin for all delivered
The pipeline manufacturer must ensure that the pipeline parts parts.
purchased from the ancillary supplier are not used or processed
further before they have been subjected to an incoming test. In – Test and acceptance reports.
certain circumstances, this prerequisite may be fulfilled by a – Reports on the welding or adhesive bonding work.
visual inspection of the condition of the pipe or fitting or by
checking whether the delivery coincides with the order – Certificates regarding the qualification of the deployed
documents and the material certificates have been enclosed. specialists.
– Proof of being a specialist company.
8.2 Intermediate Tests
The scope of documentation for an object should be agreed upon
In so far as the pipeline manufacturer joins together or performs between the customer and the contractor on the basis of the
additional processing on any vendor parts during of prefabrica- above list.
599
Table 8. Overview of Quality Assurance Measures in the Construction of Thermoplastic Pipelines.
Type of Measure Standards, Directives Preferred Application Remarks about the Frequency
and Regulations
Material tests DIN 18200 manufacture of pipe parts permanent
with certificates according to
DIN EN 10204
Incoming tests DVS 2201-1 and -2 fabrication permanent
– semi-finished products DVS 2211 with obligation to keep records
– welding filler materials
Intermediate tests DIN 18200 fabrication object-related
– components DVS 2206 with obligation to keep records
– special fittings
Final tests DIN 18200 fabrication, assembly object-related
Outgoing inspections with obligation to keep records
– pipeline parts
– assembly devices
Checking of machines and devices DVS 2208-1 fabrication, assembly at least once per year
with documentation
Monitoring of the fabrication and DVS 2202-1 fabrication, assembly permanent
laying work DVS 2203 ff. with obligation to keep records
DVS 2206
Internal pressure test Table 7, DVS 2210-1 assembly object-related
DIN 4279 ff. with documentation
Training of the supervisory personnel DVS 2213 fabrication, assembly annual updating
by attending seminars etc.
Training of the welding and adhesive DVS 2212-1 and -2 fabrication, assembly annual requalification test
bonding personnel DVS 2221-1
Advanced training of the laying Courses, seminars assembly every six months
personnel
10 Standards, Directives and Regulations that are also DIN 4279-1 Internal Pressure Testing of Pressure Pipelines
Applicable* for Water; General Information
DIN V 4279-7 Internal Pressure Testing of Pressure Pipelines
* Some of the titles of the standards, directives and regulations are indi-
for Water; Pressure Pipes Made of HDPE,
cated in an abridged form.
PE 80, PE 100, XLPE and UPVC
DIN 4279-8 Internal Pressure Testing of Pressure Pipelines
10.1 DIN and EN Standards for Water; Pressure Pipes Made of HDPE
DIN EN 1778 Characteristic Parameters for Welded Thermo- DIN 4279-9 Internal Pressure Testing of Pressure Pipelines
plastic Structures for Water; Specimen Test Reports
DIN 1910-1 Welding; Terms and Classification of the Welding DIN 4279-10 Internal Pressure Testing of Pressure Pipelines
Processes for Water; Synopsis
DIN 2401-1 Components Subjected to Stresses Caused by DIN 8061 Pipes and Pipeline Parts Made of Unplasticised
Internal and External Pressure; Pressure and with Polyvinyl Chloride (UPVC); General Quality
Temperature Data; Terms and Nominal Pressure Supplement Requirements, Testing and Chemical Resistance
Stages
DIN 8062 Pipes Made of Unplasticised Polyvinyl Chloride
DIN 2402 Pipelines; Nominal Diameters, Terms and Step- (UPVC and PVC-HI); Dimensions
ping
DIN 8063 ff. Pipe Joints and Pipeline Parts for Pressure Pipe-
DIN 2403 Marking of Pipelines According to the Transport- lines Made of Unplasticised Polyvinyl Chloride
ed Substance (UPVC); Dimensions, Quality Requirements and
DIN 2501-1 Flanges; Connecting Dimensions Testing
DIN 3441 ff. Mountings Made of Unplasticised Polyvinyl Chlo- DIN 8074 Pipes Made of High-Density Polyethylene (HDPE);
ride (UPVC) Dimensions
DIN 3441-4 Mountings Made of UPVC DIN 8075 Pipes Made of High-Density Polyethylene (HDPE);
DIN 3442 ff. Mountings Made of Polypropylene (PP) with General Quality Requirements, Testing and
Supplement Chemical Resistance
DIN 3535-3 Packings for the Supply of Gas, Packings Made
of Elastomers for Gas Supply Pipes and Long- DIN 8076 ff. Pressure Pipelines Made of Thermoplastics;
Distance Gas Pipelines; Safety-Related Require- Clamped Connectors Made of Metal and Plastic
ments and Testing of Materials DIN 8077 Pipes Made of Polypropylene (PP); Dimensions
DIN 3543-3 Tapping Valves Made of UPVC DIN 8078 Pipes Made of Polypropylene (PP); Type 1 and
DIN 3543-4 Tapping Valves Made of High-Density Polyethyl- with Type 2; General Quality Requirements, Testing
ene (HDPE) Supplement and Chemical Resistance
DIN 3544-1 Mountings Made of High-Density Polyethylene DIN 8079 Pipes Made of Chlorinated Polyvinyl Chloride
(HDPE) (CPVC); Dimensions
DIN 4102 ff. Fire Behaviour of Construction Materials and DIN 8080 Pipes Made of Chlorinated Polyvinyl Chloride
Components (CPVC); General Quality Requirements and Testing
600
DIN EN ISO Fundamentals and Guide for Quality Manage- DVS 2207-15 Welding of Thermoplastics; Heated Tool Welding
9000 to 9004 ment and Quality Assurance Systems of Pipes, Pipeline Parts and Plates Made of
DIN EN 10204 Certificates for Material Tests PVDF
DIN 16450 Fittings for Pressure Pipelines Made of UPVC DVS 2208-1 Welding of Thermoplastics; Machines and
Devices for Heated Tool Welding
DIN 16887 Testing of Pipes Made of Thermoplastics;
Determination of the Creep Rupture Behaviour DVS 2208-2 Welding of Thermoplastics; Machines and
when Subjected to Internal Pressure Devices for Hot Gas Welding
DIN 16888 ff. Assessment of the Chemical Resistance of Pipes DVS 2209-1 Welding of Thermoplastics; Extrusion Welding;
Made of Thermoplastics Processes and Characteristics
DVS 2212-1 Examination of Plastics Welders; Examination
DIN 16928 Pipelines Made of Thermoplastics; Pipe Joints,
Group I
Pipeline Parts, Laying and General Guidelines
DVS 2212-2 Examination of Plastics Welders; Examination
(Major parts of the standard are being replaced Group II
by the DVS 2210-1 guideline.)
DVS 2213 Welding Specialist; Subject Area: Plastics
DIN 16960 Welding of Thermoplastics; Principles Welding; Examination
DIN 16962 ff. Pipe Joints and Pipeline Parts for Pressure DVS 2221-1 Examination of Plastics Adhesive Bonders;
Pipelines Made of Polypropylene (PP) Examination Group I; Pipe and Spigot-and-
DIN 16963 ff. Pipe Joints and Pipeline Parts for Pressure Socket Joints Made of UPVC, CPVC and ABS
Pipelines Made of High-Density Polyethylene Using Solvent Adhesives
(HDPE)
DIN 18200 Monitoring of Construction Materials, Compo- 10.2.2 Directives of Deutscher Verein des Gas- und
nents and Designs; General Principles Wasserfaches e.V.
DIN 32502 Defects on Welded Joints Made of Plastics; DVGW W 303 Pressure Drop Tables for Plastic Pipes
Classification, Designation and Explanation DVGW GW 330 Welding of Pipes and Pipeline Parts Made of
DIN 53457 Plastic Line Pipes for Drinking Water; Health- HDPE for Gas and Water Pipes
Related Assessment and Testing
10.2.3 Laying Instructions of Kunststoffrohrverband e.V.
10.2 Directives, Leaflets and Work Sheets
KRV A 112 Push-Fit Fittings for PVC Pressure Pipes
10.2.1 Directives and Leaflets of Deutscher Verband für KRV A 113 Solvent-Cement Sockets for PVC Pressure
Schweißen und verwandte Verfahren e.V. Pipes
DVS 2201-1 Testing of Semi-Finished Products Made of KRV A 115 b Laying Instructions for PVC Pressure Pipes;
Thermoplastics; Fundamentals and Instructions Installation Inside Buildings
DVS 2201-2 Testing of Semi-Finished Products Made of KRV A 117 Adhesive Bonding Instructions for PVC Pressure
Thermoplastics; Fabrication Weldability, Testing Pipes; Adhesive Bonding Using THF Adhesive
Procedures and Requirements GKR 9.4.1 Industrial Pipes; Pipes Made of PP with the Qual-
DVS 2203-1 Testing of Welded Joints between ity Mark of Gütegemeinschaft Kunststoffrohre
Thermoplastics; Testing Procedures and e.V.
Requirements NN KRV Pressure Loss Tables; Pressure Pipelines
Made of UPVC, HDPE and LDPE
DVS 2203-2 Testing of Welded Joints between Thermo-
plastics; Tensile Test
DVS 2203-3 Testing of Welded Joints between Thermo- 10.3 Regulations, Ordinances and Miscellaneous Directives
plastics; Impact Test DruckbehV Pressure Vessel Ordinance According to Section
DVS 2203-4 Testing of Welded Joints between Thermo- 24 of the Industrial Code
plastics; Tensile Creep Test DIBt Construction and Testing Principles for Pipeline
DVS 2203-5 Testing of Welded Joints between Thermo- Parts for Thermoplastic Pipelines Laid Above
plastics; Technological Bending Test Ground
DVS 2204-1 Adhesive Bonding of Thermoplastics; UPVC TRR 120 Technical Rules for Pipelines, Construction Reg-
ulations for Pipelines Made of Thermoplastics
DVS 2204-2 Adhesive Bonding of Thermoplastics; Polyolefins
KTW Plastics / Drinking Water Recommendations
DVS 2205-1 Characteristic Values of Thermoplastics
DVS 2207-1 Welding of Thermoplastics; Heated Tool Welding WHG Water Management Act
of Pipes, Pipeline Parts and Plates Made of
HDPE
DVS 2207-3 Hot Gas Welding of Thermoplastics; Plates and 11 Explanation of the Symbols and Abbreviations
Pipes
Symbol or Unit Designation
DVS 2207-3 Hot Gas Welding of Thermoplastics; Plates and
Abbreviation
Supplement Pipes; Welding Parameters
A mm² area, cross-section
DVS 2207-4 Welding of Thermoplastics; Extrusion Welding;
Plates and Pipes AH - mounting bracket
DVS 2207-4 Welding of Thermoplastics; Extrusion Welding; d mm pipe/fitting diameter
Supplement Plates and Pipes; Welding Parameters for HDPE Ec N/mm² creep modulus
and PP
F N force, load
DVS 2207-11 Welding of Thermoplastics; Heated Tool Welding
of Pipes, Pipeline Parts and Plates Made of PP FL - pipe guide bearing
FP - fixed point
f - factor, general
601
fB - bend factor Indices

fLA - factor for the deflection A distance
fQ mm/mm factor for the swelling a outside
GL - slide bearing B (in conjunction with L) bending length, length of the bending
H m delivery head leg
HL - hanging bearing B (in conjunction with T) operating temperature
HS - heated tool butt welding b bending
HD - heated tool socket welding FP assigned to a fixed point
HM - electrofusion welding FL assigned to a guide bearing
h hour time unit ges total value
J mm4 moment of inertia grenz limiting value
K - factor for the determination of the i inside
pressure surge k buckling
k - roughness coefficient l longitudinal, axial
L m/mm length, distance M assembly
L1/2 mm system length m average value
PN - nominal pressure max maximum value
p bar pressure min minimum value
q N/mm line load p pressure-dependent
R mm bend radius Q swelling-dependent
Re - Reynolds' number R pipe, pipeline
S - safety factor RA pipeline mounting
s mm wall thickness RF pipe fitting
T °C temperature RV pipe joint
t h, min time r radial
V m³/h flow volume u circumferential, tangential
W mm³ resistance moment v comparative value
WHG - Water Management Act x, y, z direction in the coordinate system
WE - hot gas extrusion welding zul permissible value
WZ - hot gas welding with a high-speed nozzle  expansion-dependent
v - weakening factor  temperature-dependent
w m/s flow rate
 1/K coefficient of linear thermal expansion
, dT K temperature difference
l mm change in length
p bar pressure loss
 - expansion
 - pipe friction coefficient
 - Poisson's ratio
 m²/s kinematic viscosity
 kg/m³ density
 N/mm² stress
 - coefficient of hydraulic resistance
602
12 Appendix
Hydraulically rough
0)
k=
(
oth
mo
lly s
lica
rau
Hyd
Reynolds' number Re
e
rv
cu
it
Li m
Turbulent
ReCritikal
Laminar
Pipe friction coefficient 
Figure 1. Pipe friction coefficients for hydraulic dimensioning (according to Moody).
603
Table 9. Coefficients of Hydraulic Resistance of Pipe Fittings.
Type of Fitting Parameter Resistance Coefficient  = Drawing

= Flow Direction
Bends  = 90° R = 1.0  da 0.51
R = 1.5  da 0.41
R = 2.0  da 0.34
R = 4.0  da 0.23
Bends  = 45° R = 1.0  da 0.34

R = 1.5  da 0.27
R = 2.0  da 0.20
R = 4.0  da 0.15
Angles (elbows)  = 45° 0.30

 = 30° 0.14
 = 20° 0.05
 = 15° 0.05
 = 10° 0.04
T pieces z d
(90° pipe branches)
Vz/Vs = 0.0 –1.20 0.06
flow merging
Vz/Vs = 0.2 –0.40 0.20
Vs = Va + Vz
Vz/Vs = 0.4 –0.10 0.30
Vz/Vs = 0.6 –0.50 0.40
Vz/Vs = 0.8 –0.70 0.50
Vz/Vs = 1.0 –0.90 0.60
T pieces Va/Vs = 0.0 0.97 –0.10

(90° pipe branches) Vz/Vs = 0.2 0.90 –0.10
flow separating Vz/Vs = 0.4 0.90 –0.05
Vs = V a + V d Vz/Vs = 0.6 0.97 –0.10
Vz/Vs = 0.8 1.10 –0.20
Vz/Vs = 1.0 1.30 –0.35
Reducers, concentric Angle  4 ... 8° 16° 24°

(pipe expansion)
d2/d1 = 1.2 0.10 0.15 0.20
-values for R = 0.025
d2/d1 = 1.4 0.20 0.30 0.50
d2/d1 = 1.6 0.50 0.80 1.50
d2/d1 = 1.8 1.20 1.80 3.00
d2/d1 = 2.0 1.90 3.10 5.30
Reducers, concentric Angle  4° 8° 20°
(pipe constriction)
d2/d1 = 1.2 0.046 0.023 0.010
-values for R = 0.025
d2/d1 = 1.4 0.067 0.033 0.013
d2/d1 = 1.6 0.076 0.038 0.015
d2/d1 = 1.8 0.031 0.041 0.016
d2/d1 = 2.0 0.034 0.042 0.017
Positive  values = pressure drop
Negative  values = pressure rise
Va = outgoing volume flow
Vd = remaining volume flow
Vs = total volume flow
Vz = additional volume flow
604
Table 10. Coefficients of Hydraulic Resistance of Mountings.

Nominal MV GSV SSV S KH K RV RK
Diameter
DN Resistance Coefficient ()
25 4.0 2.1 3.0 2.5 1.9
32 4.2 2.2 3.0 2.4 1.6
40 4.4 2.3 3.0 2.3 1.5
50 4.5 2.3 2.9 2.0 1.4
65 4.7 2.4 2.9 2.0 1.4
0.1 ... 0.3 0.1 ... 0.15 0.3 ... 0.6
80 4.8 2.5 2.8 2.0 1.3
100 4.8 2.4 2.7 1.6 1.2
125 4.5 2.3 2.3 1.6 1.0
150 4.1 2.1 2.0 2.0 0.9
200 3.6 2.0 1.4 2.5 0.8
Explanations: The specified resistance figures are reference values and are used for approximate calculations of the pressure loss.
Component-specific calculations must be based on the information provided by the manufacturer of the mounting
concerned.
Table 11. Criteria for the Selection of Mountings.

Selection Criteria MV/GSV/SSV S KH K RV RK
Assessment
Flow resistance high low low moderate high moderate
Opening and closing times medium long medium medium medium
Actuation moment low low high moderate
Wear moderate low low moderate moderate
Flow regulation suitable not very suitable
Overall length according to Series F medium high high high medium high
Overall length according to Series K low low low
Series F = flange design DIN 3202-1
Series K = intermediate flange design DIN 3202-3
No criteria
Explanation of the Symbols in Tables 10 and 11:

MV diaphragm valve
SSV angle seat valve
GSV straight seat valve
S gate valve without necking
KH ball valve
K butterfly valve
RV free-flow check valve
RK swing-type check valve
Table 12. Guideline Values for Bolt Tightening Torques on Flange Joints.
Nominal Bolt Tightening Torque [Nm] Remarks about Table 12:
Diameter Flat ring Profiled/O ring Scope: Packings made of elastomer materials with
DN zul p  10 bar zul p  16 bar a Shore A hardness of 80°.
15 Area of Application: Because of the, normally, high bolt tightening
20 15 torques used with gasket rings, it is
25 15 recommended that such rings are only
32 20 installed in combination with torsionally-rigid
backing flanges. In addition to corrosion-
40 30 protected backing flanges made of steel or
50 35 20 nodular-graphite cast iron, backing flanges
65 25 made of plastics reinforced with fibrous
80 40 25 glass or steel are suitable for this purpose.
Attention must be paid to the permissible
100 30
loads on the backing flanges.
125 50 35
The guideline values specified in the table
150 60 40
are based on information provided by the
200 70 50 manufacturer. A working group dealing with
250 80 55 the investigation of flange joints in plastic
300 100 60 pipelines has been formed during the
350 100 70 revision of this guideline. However, specific
data were not available by the time this
400 120 80 guideline was published.
p = internal overpressure
= zul p 6 bar
605
Table 13. Recommended Spans for Pipes Made of HDPE. Table 14. Recommended Spans for Pipes Made of PP.
Pipe Size Nominal Spans (LA) in mm Pipe Size Nominal Spans (LA) in mm
da Diameter at Pipe Wall Temperature (TR) da Diameter at Pipe Wall Temperature (TR)
mm DN 20°C 30°C 40°C 50°C 60°C mm DN 20°C 30°C 40°C 50°C 60°C 70°C 80°C
16 10 500 450 450 400 350 16 10 650 625 600 775 550 525 500
20 15 575 550 500 450 400 20 15 700 675 650 625 600 575 550
25 20 650 600 550 550 500 25 20 800 775 750 725 700 675 650
32 25 750 750 650 650 550 32 25 950 925 900 875 850 800 750
40 32 900 850 750 750 650 40 32 1100 1075 1050 1000 950 925 875
50 40 1050 1000 900 850 750 50 40 1250 1225 1200 1150 1100 1050 1000
63 50 1200 1150 1050 1000 900 63 50 1450 1425 1400 1350 1300 1250 1200
75 65 1350 1300 1200 1100 1000 75 65 1550 1500 1450 1400 1350 1300 1250
90 80 1500 1450 1350 1250 1150 90 80 1650 1600 1550 1500 1450 1400 1350
110 1650 1600 1500 1450 1300 110 1850 1800 1750 1700 1600 1500 1400
100 100
125 1750 1700 1600 1550 1400 125 2000 1950 1900 1800 1700 1600 1500
140 125 1900 1850 1750 1650 1500 140 125 2100 2050 2000 1900 1800 1700 1600
160 2050 1950 1850 1750 1600 160 2250 2200 2100 2000 1900 1800 1700
150 150
180 2150 2050 1950 1850 1750 180 2350 2300 2200 2100 2000 1900 1800
200 2300 2200 2100 2000 1900 200 2500 2400 2300 2200 2100 2000 1900
200 200
225 2450 2350 2250 2150 2050 225 2650 2550 2450 2350 2250 2150 2000
250 2600 2500 2400 2300 2100 250 2800 2700 2600 2500 2400 2300 2150
250 250
280 2750 2650 2550 2400 2200 280 2950 2850 2750 2650 2550 2450 2300
315 300 2900 2800 2700 2550 2350 315 300 3150 3050 2950 2850 2700 2600 2450
355 350 3100 3000 2900 2750 2550 355 350 3350 3250 3150 3000 2850 2750 2600
400 400 3300 3150 3050 2900 2700 400 400 3550 3450 3350 3200 3050 2900 2750
Note: The specified spans apply to pipes with a

bending creep modulus according to the HDPE
material type (DIN 8074/8075).
Attention must be paid to the conversion factors
according to Table 18.
Table 15. Recommended Spans for Pipes Made of UPVC. Table 16. Recommended Spans for Pipes Made of CPVC.
Pipe Size Nominal Spans (LA) in mm Pipe Size Nominal Spans (LA) in mm
da Diameter at Pipe Wall Temperature (TR) da Diameter at Pipe Wall Temperature (TR)
mm DN 20°C 30°C 40°C 50°C 60°C mm DN 20°C 30°C 40°C 50°C 60°C 70°C 80°C 90°C
16 10 950 900 850 750 600 16 10 1000 950 900 850 750 675 600 500
20 15 1100 1050 1000 900 700 20 15 1150 1100 1025 950 875 775 700 600
25 20 1200 1150 1050 950 750 25 20 1200 1150 1100 1000 900 800 700 600
32 25 1350 1300 1250 1100 900 32 25 1350 1250 1200 1100 1000 900 800 700
40 32 1450 1400 1350 1250 1000 40 32 1500 1400 1300 1250 1150 1050 900 800
50 40 1600 1550 1500 1400 1150 50 40 1650 1600 1500 1400 1300 1200 1100 900
63 50 1800 1750 1700 1550 1300 63 50 1850 1750 1650 1600 1500 1350 1250 1050
75 65 2000 1900 1850 1700 1450 75 65 2050 1950 1850 1750 1650 1500 1350 1200
90 80 2200 2100 2000 1850 1550 90 80 2250 2100 2000 1900 1800 1650 1500 1300
110 2400 2300 2250 2050 1750 110 2500 2350 2200 2100 1950 1800 1650 1450
100 100
125 2550 2450 2400 2200 1850 125 2650 2500 2350 2250 2100 1950 1750 1550
140 125 2700 2600 2500 2300 1950 140 125 2800 2650 2500 2350 2200 2050 1850 1650
160 2900 2800 2700 2500 2100 160 3000 2850 2700 2550 2400 2200 2000 1750
150 150
180 3100 2950 2850 2650 2200 180 3150 3000 2850 2700 2500 2300 2100 1850
200 3250 3150 3000 2800 2350 200 3350 3150 3000 2850 2650 2450 2200 1950
200 200
225 3450 3300 3200 2950 2500 225 3550 3350 3200 3000 2800 2600 2350 2100
250 3650 3500 3350 3100 2600 250 3750 3550 3350 3150 3000 2750 2500 2200
250 250
280 3750 3700 3550 3300 2750 280 3950 3750 3550 3350 3150 2900 2650 2350
315 300 4100 3900 3750 3500 2950 315 300 4200 4000 3750 3550 3350 3050 2800 2450
355 350 4300 4200 4000 3700 3100 355 350 4450 4250 4000 3800 3550 3250 2950 2650
400 400 4600 4450 4250 3950 3300 400 400 4750 4500 4250 4000 3750 3450 3150 2800
Marked range: PN 16 pipes Marked range: PN 16 pipes

Other ranges: PN 10 Other ranges: PN 10
Note: Attention must be paid to the conversion factors

606
Table 17. Recommended Spans for Pipes Made of PVDF.

Pipe Size Nominal Spans (LA) in mm
da Diameter at Pipe Wall Temperature (TR)
mm DN 20°C 30°C 40°C 50°C 60°C 70°C 80°C 100°C 120°C
16 10 725 700 650 600 575 550 500 450 400
20 15 850 800 750 750 700 650 600 500 450
25 20 950 900 850 800 750 700 675 600 500
32 25 1100 1050 1000 950 900 850 800 700 600
40 32 1200 1150 1100 1050 1000 950 900 750 650
50 40 1400 1350 1300 1200 1150 1100 1000 900 750
63 50 1400 1350 1300 1250 1200 1150 1100 950 800
75 65 1500 1450 1400 1350 1300 1250 1200 1050 850
90 80 1600 1550 1500 1450 1400 1350 1300 1100 950
110 1800 1750 1700 1650 1550 1500 1450 1250 1100
100
125 1900 1850 1800 1700 1650 1600 1500 1350 1200
140 125 2000 1950 1900 1800 1750 1700 1600 1450 1250
160 2150 2100 2050 1950 1850 1800 1700 1550 1350
150
180 2300 2200 2150 2050 1950 1900 1800 1600 1400
200 2400 2350 2250 2150 2100 2000 1900 1700 1500
200
225 2550 2500 2400 2300 2200 2100 2000 1800 1600
250 2650 2600 2500 2400 2300 2200 2100 1900 1700
250
280 2850 2750 2650 2550 2450 2350 2250 2000 1800
315 300 3000 2950 2850 2750 2600 2500 2400 2150 1900
355 350 3200 3100 3000 2850 2750 2650 2500 2250 2000
400 400 3400 3300 3200 3050 2950 2800 2650 2400 2100
Marked range: PN 16 pipes

Other ranges: PN 10
Note: Attention must be paid to the conversion factors according to Table 18.
Table 18. Conversion Factors f1 and f2 for Tables 13 to 17.

Material Nominal Transported Substance Wall
Pressure Gases Water Others Thickness
PN
 (g/cm3)*
<0.01 1.00 1.25 1.50
Factor f1 f2
6 1.47 0.91
HDPE 10 1.30 1.00
16 1.21 1.07
6 1.47 0.91
PP 10 1.30 1.00
16 1.21 1.07
10 1.42 1.00
UPVC 16 1.30 1.0 0.96 0.92 1.08
20 1.20 1.15
10 1.40 1.00
CPVC 16 1.27 1.08
20 1.23 1.12
10 1.48 1.00
PVDF 16 1.36 1.08
20 1.31 1.12
* Intermediate values may be interpolated linearly.
fges = f1 · f2 (also see the example on Page 34)
607
Table 19. Conversion Factor f3 for Table 14.
Material Pipe Wall Temperature TR

20°C 30°C 40°C 50°C 60°C 70°C 80°C
Factor f3
PP-Type 1 1.00
PP-Type 2 0.90 0.89 0.86 0.84 0.80 0.78 0.75
PP-Type 3 0.75
Table 20. Guiding Distances for Axially Clamped Pipe Sections.

Pipe Size Nominal Required Guiding Distance (LF) in mm
da Diameter Depending on the Restricted Longitudinal Extension
[]
mm DN 0.001 0.002 0.004 0.006 0.008 0.010 0.012 0.015 0.020
16 10 505 355 250 205 175 160 145 130 110
20 15 645 455 320 260 225 200 185 165 140
25 20 805 570 400 330 285 255 230 205 180
32 25 1030 730 515 420 365 325 295 265 230
40 32 1290 910 645 525 455 405 370 330 285
50 40 1615 1140 805 660 570 510 465 415 360
63 50 2035 1440 1015 830 720 640 585 525 455
75 65 2425 1715 1210 990 855 765 700 625 540
90 80 2910 2060 1455 1185 1030 920 840 750 650
110 3560 2515 1780 1450 1255 1125 1025 915 795
100
125 4045 2860 2020 1650 1430 1275 1165 1040 900
140 125 4530 3200 2265 1845 1600 1430 1305 1165 1010
160 5175 3660 2585 2110 1830 1635 1495 1335 1155
150
180 5825 4120 2910 2375 2060 1840 1680 1500 1300
200 6475 4575 3235 2640 2285 2045 1865 1670 1445
200
225 7280 5150 3640 2970 2575 2300 2100 1880 1625
250 8090 5720 4045 3300 2860 2555 2335 2085 1805
250
280 9065 6405 4530 3700 3200 2865 2615 2340 2025
315 300 10195 7210 5095 4160 3605 3220 2940 2630 2280
355 350 11495 8125 5745 4690 4060 3635 3315 2965 2570
400 400 12950 9155 6475 5285 4575 4095 3735 3340 2895
Note: When the guiding distances are stipulated taking account
of the restricted longitudinal extension, attention must be
paid to the extension limiting value of the plastic in
question.
Determination of  was according to Equations (29) to (31)
608
Required
Scope
Total
Pipe
Figure 2. Determination of L-shaped expansion bends (material: HDPE).
Example of an application
For system designations, see Figures 8 to 10.
609
Required
Scope:
Total
Pipe
Figure 3. Determination of L-shaped expansion bends (material: PP, Type 1).
610
Required
Scope:
Total
Pipe
Figure 4. Determination of L-shaped expansion bends (material: PP, Type 2 and Type 3).
611
Required
Scope:
Total
Pipe
Figure 5. Determination of L-shaped expansion bends (material: UPVC).
612
Required
Scope:
Total
Pipe
Figure 6. Determination of L-shaped expansion bends (material: CPVC).
613
Required
Scope:
Total
Pipe
Figure 7. Determination of L-shaped expansion bends (material: PVDF).
614
Operating mode:
l from ges L1 requires
bending leg length LB2
System dimensions:
LB1,2  requ. LB according to Figures 1 to 6
LA = see Tables 13 to 17
Figure 8. Schematic drawing of an L-shaped expansion bend.
Operating mode:
bending leg length LB1 + LB3
System dimensions:
LB1,2,3  requ. LB according to Figures 1 to 6
Figure 9. Schematic drawing of a Z-shaped expansion bend.
Operating mode:
l from ges LB3 requires
unhindered expansion in Point 4
System dimensions:
LB1 = LB2 = R + (2 x da)
LB3  requ. LB according to Figures 1 to 6
Lu  2 x (R + da) =^ ges l
Figure 10. Schematic drawing of a U-shaped expansion bend.
Explanation of the Code Designations:

FP = fixed point
FL = guide bearing
Remarks about Figures 8 to 10: GL = slide bearing
If the pipe length between Points  and  is > LA, additional LB = bending leg lengths
slide bearings (GL) must be arranged in the area of the ges L = system lengths
expansion bend. LA = supporting distance
 L = change in the length of the system
R = bend radius
da = pipe diameter
615
Examples of Pipe Brackets
Sliding shoe
Figure 14. Fixed point (FP)
(see Section 5.7.3).
Figure 11. Slide bearing (GL) (see Section 5.7.1).
Supporting ring
Guiding element
Figure 12. Example of pipe brackets; guide bearing (FL) (see Section
5.7.2 - Type A).
Guiding pin
Figure 15. Support in a vertical pipe train (vertical stop)

(see Section 5.7.4).
Hinge
in the pipe axis
direction
Figure 13. Guide bearing (FL) in a vertical pipe train (see Section 5.7.2 - Figure 16. Hanging bearing (HL)
Type C). (see Section 5.7.5).
616
Figure 17. Mounting bracket (AH) (see Section 5.7.6).
Examples of Applications
Determination of Spans According to Tables 13 to 19:
Assuming:
Pipeline da 280 x 15.9 mm
Nominal pressure rating PN 6
Material PP, Type 2
Transported substance 25 % hydrochloric acid
Density of transported substance  = 1.15 g/cm³
Max. operating temperature max. TB = 50°C
Laying type axially mobile
Procedure:
For optimum determination of the span, the pipe wall temperature TR should be used rather than the operating temperature TB. Due to
dissipation to the surroundings, a 10 % reduction in the pipe wall temperature may be expected.
Average pipe wall temperature TR = 0.9 x max. TB 0.9 x 50°C = 45°C
Span according to Table 14, 40°C column LA (40°C) = 2750 mm
Span according to Table 14, 50°C column LA (50°C) = 2650 mm
Interpolated intermediate value for 45°C LA (45°C) = 2700 mm
Factor for transported substance according to Table 18 f1 (1.15) = 0.98
Factor for wall thickness according to Table 18 f2 (Pn 6) = 0.91
Factor for material type according to Table 19 f3 (Type 2) = 0.85
zul LA = 0.98 x 0.91 x 0.85 x 2700
Permissible span for the pipeline zul LA = 2045 mm
Determination of Guiding Distances According to Table 20:

Assuming:
Pipeline da 280 x 15.9 mm
Material PP, Type 2
Assembly temperature TM = 20°C
Laying type axially clamped
Procedure:
Temperature difference   = max. TB - TM = 45 - 20 = 25 K
Restricted thermal extension according to Equation (29)  = 0.00015 x 25 = 0.00375
Required guiding distance according to Table 20  = 0.002 results in: requ. LF = 6405 mm
or  = 0.004 results in: requ. LF = 4530 mm
Determination for  = 0.00375: 6405 – [(6405-4530)/(0.004-0.002) x (0.00375-0.002)] = 4764.4 mm
Required guiding distance of the pipeline requ. LF = 4760 mm
Determination of L-Shaped Expansion Bends According to Figure 2:

Assuming:
Pipeline da 250 mm
Nominal pressure rating PN 10
Material HDPE
Assembly temperature TM = 20°C
Average pipe wall temperature TR = 0.9 x max. TB = 0.9 x 45°C = 40°C
System length according to Figure 8 ges L1 = 5000 mm
Laying type axially mobile
Procedure:
Temperature difference   = TR - TM = 40 - 20 = 20 K
According to Figure 2, ges L1 = 5000 mm and  = 20 K result in the following:
Required bending leg length = erf LB2 = 1800 mm
Note: Other examples of applications are shown in Supplement 1 to the DVS 2210-1 directive.
617
File:
D:\Eigene Dateien\Kunden\DVS\Ri+Me\2210\teil1_englisch\e2210-1bb1.fm
April 2003

Industrial piping made of thermoplastics
FÜR SCHWEISSEN UND
Design and execution Technical Code
Above-ground pipe systems DVS 2210- 1
Calculation example Supplement 1
Contents: 2 Remarks about utilisation
1 Scope of application The calculation steps are represented using columns and lines.
2 Remarks about utilisation The chosen order, with the input data and substance values
3 Calculation example specified first, is an example of what a calculation for a pipe
4 Appendix: Drawings system should look like.
Remarks: In order to keep the calculation example in compliance As far as it is possible, the calculation operations are carried out
with the DVS 2210-1 technical code, the designations in Section 4 strictly according to the order of the equations given in
and the corresponding preceding numbers have been completely DVS 2210-1. In the cases where the information about the appli-
incorporated into the supplement. The following overview shows cation of the equations is not fully comprehensive, supplemen-
the contents and systematic structure of the calculation example. tary footnotes or remarks have been inserted. For clarity, these
4.1 Hydraulic calculations remarks are highlighted.
4.1.1 Determining the clear pipe diameter
4.1.2 Establishing the flow rate 2.1 Significance of the columns
4.1.3 Characteristic hydraulic values
4.1.4 Establishing the hydraulic losses 2.1.1 "Section" column
4.1.4.1 Pressure loss in the straight pipe section This refers to the sub-sections in Section 4 of the DVS 2210-1
4.1.4.2 Pressure losses in pipe mouldings technical code. If no numerical identification is specified in this
4.1.4.3 Pressure losses at joints column for a calculation line or an operation, the information is
4.1.4.4 Pressure losses in valves from another source, which is inserted instead.
4.1.4.5 Pressure surges
4.2 Strength calculations 2.1.2 "Equation no." column
4.2.1 Determining the pipe wall thickness
4.2.2 Determining moulding wall thicknesses This refers to the equation number given in DVS 2210-1 and
4.2.3 Proof of the stresses gives a direct relationship with the input values and units.
4.2.4 Proof of the strains
Remark: In order to avoid any input errors, it is strongly recom-
4.3 Calculations for pipe laying
mended to carefully work through Section 4 in the DVS 2210-1
4.3.1 Establishing length changes
technical code.
4.3.2 Compensating for length changes
4.3.3 Fixed-point loads
2.1.3 "Index" column
4.3.4 Pipe spans
4.3.5 Distances between pipe guides This illustrates which operation is referred to in the calculation
line concerned. The symbols are explained at the start of the
calculation example.
2.1.4 "Subject" column
The DVS 2210-1 technical code includes fundamentals for the
design, calculation, prefabrication and assembly of industrial The main column gives the calculation title as well as explana-
piping made of thermoplastics and laid above ground. Section 4 tions and remarks. For clarity, the text is given in short form. If the
of the technical code deals with calculations and stipulates the description is not understood, it is recommended to look up
mathematical relationships (equations) for these. details under the section number concerned in the DVS 2210-1
technical code.
In order to support the user of the technical code with regard to
the practical use of the equations, Working Group W 4.3 a has Lines and pointers (arrows) have been inserted in some places at
decided to offer a worked example. the right edge of the column. These give an indication of where
connections exist between variables within a calculation section.
The scope of application of the worked example is restricted to
that of the DVS 2210-1 technical code. Since the material chosen 2.1.5 "Abbreviations" column
for the example is PP-H (Type 1), the results cannot be directly
applied to other thermoplastics. This refers to the abbreviations for equation parameters, dimen-
sions, technical and physical variables and similar items. The
As far as the input data is concerned, the relevant values for
meaning of each abbreviation is explained in Section 11 of the
other thermoplastics can be input into the equations as shown in
DVS 2210-1 technical code.
this worked example. The user is responsible not only for the
correct input of the material data, the characteristic values and Any abbreviations that have not been explained in the
the loading parameters but also for the interpretation of require- DVS 2210-1 technical code but are used for supplementary cal-
ments. culations are summarised in Section 2.2 below.
618
Remark: With regard to the abbreviations used in DVS 2210-1 3 Calculation example
and in the calculation example, it should be noted that European
standardisation has resulted in various amendments to the no- Basis: DVS 2210-1 technical code (04/97 edition)
menclature. For example, de is written for the outside diameter of General data:
a pipe instead of da and e for the wall thickness instead of s.
Pipe system: Piping laid above ground in a plant building
However, the main purpose of the worked example is to provide
the user with assistance rather than ensure that it conforms to the Material: PP-H (Type 1)
latest nomenclature. It is left to the user of the DVS 2210-1 tech- Representation of the piping course: See the isometric drawing in
nical code and of the calculation example in Supplement 1 to the appendix
revise the abbreviations as necessary. Operating loads:
2.1.6 "Input or result" and "Unit" columns Transported substance: Chemical waste water with low solvent
proportions
These columns are self-explanatory since they include the es-
Maximum operating temperature: max TB 40 °C
sential contents of the calculation. It is important for the user to
pay attention to the units of the input variables when inputting the Minimum operating temperature: min TB 20 °C
values into the equation or ancillary calculations concerned. In- Computational operating rechn TB 40 °C
formation about this is included in the remarks about the equa- temperature1):
tions in the DVS 2210-1 technical code.
Computational temperature ∆ϑ 20 K
difference:
2.2 Abbreviations and their explanation
Computational service life2): tLD 25 years
The calculation example includes abbreviations that have already
been explained in Section 11 in the DVS 2210-1 technical code.
New terms that have been added and cannot be explained by the Hydraulic data for the pipe system:
text are listed below. Feed pressure of the pumps: p 4.0 bar
Symbol/ Unit Designation Feed volume per pump: V’z 40 m3/h
abbreviation Number of pumps: np 3
empf – Recommended variable Flow volume of the pipe system: V’ 120 m3/h
erf – Necessary variable
geo m Geodetic Geometrical data for the pipe system:
rechn – Computational variable Pipe system length according to
vorh – Existing variable the isometric drawing in the ges LR 1,220 m
appendix3):
n pieces Number
Max. height difference between geod H 6.0 m
q N/m (N/mm) Specific weight loads the pump and pipe axes:
∆ – Difference Number of pipe bends in the main nRF 27
Indices line:
F Guide Number of supply lines (T pieces),
LA Linear distance nominal width of the supply lines nRF 3
= DN 100:
LD Service life
Number of reducers: nRF 0
Z Supply line
Number of welds: nRV 275
Number of shut-off valves nRA 3
(diaphragm valves):
Number of check valves: nRA 3
Laying-specific data for the pipe system:

Distances between the pipe LA 2,000 mm
supports in the building:
Pipe length with free expansion
into the sewage treatment basin: L∆ 49 m
Pipe length with compensation L∆ 380 m
using U bends:
Axial clamping of the pipe between In part
fixed points:
Permissible loads on the fixed
points in the line section on a steel zul FFP 10 kN
structure:
Mean laying temperature TM 20 oC
(assembly temperature):
Explanations: Joining process: Heated tool butt
1) welding
Unless any information is provided about the loading cycles,
the maximum operating temperature must be taken into ac- Substance values:
count during the dimensioning. Density of the transported sub- ρ 1,000 kg/m3
2) To define the characteristic material values. stance (weight γ = ρ · g [N/m3]):
3) Including the additional length of U compensators since their Kinematic viscosity of the trans- ν 1.00E-06 m2/s
dimensions must be determined by calculation. ported substance:
619
Remarks about, and explanation of, the symbols:

"Index" column: "Section" and "Equation no." columns:
P Project information
Unless otherwise is noted, the remarks relate to the contents of
W Chosen variable, table or diagram value
the DVS 2210-1 technical code (04/97 edition). For calculations
B Calculation according to the specified equation
that are not dealt with in the DVS technical code, (NN) is speci-
NR Ancillary calculation
fied as the equation.
Σ Total
! Special remark
Section Remarks Subject Abbre- Input or Unit

Equation Index viations result
no.
4.1 Hydraulic dimensioning
Pipe dimensions of the main line:
P Flow volume of the main line V’ 120 m3/h
W Permissible flow rate w 2.0 m/s
4.1.1 2 B Determining the clear pipe diameter di 145.62 mm
W Relevant nominal width DN 150 (–)
W Chosen pipe outside diameter da 180 mm
W Chosen wall thickness s 10.2 mm
W Diameter-to-wall-thickness ratio of the pipe SDR 17.6 (–)
NR Actual inside diameter di 159.6 mm
4.1.2 3 B Actual flow rate w0 1.67 m/s
Pipe dimensions of the supply lines:
W Chosen pipe outside diameter da 110 mm
W Chosen wall thickness s 6.3 mm
W Diameter-to-wall-thickness ratio of the pipe SDR 17.6 (–)
4.1.2 3 B Actual flow rate in the supply lines w1 1.49 m/s
! In order to establish the hydraulic losses using a simplified method, the flow rate in the three
DN 100 pressurised pump lines is assumed to be equal to that in the main line.
4.1.3 Determining the characteristic hydraulic values:
4.1.3.1 4 B Reynolds number Re 2.66E+05 (–)
4.1.3.2 Fig. 1 W Pipe friction coefficient for the established Re number λ 0.0155 (–)
! Practice-related computation value λ 0.020 (–)
NR Ratio number di/k 15,960 (–)
W Operating roughness coefficient for the plastic pipe k 0.01 mm
4.1.4 Establishing the hydraulic losses:
4.1.4.1 7 B Pressure loss in the straight pipe section ∆pR 1.65 bar
4.1.4.2 8 B Pressure loss in the pipe bends (total) ∆pRF 0.19 bar
4.1.4.2 8 B Pressure loss in the pipe branches (total) ∆pRF 0.01 bar
4.1.4.3 9 B Pressure loss at the pipe joints (total) ∆pRV 0.38 bar
4.1.4.4 10 B Pressure loss in the valves (total) ∆pRA 0.20 bar
4.1.4.4 10 B Pressure loss in the check valves (total) ∆pRA 0.05 bar
4.1.4 6 Σ Total pressure loss of the pipe system ges ∆pRL 2.48 bar
P Geodetic pressure difference (maximum value) ∆pgeod 0.60 bar
= [(geod H) · γ · 10-5]
Total Σ Computational pump pressure = internal pressure loads rechn p 3.08 bar
on the pipe system
! The strength calculations according to Section 4.2 are made using the calculated internal pressure
loads for a duration of 25 years.
Ancillary calculations for Section 4.1.4:
Table 9 W Resistance coefficient of the pipe bend ζRV 0.51 (–)
Table 9 W Resistance coefficient of the pipe branch (flow unification) ζd 0.26 (–)
W Resistance coefficient of the pipe joints (welds) ζRV 0.10 (–)
Table 10 W Resistance coefficient of the DN 100 valves ζRA 4.80 (–)
Table 10 W Resistance coefficient of the DN 100 check valves ζRA 1.20 (–)
Table 9 P Bend radius R 1.0 × da mm
Table 9 NR Volume ratio for the T3 supply line Vz/Vs 0.33 (–)
620

no.
4.1.4.5 11 B Testing for the danger of pressure surges K 321.7 (–)
! Because of K > 70, no quick-acting valves should be installed in the piping since there is the danger
of pressure surges. For example, this requirement can be met by using diaphragm valves. Pressure
surge calculations must be made using special computation programs.
4.2 Strength calculations
4.2.2 Determining the wall thicknesses
4.2.1 12 B Minimum wall thickness of the pipes min sR 7.3 mm
4.2.2.1 13 B Minimum wall thickness of the pipe bends on the inside (max- min sB 9.3 mm
imum)
4.2.2.2 15 B Minimum wall thickness of the pipe branches (base pipe wall min sA 12.0 mm
thickness)
DIN 8077 W Standard wall thickness of the pipe vorh sR 10.2 mm
The pipe branch requires an enlargement of the base pipe erf sA 12.0 mm
wall thickness in the area influenced by the nozzle to at least:
! For calculations relating to the wall thickness of fittings, it is generally true that, in the event of
deviations between the manufactured and calculated wall thicknesses, it is sufficient for the fitting
manufacturer to prove the creep strength.
Establishing the permissible circumferential stress:
DVS Supple- W Comparative stress from creep strength curve σV 7.40 N/mm²
2205-1 ment 1
DVS Appendix W Influence of the transported substance A2 1.10 (–)
2205-1
DVS Table 2 W Influence of the material viscosity (mean for max TB and A4 1.15 (–)
2205-1 min TB)
DVS Table 4 W Safety coefficient (intermediate value in the table) S 1.60 (–)
2205-1
NR Factor (safety margin x total reduction) S× 2.02 (–)
(A1 ... An)
DVS 1 B Permissible stress in the circumferential direction4) zul σu 3.66 N/mm²
2205-1
! The stipulation of the safety coefficient is intended to be related to the hazard potential of the
transported substance as well as to the route of the piping (e.g. crossing pedestrian traffic areas).
S = 2.0 must be used in the case of transported substances that are hazardous to people and/or the
environment.
Establishing the permissible longitudinal stress:
NR zul σa = zul σu · fs zul σa 2.92 N/mm²
DVS Table 3 W Long-term welding factor (heated tool butt welding) fs 0.80 (–)
2205-1
Establishing the geometrical influencing factors:
Table 1 W Wall thickness factor for the inside of the bend (R = 1.0 × da) fBi 1.27 (–)
P Nozzle diameter of the pipe branch dS 110 mm
W Nozzle wall thickness of the pipe branch according to SDR sS 6.3 mm
AD-B9 Fig. 7e W Weakening factor for the T piece vRF = VA 0.61 (–)
AD-B9 NR Wall thickness ratio sS/sA 0.62 (–)
AD-B9 NR Diameter ratio di/Di 0.61 (–)
AD-B9 NR Wall-thickness-to-diameter ratio sA/Di 0.10 (–)
4.2.3 Proof of the stresses
4.2.3.1 Establishing the stress component in the X axis
16 B Stress from the internal overpressure in the longitudinal + σl 1.13 N/mm²
direction
19 B Stress from the pipe deflection in the longitudinal direction + σb 0.57 N/mm²
20 B Compressive/tensile stress from restricted thermal expansion – /+ σϑ 0.90 N/mm²
Total Σ Total stress in the longitudinal direction added up ges σa 2.60 N/mm²
621

no.
Establishing the stress component in the Y axis
17 B Stress from the internal overpressure in the circumferential di- + σu 2.58 N/mm²
rection
Establishing the stress component in the Z axis
18 B Stress from the internal overpressure in the radial direction + σr – 0.31 N/mm²
Checking the comparative stress
e.g. NR Comparative stress according to the shear stress hypothesis σV* 2.90 N/mm²
Dubbel
e.g. NR Comparative stress according to the distortion hypothesis σV* 2.89 N/mm²
Dubbel
DIN 8077 W Vertical load from the pipe weight qR 52.5 N/m
NR Vertical load from the filling weight, qM = di² · π/4 · γ · 10-5 qM 200.1 N/m
NR Line load per mm pipe length, qges = (qR + qM) : 1,000 qges 0.253 N/mm
Table 2 W Coefficient of linear thermal expansion α 0.00016 1/K
NR Temperature difference, ∆ϑ = max TB – min TB ∆ϑ 20 K
DVS Fig. 23 W Creep modulus for min TB, load duration = 25 a / 2 N/mm² min Ec 310 N/mm²
2205-1
DVS Fig. 23 W Creep modulus for max TB, load duration = 25 a / 2 N/mm² max Ec 250 N/mm²
2205-1
NR Mean creep modulus, load duration = 25 a / 2 N/mm² Ecm 280 N/mm²
NR Resistance moment of the pipe cross-section, WR 222,738 mm³
WR = (da4– di4) : (10 · da)
4.2.4 Proof of the strains
21 B Strain in the X direction (with Ecm and µ = 0.38) εσx 0.62 %
22 B Strain in the Y direction (with Ecm and µ = 0.38) εσy 0.61 %
DVS W Poisson's ratio for thermoplastics µ 0.38 (–)
2205-1
DVS Table 1 W Permissible strain limiting value for PP-H (Type 1) zul ε 2.0 %
2205-1
23 B Safety margin relating to critical strain Sε 3.2 (–)
23 W Required minimum safety margin erf Sε 1.3 (–)
4.3 Calculations for pipe laying
4.3.1 Establishing the length changes
P Freely mobile pipe section upstream of the sewage treatment L∆ 49 m
basin
4.3.1.1 24 B Short-term length change with ∆ϑ from the temperature ∆lϑ 156.8 mm
change
4.3.1.2 25 B Long-term longitudinal strain due to internal pressure loads ∆lp 47.6 mm
4.3.1.3 26 B Long-term length change due to chemical effects ∆lQ 98.0 mm
4.3.1.3 P Factor for the chemical effect due to solvents5) fQ 0.002 mm/mm
! For dimensioning the expansion bends, it is necessary to take account of the length change from
the temperature change plus the chemical effect. In practice, the long-term longitudinal strains from
the internal pressure, calculated for friction-free supports, do not have any influence on the
longitudinal bending stress in the expansion bend.
4.3.2 Compensating for the length changes
4.3.3.1 29 B Specific length change, εaxial = α · ∆ϑ + fQ εaxial 0.0052 mm/mm
NR Permissible bending stress for the dimensioning zul σb 1.79 N/mm²
(zul σb = zul σa – σl)
4.3.2.1 Dimensioning the expansion bends
System I (See the drawing in the appendix)
System Length 1 ges L1 49.0 m
Fig. 8 27 B Bending Leg Length 1 for an L bend min LBL1 4,637 mm
System Length 2 ges L2 4.637 m
Fig. 8 27 B Bending Leg Length 2 for an L bend min LBL2 1,427 mm
622

no.
System II (See drawing in the appendix)
Fig. 9 27 B Bending leg length for a Z bend6) min LBZ 1,325 mm
System III (Dee drawing in the appendix)
P Permissible loads from the project requirements (maximum value) zul FUB 10,000 N
NN B Equivalent sliding length for zul FUB from the friction at the LR 79.2 m
pipe fastenings, LR = zul FUB : (1,000 · qges · µR)
! zul FUB = zul FFP = 10 kN
NN B Permissible system length, ges L0 = 2 · LR ges L0 158.4 m
P Existing system length ges L0 126.0 m
24 B Short-term length change with ∆ϑ from the temperature change ∆Iϑ 201.6 mm
26 B Long-term length change due to chemical effect ∆IQ 126.0 mm
B Total from the results according to Equations 24 + 26 ∆IU = dI 327.6 mm
Fig. 10 NR Apex length in the case of the U bend min Lu 1,015 mm
Fig. 10 NN B Bending leg length in the case of the U bend7) min LB 2,100 mm
! The bending leg lengths for U bends and three-dimensional bend pieces cannot be established with
simple equations. It is therefore essential to use computer programs.
4.3.3 Fixed-point loads
4.3.3.1 Without any compensation for the length change, the resulting loads are as follows:
28 B Fixed-point loads in the case of an axially-clamped pipe section max FFP 13,929 N
With compensation for the length change using an L-shaped expansion bend (System I),
the resulting loads are as follows:
32 B Loads from the deformation of the bending section FLB 303 N
NN B Loads from the friction at the pipe fastenings: FR 6,188 N
FR = ges L1 · qges · µR
Σ Fixed-point loads in the case of the L-shaped expansion max FLB 6,490 N
bend (total of FLB + FR)
Fixed-point loads in the case of the Z-shaped expansion
bend (System II):
NN B Approximate calculation: FZB 265 N
max FZB = 3 · L0/2 · α · ∆ϑ · EK · IR/LBZ³
Loads from the friction at the pipe fastenings8) FR Negligible
Σ Fixed-point loads in the case of the Z-shaped expansion bend max FZB 265 N
(total of FZB + FR)
Fixed-point loads in the case of the U-shaped expansion
bend (System III):
! In the case of the U bend, the force associated with the deformation of the bending legs can be
neglected in comparison with the friction forces. FUB Negligible
B Friction at the pipe fastenings: FR = 0.5 · ges L0 · qges · µR FR 7,956 N
Σ Fixed-point loads in the case of the U-shaped expansion max FUB 7,956 N
bend (total of FUB + FR)
! With max FUB = 7,956 N, the project requirement of max FFP = 10,000 N is fulfilled.
! According to Section 4.3.3, the fixed-point forces must be established using the least favourable
load case. It is not necessary to computationally superimpose (add) the loads from restricted
thermal expansion and internal pressure as long as they act in different directions (compressive and
tensile stresses). Chemical actions that cause longitudinal strain must be included in the fixed-point
loads taking account of the elastic moduli reduction due to solvents and the time-dependent stress
relaxation (a special case that is not dealt with in the calculation example). Friction forces of longer
pipe sections must be taken into consideration. In this respect, the fixed-point loads resulting from
them cannot be greater than the maximum value according to Equation (28). The relief of the loads
on the fixed points due to the counterforce concerned can be neglected in the calculations.
DVS Table 6 NR Creep modulus for 100 min Ec100min 800 N/mm²
2205-2 (mean for 0.5 · (minT + maxT = 30°C))
! In order to determine Ec100min approximately, EK(30°C) = 960 N/mm² (DVS 2205-2, Table 6) and
Ec1a = 375 N/mm² (DVS 2205-1, Fig. 21, σ = 2 N/mm²) must be plotted on a graph with a
logarithmic time axis (10-1 ... 8.76 · 10³ h) and both the points must be connected with a straight
line. The intersection between the 100 min vertical line and the connecting straight line results in the
above Ec100min.
623

no.
NR Circular ring area of the pipe (AR = da² – di²) · p/4) AR 5,441 mm²
NR Moment of inertia of the pipe cross-section, IR = (da4 – di4)/20 IR 20.0E+6 mm4
W Friction coefficient at the pipe fastenings made of steel (St)9) µR 0.5 (–)
4.3.4 Establishing the pipe spans
33 B Calculated distance between supports rechn LA 2,315 mm
Table 14 W Recommended distance between supports for rechn TB empf LA 2,200 mm
P Existing distance between supports vorh LA 2,000 mm
! The calculated distance between supports is based on a 25 year creep modulus. The creep modu-
lus is influenced by the action of chemicals. This may lead to a decrease in the values according to
DVS 2205-1. This influence is taken into consideration in the ancillary calculations for this section.
DVS Fig. 23 NR Creep modulus for 25 years / σ = 2.0 N/mm² subjected to Ecm(20...40°C) 280,255 N/mm²
2205-1 chemical action Ec/A2
N/mm²
W Influences caused by the action of chemicals A2 1.10 (–)
NR Moment of inertia of the pipe cross-section IR 20.0E+6 mm4
NR Line load of the pipe qges 0.253 N/mm
Remark about W Chosen factor for the deflection gew fLA 0.85 (–)
Equation 33
4.3.5 Establishing the distances between guides for the axially clamped pipe sections
34 B Calculated distance between pipe guides for rechn ε rechn LF 2,668 mm
Table 20 W Recommended distance between guides for rechn ε10) empf LF 2,589 mm
P Existing distance between supports*) vorh LF 2,000 mm
* there is no danger of buckling since rechn L > vorh L
NR Moment of inertia of the pipe cross-section IR 20.0E+6 mm4
NR Circular ring area of the pipe AR 5,441 mm²
4.3.3.1 29 B Longitudinal strain due to axial clamping rechn ε 0.0052 = mm/mm
0.52 %
4) Without the influence of the welding factor fs.

5) Must be established for each case on the basis of laboratory tests using the transported substance.
6) Approximate calculation using a halved system length.
7) Established using a computer program.
8) Can be neglected because of the short pipe sections.
9) Sliding guide bearings made of St on an St support, µR = 0.20 can be used for plastic on St.
10) Established from: 2,910-[(2,910-2,375)/(0.006-0.004) · (0.0052-0.004)].
624
Appendix
625
System I: L-shaped expansion bend
System II: Z-shaped expansion bend
System III: U-shaped expansion bend
dl = Displacement of LBu from length change
626
File:
D:\Eigene Daten\Kunden\DVS\Ri+Me\2210\englisch_2210-1\e2210-1bb2.fm
July 2004

DVS – DEUTSCHER VERBAND Design and execution
FÜR SCHWEISSEN UND Above-ground pipe systems Technical Code
VERWANDTE VERFAHREN E.V. Recommendations for the internal pressure DVS 2210- 1
and leak tests Supplement 2
Contents: which may even lead to a reduction of the service life if the pipe
wall temperature TR = 20°C is exceeded by more than 5°C dur-
1 Scope of application ing the internal pressure test, depending on the nominal pres-
2 Explanations sure.
3 Details about the internal pressure test DVS Working Group AG W 4.3a proposes the stipulation of a test
4 Facilities for and remarks about the execution of the internal pressure which is regulated according to SDR and depends on
pressure test the pipe wall temperature and the strength parameter V(T) at
5 Other test procedures and leak test 100 h. As the pipe wall temperature increases, the test pressure
6 Test report and test supervision must also be reduced in such a way that a constant safety margin
7 Testing pressures, testing temperature and testing duration to the creep strength V(T,100h) is maintained.
8 Standards, rules and regulations which are also applicable
9 Example of the execution of an internal pressure test with the Since not all thermoplastic pipes have an SDR classification, the
elaboration of a test report value of da/s ( SDR ratio) is chosen as the reference variable for
Appendix: Specimen for test report (test record sheet) determining the test pressure.
During the execution of a temperature-influenced internal pres-
sure test, as well as the internal pressures determined for the
1 Scope of application maximum temperature, variable internal pressures can be used.

For pipes that are laid outside buildings, either above ground or
The DVS 2210-1 technical code includes fundamentals for the
not buried, the internal pressure test may be carried out at an
design, calculation, prefabrication and assembly of industrial
early or late time of the day in order to reduce the influence of
piping made of thermoplastics and laid above ground.
temperature.
Section 7 of the technical code deals with tests, inspections and
When determining the permissible testing pressure, attention
acceptances, including the internal pressure test on the com-
must be paid not only to the influence of temperature but also to
pleted pipe system. For reasons explained in greater detail in
the load-bearing capacity of fittings, valves or measuring compo-
Section 2 below, it has been decided to refer to the internal
nents.
pressure testing of thermoplastic pipe systems in a separate sup-
plement. The whole scope of Section 7.5 of the DVS 2210-1 Piping that contains components with a load-bearing capacity
technical code is being replaced with the publication of the lower than that of the pipe may only be subjected to loads up to
DVS 2210-1 technical code, Supplement 2. the level of the internal pressure specified by the manufacturer. If
necessary, the components with a lower load-bearing capacity
The scope of application of the internal pressure test recommen-
must be removed during the internal pressure test.
dations given in Supplement 2 can also be transferred to those
areas of application and materials that are not expressly listed in
Section 1.1 or 1.2 of DVS 2210-1.
3 Details about the internal pressure test
Buried piping that is made of thermoplastics and whose joints
can be inspected visually during the test can be included in the The internal pressure test forms the conclusion to the pipe laying
scope of application. If the testing of buried piping is subject to work and requires a ready-to-operate pipe system or ready-to-
other rules or regulations, exclusively these must be applied (e.g. operate sections for testing. The stresses resulting from the test
DIN 1988-2). pressure should constitute the experimental proof of the opera-
If the scope of application is extended, the user must ensure that tional safety of the system. In this respect, emphasis should not
the recommendations made in the DVS 2210-1 technical code be placed on the calculated operating overpressure but instead
and in Supplement 2 are taken into appropriate consideration. on the internal pressure capacity originating from the pipe wall
The recommendations for carrying out an internal pressure test thickness.
according to Supplement 2 do not exclude the application of oth- The recommendations for carrying out the internal pressure test
er technical codes, guidelines, standards and similar documents are according to DIN 4279 ff. Table 1 includes a summary which
or any modified testing conditions. is intended to provide the essential key data of the test. The
specified test duration is based on empirical values, which take
account of both the practical requirements and the efficiency of
2 Explanations the test.
With the introduction of the SDR classification for thermoplastic 3.1 Preliminary test
pipes, which is intended to replace the nominal pressure ratings
The preliminary test serves to prepare the piping system for the
[PN], a reference variable that is different from the reference
actual test (main test). A stress-strain equilibrium, generated by
variable specified in DVS 2210-1, Table 7 must be chosen for
the internal pressure loads, arises during the preliminary test.
determining the test pressure.
This leads to a material-dependent pressure drop that requires
Another reason for modifying the former approach is the fact that the repeated addition of water (repumping) in order to restore the
pipes made of thermoplastics with restricted temperature resis- test pressure as well as the frequent retightening of the flanged
tance may be subjected to excessive stresses for a short time, joint screws.
627
Table 1. Recommendations for carrying out an internal pressure test.
Subject with explanations Preliminary test Main test Short-term test

Test pressure pP Depending on the pipe wall tem-  pP(zul)  0.85 ∙ pP(zul)  1.1 ∙ pP(zul)
(see Section 7) perature or the permissible testing
pressure of the installed parts
Test duration Piping with or without branches 3h 3h 1h
(see also Section 7.5) and a total length, ges L  100 m
1)
Piping with or without branches 6h 6h 3h

and a total length
100 m < ges L  500 m
Piping with or without branches The pipe system must be checked section by section. In this respect, it
and a total length, ges L > 500 m is necessary to comply with the test length LPrüf  500 m 1)
6h 6h 3h
Inspections during The inspection results, as well as  3 inspections  2 inspections  1 inspection
the test the pressure and temperature carried out over the carried out over the while keeping the test
(see also Section 7.4) changes during the test, must be test duration with test duration without pressure constant
documented in a test report restoration of the test restoration of the test
pressure pressure
Material-specific Reference values, depending on PE:  1.0 bar/h PE:  0.5 bar/h No values for the
pressure drop the elastic modulus of the plastic pressure drop are
concerned PP 2) PP 2) available for short-
PVC 2) PVC 2) term loads
PVDF 2) PVDF 2)
Remarks: Normal case Special case
1) If ges L exceeds the stipulated limiting length by no (In relation to the specified duration of the pre- (Consent of the
more than 10 %, the specified testing conditions may be liminary and main tests) customer or operator
retained. required)
For further remarks, see the footnote on Page 8.
2) See the explanations in the footnotes on Page 8.
3.2 Main test Table 2. Reference values for filling the line.
The main test immediately follows the preliminary test. During the
main test, a substantially lower pressure drop may be expected DN V [l/s] DN V [l/s]
at an approximately constant pipe wall temperature.  80 0.15 250 2.0
In most cases, this makes it unnecessary to add any water to 100 0.3 300 3.0
restore the test pressure. The inspections may essentially con- 150 0.7 400 6.0
centrate on the leak-tightness of the flanged joints and on any 200 1.5 500 9.0
conspicuous features in the pipe system (e.g. major position
changes).
If a pipe system has several low points it may be necessary, in
certain circumstances, to fill it section by section from each
3.3 Short-term test individual low point.
The short-term test represents a special case since, according to Between filling and testing the pipe system, enough time must be
general experience, no stress-strain equilibrium can arise in the left for the air in the system to escape via the venting points
available time. In certain circumstances, imperfections at the (guide time:  6 - 12 h, depending on the nominal pipe diameter.
joints may not be detected due to the short-term loads, which
contradicts the point of the test. The short-term test should there- In the case of piping larger than DN 150 which does not have any
fore only be used for pipe systems that do not have a hazard definite high points and is laid with only a slight inclination, it may
potential. be necessary to use a pig to eliminate any air bubbles remaining
inside the pipe.
3.4 Preparation of the internal pressure test
3.4.2 Application of the test pressure
A prerequisite for the internal pressure test on plastic piping is the When applying the test pressure up to its maximum value, it must
elimination of any air bubbles (residual air volume) in the system be ensured that the chosen pressure rise rate does not cause
before the preliminary test. To accomplish this, venting points, any surges in the pipe system to be tested. Guide values for this
which must be open during the rinsing or filling of the line, must are given in Fig. 1.
be provided, if at all possible, at all the high points of the pipe
system. The rinsing speed should be at least 1.0 m/s.
4 Facilities for, and remarks about, the execution of the
3.4.1 Filling of the line internal pressure test
The pipe system is filled from the geodetically lowest point. The It is advisable to use motor-driven pumps for carrying out the
filling rate must be set such that the air emerging at the high internal pressure test. The use of small manually-actuated
points has time to escape. Reference values for the filling rate pumps (e.g. piston pump) must be restricted to short pipe sec-
are given in the following table. tions with nominal diameters up to DN 50.
628
Range of the
pressure rise rate
for piping
> DN 100 - 400
Test pressure [%]
Pressure rise rate

for piping up
to DN 100 Guide value for the pressure rise rate
for piping  DN 500:
Time for the test pressure rise [min]
Figure 1. Time for the test pressure rise.
The standard equipment for pressure testing comprises the fol- 4.2 Testing and measured results
lowing components:
4.2.1 Checking of the pressure drop rates
– centrifugal, or piston, pump
– receiver vessel During the preliminary and main tests, the pressure drop rates
– non-return valve specified in Table 1 must not be exceeded. The pressure drop
– water meter (if necessary, also a measuring vessel) rates established on the basis of the recorded data must be
– pressure gauge (displaying and recording) transferred to the test record sheet. The pressure drop rate may
– temperature gauge (displaying or recording) be calculated from the maximum value, over a test duration of
– shut-off, and venting, valves two hours. In this way, the higher pressure drop rate at the start is
– venting possibility for the testing facility compensated for.
If there is a specific pressure drop that is considerably above the
4.1 Measuring and display devices values specified in Table 1, the pipe system under test must be
subjected to a detailed inspection, in particular the joints, espe-
4.1.1 Internal pressure measurement cially the flanged joints. If necessary, the screws of the flanged
The internal pressure is measured at the absolute low point of the joints must be retightened due to the strain processes from the
line. The device displaying the internal pressure (manometer) internal pressure loads. It is recommended to use a torque-con-
must have a reading accuracy of 0.1 bar over the range of the trolled tool (see DVS 2210-1, Supplement 3).
test pressure. As well as a pressure display it is also necessary
Furthermore, it must be established whether the ambient temper-
to have a recording pressure gauge of Accuracy Class 0.6
ature has an influence on the increase in the pressure drop rate.
(DIN 16070). The internal overpressure must be recorded contin-
If there are no indications of any external influences and the
uously throughout the test duration.
pressure drop does not diminish, the test must be terminated and
repeated.
4.1.2 Temperature measurement
In order to be able to evaluate the influences of temperature dur- 4.2.2 Reduction in the test pressure
ing the test, it is advised to measure the ambient temperature
If the pressure drop corresponds to the guide values specified in
and the water temperature in the pipe system at the same time. It
Table 1 and the test pressure is reduced within  2 min at the end
is recommended to use devices that record the temperature.
of the preliminary test by draining water, it is necessary to ob-
On exposed pipe sections that are subjected to direct sunlight serve the subsequent change in internal pressure. The main test
during the test, it is necessary either to check the pipe surface can be continued if the internal pressure stabilises or increases
temperature TRa or to protect the pipe section against uncon- slightly within 30 min.
trolled heating. The results must be noted in the test report.
4.3 Repetition of the preliminary test
4.1.3 Measurement of the quantity of supplied water
If there is no cease in the pressure drop after reducing the test
Particularly in the case of piping that cannot be inspected visual- pressure at the end of the preliminary test and if the pressure
ly, it is mandatory for the quantity of supplied water for increasing drop cannot be attributed to any external temperature influences,
or restoring the test pressure to be measured. If the quantity of a leak may be assumed. In this case, the test must be halted, the
supplied water reduces continuously during a 6-hour test with on- piping inspected and the internal pressure subsequently in-
ly a slight change in the ambient temperature ( 5°C), the pipe creased to the initial value of the preliminary test, while simulta-
system may be assumed to be leak-tight. neously measuring the supplied water quantity.
It is sufficient to install a calibrated water meter (impeller wheel or After a minimum of 1 h, the reduction in the test pressure must be
ring piston meter) as the measuring facility with which the small- repeated while measuring the discharged water quantity. If there
est unit can be read off in litres. If measuring vessels are used, a is once again no stabilisation of the test pressure, the pressure
scale division of  0.1 l should be chosen. The permissible error on the pipe section under test must be relieved (pp = 0) and the
limit when reading off the quantity of supplied water is 5 %. entire preliminary test repeated.
4.1.4 Measurement of the quantity of discharged water 4.4 Repetition of the main test
Since the test pressure must be reduced at the beginning of the If the internal pressure during the main test drops by more than
main test, it is recommended to measure and log the quantity of the pressure drop rates specified in Table 1, a leak may be
discharged water as well as the reduction in the internal pressure assumed. If the cause of the increased pressure drop is found
[pp]. This should be carried out using the same criteria as for and rectified during the inspection of the piping without the test-
measuring the quantity of supplied water. ing pressure falling to less than 80 % of its initial value, the main
629
test can be continued. In all other cases, the main test must be Since the efficiency of the leak test is significantly restricted be-
terminated and repeated. If there is a time span of > 4 h between cause of the reduced loads on the piping, this should preferably
the termination and repetition of the main test, the preliminary be applied to systems with operating overpressures pB  0.5 bar.
test must also be repeated.
5.3 Leak test at pP > 0.5 bar
The application of test procedures at air overpressures pP > 0.5 bar,
5 Other test procedures and leak test
e.g. according to DVGW G 469 or DVGW G 472, is permissible if
the described approach is complied with strictly and knowledge-
For some applications of thermoplastic piping, there are systems able testing personnel are deployed.
which, because of their design or components, are not capable of
withstanding an increased overpressure or one that acts for a 5.4 Testing using a vacuum or external overpressure
longer duration. In addition, an internal pressure test using water
may also be prohibited by the requirement to keep the piping dry. For double pipe systems whose annular space is to be monitored
using overpressure or a partial vacuum, the testing conditions
For this reason other test procedures, described below in an must be adjusted correspondingly. During the test using a vacu-
informative form, have been developed. um or external overpressure, it is necessary to prove not only
leak tightness but also that there is a sufficient safety margin to
5.1 Internal pressure test according to DIN EN 805 the elastic buckling of the inside or outside pipe.
in conjunction with DVGW W 400-2
A vacuum test may also be appropriate in the case of piping that
This constitutes a test procedure in which the leak tightness is was manufactured using lap-welded joints (e.g. sleeve welding
proven by producing a contraction of the piping. processes with an incorporated electric heating element). In par-
Once again, the test is divided into a preliminary test and a main ticular, the formation of cannulae in the joining plane tends to be
test. In the course of the preliminary test, the test pressure recognised more easily in a vacuum test than during the test
should be achieved within ten minutes and maintained for anoth- using internal overpressure.
er 30 minutes by means of repumping. It is necessary to take ac-
count of the test pressures established according to Equation (1).
6 Test report and test supervision
This is followed by a one-hour rest phase during which the piping
will expand viscoelastically due to the internal overpressure.
The internal pressure test procedure and other test procedures,
During the rest (deformation) phase, the test pressure is allowed as well as their results must be logged. All the data relevant to
to decrease by max. 30 % because of the increase in volume. the evaluation of the test must be specified on the record sheet,
Piping made of less elastic thermoplastics (e.g. PVC or PVDF) according to the example template given in the appendix.
will exhibit a lower pressure drop at the end of the preliminary
The execution of the test should be overseen by a supervisory
test (guide value: pP  0.20 ∙ pP).
person or a construction supervisory agency.
If the pressure drop is higher than the material-dependent guide
In particular, knowledge and experience relating to the handling
values, a leak must be assumed. As far as possible, the piping
of piping made of plastics are a prerequisite for stipulating the
must be inspected for signs of leaks and these must be rectified if
test pressures as well as for recording and documenting the test
necessary. The preliminary test must be repeated after a relax-
results.
ation phase at pp = 0 and a minimum duration of 60 minutes.
If the prerequisites with regard to the permissible pressure drop
are fulfilled, the main test follows immediately after the prelimi- 7 Test pressures, test temperature and test duration
nary test. In this respect, the following testing steps must be tak-
en: 7.1 Establishing the test pressure
– rapid lowering of the pressure by pab = 10 - 15 % of the pres- The permissible test pressure [pP(zul)] is calculated according to
sure existing at the end of the preliminary test the following equation:
1 20   v (T,100 h)
– measurement of the drained water volume with a comparison
with the calculated volume p P(zul) = ------  ------------------------------------- [bar] Equation (1)
da SP  AG
– a half-hour contraction duration after the lowering of the pres- ------
sure s
– monitoring and recording of the pressure during the contrac- Where:
tion phase da, (de) Pipe outside diameter (mm)
The piping is regarded as leak-tight if the pressure drop is close s, (e) Pipe wall thickness (mm)
to p = 0 during the contraction phase.
v (T,100h) Creep strength for a pipe wall temperature TR and
with t = 100 h (N/mm2)
5.2 Leak test at pP  0.5 bar
(e.g. according to the supplements to DVS 2205-1)
In contrast with the test at an increased internal pressure, the
SP Minimum safety margin for the creep strength
leak test is carried out at a slight overpressure. Not only water but
(Table 3) (-)
also air or any other suitable gas (e.g. nitrogen) may serve as the
testing medium. For safety reasons, the internal overpressure AG Processing-specific or geometrical reduction factor
must be limited to pP  0.5 bar during leak tests using a gas as (AG  1.0) 3) (–)
the testing medium. da/s  SDR (–)
If the leak test is carried out with water, the permissible test pres-
sure is limited either by the load-bearing capacity of the pipe sys-
tem or by application guidelines (e.g. sewers according to 3) For further remarks, see Page 8
DIN EN 1610).
Throughout the duration of the leak test using a gas, the leak
tightness of all the joints in the system must be checked by
spraying or brushing them with a foaming agent.
630
Table 3. Minimum safety margin for the creep strength for In the case of plastic piping to be tested outdoors, it is a problem
determining the permissible test pressure. to keep the pipe wall temperature constant and this may restrict
the use of the test procedure concerned. In order to ensure the
Material PE PP-H PP-(B or R) PVC PVDF meaningfulness of the test, it is imperative to record the tempera-
tures as listed in the example of the test record sheet template.
SP 1.25 1.80 1.40 2.50 1.40
If it is anticipated that the mean pipe wall temperature of a pipe
section will be higher than the temperature resulting from Equa-
The user is free to stipulate a greater safety margin than speci- tion (2) because of direct sunlight, the test pressure must be low-
fied in Table 3. ered correspondingly.
The permissible test pressure [pP(zul)] depending on the pipe wall The measurement and recording of the temperature inside the
temperature can be taken directly from the diagrams in Figs. 2 to pipe (temperature of the testing medium) requires the positioning
6. of a measuring nozzle at the least favourable position in the pipe
When working at test pressures that are lower than the test pres- system. If it is ensured, by taking suitable measures, that the pipe
sure established according to Equation (1), pP = 1.3 x pB may be wall temperature does not rise above a predetermined maximum
assumed as the minimum value. value, it is not necessary to measure the temperature of the test-
ing medium. In the case of piping made of plastics with a low
(pB = operating overpressure) notched-bar impact strength (e.g. PP-H or PVC-U), an internal
pressure test is not advised for pipe wall temperatures < 10°C.
7.2 Test pressure diagrams
The diagrams in Figs. 2 to 6 are intended to illustrate the tem- 7.4 Remarks about automatically operating testing facilities
perature-dependent test pressures for thermoplastic piping.
If automatically operating facilities are used for internal pressure
Moreover, they serve to make it easier for the building site per-
tests, the visual inspections during the test may be reduced to
sonnel to determine the test pressure.
two operations in total. The inspections must be carried out 1 h
The test pressure curves compiled for one group of plastics take after the test pressure has been reached as well as at the end of
account of the lowest strength parameter in each case and the the main test. The prerequisites for reducing the inspections are
minimum value of pP(zul) calculated according to Equation (1). that the test pressure and temperatures (Ti, TRa and TU) are
recorded continuously and that the water inflow is automatically
No processing-specific or geometrical reduction factors have
stopped in the event of a leak.
been used in these curves.
7.3 Remarks about the pipe wall temperature 7.5 Remarks about the test duration
(testing temperature) The test duration specified in Table 1 relates to a test without
If it is assumed that the pipe wall temperature (testing tempera- interruptions. If leaks or any other incidents require an interrup-
ture) will change during the internal pressure test, the test pres- tion of the test or the temporary lowering of the test pressure, the
sure must relate to the maximum temperature to be expected. corresponding interruption times are not included in the overall
test duration.
If a temperature that leads to a higher pipe wall temperature [TR]
than was assumed is measured on the pipe surface when taking If an internal pressure test has already been carried out on piping
control measurements during the test, the test pressure must, that had subsequently been modified, which necessitates anoth-
immediately after the measurement, be reduced to the diagram er test, this can be performed using the same conditions as the
or calculated value corresponding to that temperature. first test.
In a simplified form, the pipe wall temperature may be assumed The prerequisite for internal pressure tests that are conducted
to be the arithmetic mean between Ti and TRa (mean pipe wall over extended times or are repeated is that the entire test dura-
temperature). tion does not exceed 100 h, on which Equation (1) is based.
T i + T Ra Particular attention must be paid to the fact that the loading time
T R = --------------------
- Equation (2) of t = 100 h assumed for calculations, i.e. the maximum test du-
2 ration, relates to a permissible test pressure at a defined pipe
Ti Temperature of the testing medium inside the pipe wall temperature. If the correlation between the test pressure and
TRa Temperature at the pipe surface the test temperature changes, this may lead to the shortening of
the maximum test duration to < 100 h. In general, it is necessary
Attention must be paid not only to the influence of the tempera- to avoid any extension to the test duration specified in Table 1.
ture on the test pressure of the plastic piping but also, particularly
in the case of the contraction procedure according to Section 5.1, In order to prevent any damage to the piping during the test, all
to ensuring a pipe wall temperature which is as constant as pos- operations and their associated times must be recorded conti-
sible. nuously and subjected to an accompanying loading analysis.
631
30
PE 80
25
pressure
Prüfdruck [bar]
[bar]
20
zulässigertest
dada/s
/s = =66
Permissible
15 /s = =7.4
dada/s 7,4
/s = =99
dada/s
10
/s = =11
dada/s 11
/s = =1717,6
dada/s ... 17.6
5
10 15 20 25 30 35 40 45 50
oC]
Rohrwandtemperatur
Pipe wall temperature [[°C]
Figure 2. Test pressure curves for piping made of PE 80.
35
PE 100
30
[bar]
[bar]
[bar]
pressure
25
Prüfdruck
Prüfdruck
dda/s
a/s = 66
20
zulässigertest
zulässiger
dda/s
a/s = 7,4
7.4
Permissible
15
dda/s
a/s = 99
10 dda/s
a/s = 11
11
dda/s
a/s = 17,6
17 ... 17.6
5
10 15 20 25 30 35 40 45 50
Rohrwandtemperatur
Rohrwandtemperatur
Pipe [oC]
[°C]
wall temperature[°C]
Figure 3. Test pressure curves for piping made of PE 100.
632
35
PP-H
30
PP-B
[bar]
pressure[bar]
PP-R
25
Prüfdruck
20
zulässigertest
da/s = 6
da/s
Permissible
da/s = 7.4
da/s 7,4
15
da/s = 9
da/s
10 da/s = 11
da/s
da/s = 17,6
da/s 17 ... 17.6
5
10 15 20 25 30 35 40 45 50
Rohrwandtemperatur
Pipe wall temperature [°C] [oC]
Figure 4. Test pressure curves for piping made of PP.
35
PVC-C
[bar]
30
[bar]
PVC-U
pressure
25
Prüfdruck
20 da/s ==99
da/s
zulässiger test
15 da/s ==11
da/s 11
Permissible
10 da/s ==13.6
da/s 13,6
da/s ==21
da/s 21
5
da/s ==34.4
da/s 34,4
0
10 15 20 25 30 35 40 45 50
Pipe wall temperature [o[°C]
Rohrwandtemperatur C]
Figure 5. Test pressure curves for piping made of PVC.
633
30
PVDF
25
[bar]
pressure[bar]
Prüfdruck
20
da/s = 17
da/s = 17
zulässigertest
Permissible
15 d /s = 21
a = 21
da/s
da/s = 33
10 da/s = 33
5
10 15 20 25 30 35 40 45 50
Rohrwandtemperatur
Pipe wall temperature [°C] [oC]
Figure 6. Test pressure curves for piping made of PVDF.
8 Standards, rules and regulations that are also applicable 8.1 Literature references
[Klingenfuß (SKZ, Würzburg)]
DIN EN 805 Water supply – Requirements for systems and
Unpublished report on experience with regard to the leak testing
components outside buildings (Section A. 27)
of pressurised piping made of plastic
DIN EN 1610 Construction and testing of drains and sewers
[Hoch, Raab, (3R international, Issue 9/2001)]
DIN EN 837-1 Pressure gauges – Part 1: Bourdon tube pres- Pressure tests on PE piping in the water supply
sure gauges; dimensions, metrology, require-
ments and testing
DIN 1988-2 Drinking water supply systems; materials,
components, appliances, design and installa-
tion (DVGW code of practice)
DIN V 4279-7 Internal pressure testing of pressurised piping
for water – Pressurised pipes made of PE-HD
and PVC-U
DVS 2210-1 Industrial pipelines made of thermoplastics –
Planning and execution – Above-ground pipe
systems
DVGW W 400-2 Construction and testing of water distribution
installations
Explanation of the footnotes in Sections 1 to 7

1) A limitation on the test length results from the necessity of being able to detect and evaluate reactions caused by changes in the test pressure and test
temperature within the test duration. The longer the test length is, the more difficult it is to assign test pressure fluctuations. At test temperatures of
20  5 °C, test lengths > 500 m may also generate usable results. The decision about this must be taken by the test supervisor responsible.
2) DVS Working Group AG W 4.3a has decided to publish guide values for the pressure drop rates of the various thermoplastics on the basis of experi-
mental tests. As soon as results are available, these will be published in the trade press.
3) Processing-specific and geometrical reduction factors are, for example, welded joints with a long-term welding factor fs  0.5 or unreinforced nozzle cut-
outs in the piping. Information about this can be taken from the documents of the fitting manufacturers. If necessary, reduction factors must be
established using common strength calculations.
634
9 Example of the execution of an internal pressure test and

of a test report
The test report template shown in the appendix includes the

essential data that must be documented by the testing agency.
The user is at liberty to make use of this template or other printed
forms. For better understanding of the entries, attention should
be paid to the following example.
9.1 Characteristic data of the piping and test conditions
Pipe dimensions: da = 110 mm, s = 10 mm, SDR = da/s = 11

Piping length: ges LR = 150 m
Geodetic height diifference: Hgeod = 2.5 m  0.25 bar
Material: PE 80
Assumed pipe wall temperature: max. TR = 25°C
Type of test: Preliminary test (PT)  Main test (MT)  Short-term test (STT)
Connection of the testing facility: At the lowest point of the piping
Permissible test pressure of the piping parts According to the diagram According to Table 1: (–) bar
(rounded): on Fig. 2:  13 bar 0.85 ∙ 13  11 bar
Nominal pressure of the valves and installed parts: PN 16 (–) bar
Test pressure at the highest point of the piping: 13 - 0.25 = 12.75 bar 11 - 0.25 = 10.75 bar (–) bar
Test duration according to Table 1: 6h 6h (–) h
Chosen number of inspections: 3 3 (–)
Beginning and end of the test: 7:20 to 13:20 hours 13:20 to 19:25 hours (–) hours
9.2 Information about the timing of the test
Period 1 2 3 4 5 6 7 Unit
Type of test (PT, MT or STT) PT PT PT PT/MT MT MT MT –
Time-related course of the test operations or inspections 7:20 9:20 11:20 13:20/13:25 15:25 17:25 19:25 h:min
Test pressure at the manometer (low point of the line) 13.0 13.0 13.0 12.2/11.0 10.5 10.3 10.3 bar
Pressure change in relation to the previous period – -2.5 -1.0 -0.8/1.2 -0.5 -0.2 0.0 bar
Specific pressure drop – 1.25 0.5 0.4 0.25 0.1 0.0 bar/h
Water addition to restore the test pressure – 6.5 4.1 – – – – l
Water drainage to reduce the test pressure PT/MT Optional l
Water temperature inside the pipe 4) 12 15 16 18 20 19 19 °C
Ambient temperature 15 17 19 22 25 22 20 °C
Pipe surface temperature 12 15 20 28 30 25 20 °C
Mean pipe wall temperature [TR] 12 15 18 23 25 22 19.5 °C
Results of the inspections during the test 5) – lfj nc rtp nc nc nc –
4) On this subject, see the remarks in Section 7.2.
5) If necessary, explain the results on the back.
Explanation of abbreviations:
PT Preliminary test nc No complaints
MT Main test rtp Reduced test pressure
STT Short-time test lfj Leaky flanged joint
635
9.3 Diagram of the variation of the test pressure with time (corresponding to the example on Page 9)
Pressure rise according

Drucksteigerung to Fig.
nach Bild 1 1
Permissible pressure drop
zulässiger Druckabfall (see
(siehe Table 1)
Tabelle Beginn der
Beginning of Hauptprüfung
the main test
End ofEnde
the preliminary test
der Vorprüfung
14
14
12
12
10
10
[bar]
pressure[bar]
88
Prüfdruck
If at all possible
möglichst < 5 min< 5 min
66
Test
44
22 Evaluation of the test pressure: because the pressure drop rates become
lower in stages, it can be assumed that there are no leaks in the pipe system
00
0 0 1 1 2 2 3 3 4 4 5 5 6 6 [Std] [Hours]
7.20 7.20 9.20 9.20 11.2011.20 [Uhr][Hours]
13.2013.20
Time-related course of the test
zeitlicher Verlauf der Prüfung
Figure 7. Schematic variation of the test pressure during the preliminary test.
Lowering of the test pressure

Prüfdruckabsenkung by draining water
durch Wasserablass (see
(siehe Sections
Ziffer 4.1.4 4.2.1)
4.1.4 bzw. and 4.2.2)
Beginning of the main test

Beginn der Hauptprüfung
End of the internal
mit zul Wert
Compare nach
with the Tab. 1 vergleichen
permissible Ende der
value according Innendruckprüfung
to Table 1
pressure test
14
14
12
12
10
10
[bar]
pressure[bar]
88
Prüfdruck
66 Vorprüfung
Preliminary
test
Test
44
Evaluation of the test pressure: the tendency of the decreasing pressure drop
22 seen in the preliminary test continues so that an operationally-safe piping system
may be assumed
00
66 77 8 99 10
10 11
11 12
12 [Hours]
[Std]
13.25 15.25
15.25 17.25 19.25
19.25 [Hours]
[Uhr]
Time-related course
zeitlicher Verlauf der of the test
Prüfung
Figure 8. Schematic variation of the test pressure during the main test.
9.4 General remarks

In the case of plastic piping laid above ground, the entire pipe tion 7.3. Usually, the inspections must be carried out during the
system must be inspected visually, irrespective of the test pres- preliminary test after the test pressure has been restored each
sure values during the test. The number of tours of inspection time. During the main test, an intermediate inspection is sufficient
should be according to the information given in Table 1 and Sec- in many cases.
636
Appendix: Example of test report (test record sheet) template
Internal pressure test on piping made of thermoplastics
Type of test: Preliminary test (PT)  Main test (MT)  Short-term test (STT) 
Test pressure: bar bar bar
Test duration: h h h
Beginning of test: hours End of test: hours Test date:
Designation of the piping:
Customer / principal:
Erector of the piping:
Dimensions / nominal sizes: da = mm s= mm SDR: PN:
Length of the test section: ges LR = m Geodetic height difference: Hgoed = m
Pipe material: Pressure testing device:
Detailed information
Period 1 2 3 4 5 6 7 Unit
Type of test (PT, MT or STT) –
Time of the test operations or inspections h:min
Test pressure at the manometer (low point of the bar
line)
Pressure change in relation to the previous period bar
Specific pressure drop bar/h
Water addition to restore the test pressure l
Water drainage to reduce the test pressure l
Water temperature inside the pipe °C
Ambient temperature °C
Pipe surface temperature °C
Mean pipe wall temperature °C
Results of the inspections during the test *) –
*) For results and explanations, see overleaf
Overall result of the test:
Pass  Test terminated  Test repeated 
Remarks and faults:
Signature of the tester Signature of the test supervisor
637
File:
D:\Eigene Dateien\Kunden\DVS\Ri+Me\2210\teil1_englisch\e2210-1bb3.fm
May 2006

DVS – DEUTSCHER VERBAND Design and execution
FÜR SCHWEISSEN UND Above-ground pipe systems Technical Code
VERWANDTE VERFAHREN E.V. Flanged joints: DVS 2210- 1
Description, requirements and assembly Supplement 3
Contents: clude tank flanges if they are joined with piping in a non-positive-
locking form.
1.1 Remarks about application Any flange nozzles (not connected by piping) on plastic tanks
1.2 Materials with an internal overpressure of p ≤ 0.5 bar must be structurally
2 Components of the flanged joint designed according to the DVS 2205-4 technical code, Supple-
2.1 Welding necks ment 1.
2.2 Neck bushes Special flanges, e. g. in an oval or rectangular shape, are not
2.3 Loose flanges included in the scope of the DVS 2210-1 technical code or its
2.4 Blind flanges supplements.
2.5 Integral flanges
2.6 Special flanged joints The scope of application can only be extended to flanged joints in
2.7 Seals buried piping if loads from outside (e. g. due to the installation
2.8 Bolts location) are considered separately.
3 Assembly of flanged joints
3.1 Joining of the parts 1.2 Materials
3.2 Alignment of the parts
The area of application of Supplement 3 is valid without restric-

3.3 Bolt assembly
tions for pipe systems made of:
4.1 Manufacturers' tests and inspections Polyethylene: PE (PE 80 and PE 100)
4.2 Visual inspection of the flanged joint Polypropylene: PP-H, PP-B and PP-R (Types 1, 2 and 3)
4.3 Internal pressure testing of the piping Polyvinyl chloride: PVC-C and PVC-U
5 Standards, technical codes and regulations which are
Polyvinylidene fluoride: PVDF
also applicable
5.1 Material-related standards Comprehensive parameters and experience relating to their
5.2 Flange standards behaviour when subjected to long-term loads are available for the
5.3 DVS technical codes and technical bulletins thermoplastics named above. Therefore, it may be assumed that
the fundamental principles are the same for these materials.
1 Scope of application The diversity of thermoplastics, with their different material prop-
erties, does not permit the generalisation of all the fundamental
The DVS 2210-1 technical code includes fundamentals for the principles summarised in Supplement 3.
design, calculation, prefabrication and assembly of industrial The behaviour of other thermoplastics, such as ABS, PB or ECTFE,
piping made of thermoplastics and laid above ground. is similar to that of the above plastics but their applicable param-
Supplement 3 describes the fundamental design principles and eters are currently incomplete.
requirements for flanged joints in above-ground piping made of When choosing the seal material, attention must be paid not only
thermoplastics. It should serve to supplement the generic stan- to good ductility but also to the chemical and thermal suitability.
dards (e. g. DIN 16962-4/12, DIN 16963-4/11 and DIN 8063-4 as
well as DIN EN ISO 15493 ff. and DIN EN ISO 10931) with regard When choosing the material for the loose flanges, the loads to be
to the proper application in the construction of plastic piping. This expected on the flanged joint are an essential factor. It must be
supplement will replace Section 5.3.3.3 of DVS 2210-1. guaranteed that the bolting force applied during assembly is
The fundamentals for the dimensioning of flanged joints are dealt maintained permanently, i.e. the flanges subjected to permanent
with in DVS 2210-1, Supplement 4 (under preparation). The loads must have insignificant creep.
recommendations included in Supplement 4 encompass not only If the parameters for determining the material properties and
flanged joints whose dimensions have not yet been standardised behaviour of flanged joints subjected to loads are available for
but also flanged joints whose loading limits should be established any particular application, the fundamental principles specified in
by caculation. Supplement 3 can be used accordingly. This applies, for exam-
ple, to flanged joints in pipe systems made of thermoset plastics.
1.1 Remarks about application
Unless otherwise mentioned, Supplement 3 only deals with those
The application of Supplement 3 is not restricted to certain areas flanged joints whose parts have standardised shapes and dimen-
of use of thermoplastic piping. sions (see Section 5).
The fundamental principles are applicable to all flanged joints
Flanged joints outside the above scope may be subject to other
that are joined in a non-positive-locking form using bolts and a
standards, technical codes and guidelines that are not included in
seal.
the scope of DVS 2210-1. In this case, no or only limited refer-
Supplement 3 deals exclusively with flanged joints that must bear ence may be made to Supplement 3 in order to solve specific
forces from internal pressure loads and/or forces or moments problems. In any case, the user is responsible for the proper use
from the thermal expansion of the pipe system. These also in- of the fundamental principles described in Supplement 3.
638
2 Components of the flanged joint Table 1. Designation of the connecting dimensions.
Below, the essential components of a flanged joint are listed and DN d3 (DIN EN 1092-1) d4 (DIN 2501-1)
described. The flanged joint predominantly used in the construc-
tion of plastic pipe systems using loose flanges is depicted in Fig. 1. Up to DN 150 After PN 40
After PN 10
As from DN 200 After PN 10
Remark: The connecting dimensions according to Table 1 de-

pend on the nominal pressure and do not provide any information
about the load-bearing capacity of the welding neck or of the
flanged joint.
Depending on the strength of the material, the welding neck with
associated dimensions related to the nominal pressure can, if
necessary, be subjected to an internal overpressure p > nominal
pressure. In applications above the nominal pressure, calcula-
tional proof must be provided or a manufacturer's certificate
obtained.
2.2 Neck bushes

Neck bushes (Fig. 3) are joined to the pipe using an overlap joint.
Depending on the properties of the material concerned, the joint
can be formed by means of heated tool sleeve welding or
adhesive bonding.
Shell
Figure 1. Standard flanged joint with loose flanges.

Ring
2.1 Welding necks
Necks with welding ends, generally called welding necks, can be
joined with the pipe using both the heated tool butt welding
process (HS) and the electrofusion welding process (HM) – this
applies mainly to PE but also to PP. Necks with short (HS) and
long (HS and HM) welding ends are available for this purpose.
Standardised dimensions for welding necks are specified in DIN Figure 3. Neck bush.
16962-4, DIN 16963-4 and DIN EN ISO 10931. The standardisa-
tion of the welding necks does not cover all pipe series. There- Standardised dimensions for neck bushes are given in DIN
fore, dimensional requirements outside standardised specifica- 8063-4, DIN 16962-12, DIN 16963-11, DIN 16832-1 and DIN EN
tions must be made for applications with higher internal pres- ISO 10931. With regard to the designation of the connecting
sures (see also Section 2.6). dimensions of neck bushes and their internal pressure capacity,
In this respect, it must be ensured that the diameter of the neck attention must be paid to the information in Section 2.1.
shoulder, d3, remains within the dimensional limits specified in
DIN EN 1092-1 (Fig. 2). 2.3 Loose flanges
Loose flanges are supported on the ring of the welding neck or
The connecting dimension, d4, of the standardised welding the neck bush and must exhibit a sufficient bending stiffness
necks, classified according to nominal pressure, should comply when the bolting forces are applied. In addition, attention must be
with DIN 2501-1 with the designation according to Table 1. paid to their corrosion resistance, depending on the application.
It is possible to manufacture loose flanges from solid plastic if the
material strength permits economically viable dimensioning (e. g.
d4 loose flanges made of glass-fibre-reinforced plastic or PVC). The
d3 combination of a plastic flange with an insert made of steel or
cast iron has proven to be suitable due to its low deformation.
d
The standardisation of loose flanges for welding necks and neck
Schale
Shell bushes made of plastic is based on the dimensions in
DIN EN 1092-1, "Steel flanges, PN 10".
2.4 Blind flanges

Ansatz
Shoulder Blind flanges are used to shut off a section of pipe and permit the
subsequent continuation of an existing line. Blind flanges analo-
Ring gous to Shape A (without a sealing strip) in DIN EN 1092-1 are
Ring predominantly used in the construction of plastic pipe systems. In
this case, the load-dependent thickness of the flange is deter-
mined mainly by the strength of the material used. As in the case
of loose flanges, various materials and material combinations are
Figure 2. Welding neck. used.
639
During the operation of the pipe system, blind flanges frequently 2.5 Integral flanges
come into contact with the medium being transported. It is there-
In valve, tank and apparatus construction integral flanges are
fore advantageous to use blind flanges made of the same materi-
preferred rather than a neck and a loose flange. In addition to the
al as is used for the piping. If plastic blind flanges that are not
information about welding flanges in DIN EN 1092-1, dimensions
standardised are used, the flange thickness must be dimen-
for integral flanges made of plastic can be found in the supple-
sioned according to the stresses from internal overpressure.
ment to DVS 2205-4. The dimensions begin at DN 500 and apply
Plastic blind flanges can be equipped with connecting nozzles for to a maximum operating overpressure of 0.5 bar.
pressure tests, venting or for the attachment of sampling valves.
At higher operating overpressures or for integral flanges < DN 500,
the flange thickness can be dimensioned according to DVS
2205-4. Integral flanges are usually designed for the same load-
bearing capacity of the pipe. The bolt-tightening torques to be
applied are given in Table 5.
Integral flanged joints can be equipped with either a flat seal or
an O-ring seal. Variants with a shimmed or integrated steel disc
keep the deformation of the plastic integral flange within permis-
sible limits (Fig. 7).
Connecting dimension = DN
s
von DN = d
dimension
on DN
ds
Anschlussmaß = DN
s
Depending =on
Metallic
metallischer Integral
Festflanschflange
aus
abhängig von
Figure 4. Blind flange with an optional connecting nozzle.
welding flange made of plastic
Anschlussmaß
Vorschweißflansch Kunststoff
Depending
abhängig
A combination of a plastic blind disc (protective function) and a
Connecting
shimmed steel flange (load-bearing function) has proven to be

suitable for high internal pressures or large nominal diameters
(Fig. 5).
Blind disc
made of plastic
Figure 7. Plastic integral flange for connections to metallic piping

with the same inside diameter.
Blind flange
Plastic integral flanges with an integrated or shimmed steel disc
made of steel
are suitable, in particular, for connection to metallic piping or
valves with the same inside diameter. Piping parts with different
nominal diameters can be joined in this way. This is made possi-
ble by adjusting the plastic integral flange to the dimensions of
the connecting steel flange.
In the case of piping with nominal diameters ≥ DN 200, there is
misalignment of the inside diameters between flanged joints
Figure 5. Blind disc made of plastic with a protective function.
using metallic welding flanges and a standard neck made of
plastic and a loose flange. This is extremely unfavourable from a
One additional possibility of using blind discs made of plastic is hydraulic viewpoint.
shown in Fig. 6. The supporting effect of the counterflange is
used so that the blind disc can reliably bear the internal pressure Fig. 7 shows how the inside diameters can be adjusted without
loads. misalignment using the integral flanged joint.
2.6 Special flanged joints

In the case of internal pressures above the nominal pressure or
at a higher operating temperature, design-related measures for
stiffening the flanged joint may be necessary in order to prevent
the thermoplastic from deforming. For this purpose, the manufac-
Blind disc that can be turers of necks, neck bushes and loose flanges provide an exten-
subjected to loads sive range of special products, some of which are described
below.
2.6.1 Flanged joints with optimised dimensions

In the case of the standardised flanged joint (Fig. 1), a gap can
be seen between the loose flange inside diameter [d6] and the
neck shoulder diameter [d3]. The unsupported neck region may
deform when it is subjected to high internal pressures, which may
Figure 6. Blind disc made of plastic that can be subjected to loads. lead to leaks at the flanged joint.
640
Fig. 8 shows how the bending stiffness of the flanged joint can be 2.6.2 Flanged joints with chambered necks
improved by changing the shape of the neck and adapting it to
Another method of increasing the load-bearing capacity of
the standardised loose flange.
flanged joints is to encapsulate the welding neck with the aid of a
Further optimisation of the dimensions not only increases the re- positive-locking loose flange. This can counteract the neck ring
sistance moment of the neck but also increases the contact area deformation during the tightening of the joining bolts and keep
between the neck and the loose flange. This leads to a reduction this within permissible limits.
in the interface pressure.
2.6.3 Flanged joints with special loose flanges
In order to achieve a more uniform interface pressure, it is possi-
ble to increase the number of bolts and, at the same time, reduce The standard flanged joint may also be improved by modifying
the bolt size. the standard loose flange shape according to DIN EN ISO 15493
or DIN EN ISO 15494 in order to increase the tilting stability of
the loose flange and achieve a more uniform force distribution at
the neck.
2.6.4 Flanged joints without a seal

Because of the elasticity of some thermoplastics, flanged joints
may be used without a seal subject to certain conditions. Such
(Standard)
flanged joints must not only have distinctly smooth sealing faces
(Standard)
but must also be assembled carefully using mechanical screw-

vergrößert
Enlarged
d4
drivers (Classification I in Table 4). The applicability of the

(+)
flanged joints without a seal is limited and requires a prior suit-

(Enlarged)
(vergrößert)
ability test.
d3
d
2.6.5 Flanged joints at butterfly valves

Enlarged
vergrößert
(Enlarged)
(++)
(vergrößert)
When installing butterfly valves in thick-walled thermoplastic pipe

d4
systems, it must be ensured that the valve disc can be opened

totally without hitting the inside of the pipe.
If possible, butterfly valves that are adapted to plastics and
whose valve disc is adjusted to the reduced inside diameter of
the pipe should be utilised.
Necks with funnel-shaped bevels may be used as an alternative,
providing the bevelling is carried out properly (no notches or
grooves) and the neck is not weakened (preservation of the
resistance moment). If necessary, calculational proof should be
Figure 8. Increase in the bending stiffness by changing the shape of the carried out to prove that this is the case.
welding neck (analogous to DIN EN ISO 15494).
The installation of adapters upstream and downstream of the
butterfly valve is complicated but is another alternative.
Fig. 9 shows another approach, where as well as the loose
flange, the dimensions of the neck are also optimised. This
increases the contact area between the neck and the loose 2.7 Seals
flange, leading to a reduction in the interface pressure. Taking account of the operating conditions and the sealing forc-
es, the selection of suitable flange seals in thermoplastic piping is
dependent on the following factors:
– shape
– dimensions
– material
2.7.1 Shape of the seal

The seal may be formed as a flat ring, a profiled ring, an O ring,
or a combination of the above shapes. The conventional flat seal,
with minimum thicknesses according to Table 3, is adequate for
most applications. If a wide flat seal is used, it must be ensured
(verringert)
66
(Enlarged)
that the bolting forces applied for the preliminary deformation of

or dd
dd4 4
the seal do not cause an overloading of the welding neck or the

dd33 bzw.
dd
neck bush.
Profiled flat seals, as well as the O-ring seal, have proven to be
suitable at increased operating and testing pressures. For stabili-
sation and to prevent blowing-out, the seal may be reinforced
with a steel flat ring. However, the reinforcement must not influ-
ence the elasticity on the inside of the seal. Seals can be used
The profiled seal and O-ring seal offer the following advantages:
– reliable leak tightness with low bolt-tightning torques
– can be used at higher internal pressures and with an internal
partial vacuum
– reduced influence of the flange or neck surface
Figure 9. Improving the load-bearing capacity by adjusting the dimen-
sions of the loose flange and the welding neck. – safety when joining piping made of different materials
641
Table 2. Operational limits for seals. 2.8 Bolts

According to DIN 2501-1, bolt dimensions and the number of
Seal Recommended opera- Flange and neck design bolts for flanged joints are stipulated depending on the nominal
shape tional limits pressure.
Flat ring p up to 10 bar for With sealing grooves * Due to the high strength of the bolt material and the limited inter-
DN ≤ 150 nal pressure resistance of thermoplastic piping, the bolting forces
p up to 6 bar for Seal width: used are usually significantly below the maximum permissible
DN > 150 - 600 Depending on the permis- value. For this reason, the bolt quality is less significant than in
T up to 40°C sible loads on the neck the case of metallic piping. More stringent requirements are,
however, frequently set on the corrosion resistance of the bolts.
Profiled p up to 16 bar With or without sealing
flat ring All nominal widths grooves * The bolt tightening forces on flanged joints in thermoplastic pip-
All temperatures within ing are influenced more by ambient and operating temperatures
the range of application * concentric arrangement as well as by the material behaviour than for metallic piping.
O ring General use Groove dimensions: The above factors require multiple checking and retightening of
p = -1 to 16 bar the bolts during ,and on completion of the, pressure test, and if
DIN 8063-4 necessary, also after commissioning the pipe system.
All temperatures within DIN 16962-4
the range of application DIN 16963-4
3 Assembly of flanged joints
2.7.2 Dimensions of the seal
With regard to the assembly of flanged joints, particular attention
The seal dimensions are stipulated in the generic standards for must be paid to the following remarks.
pipe joint parts (see Section 5). Greater dimensional differences
between the inside diameter of the welding neck or neck bush 3.1 Joining of the parts
and the inside diameter of the seal may, in certain circumstanc-
es, lead to disturbances at the flanged joint. Deviations in the in- The construction length of the neck must be taken into consider-
side diameter of the seal greater than ± 10 mm are not accept- ation when welding necks are joined to the pipe using the HS
able. process. For short welding necks that do not have sufficiently
long cylindrical ends for clamping, welding machines with a neck
If the seals have excessive inside diameters, there is a danger holder must be used, if possible. In particular, this applies when-
that deposits will accumulate in the annular gap (dead space), ever, due to space constraints, the loose flange has to be pushed
which may lead to a concentration of the medium at the seal and over the neck before welding.
premature failure. If the seal protrudes into the pipe, this may
cause accelerated wear on the inside of the seal and reduced When integral flanges are welded on, it must be ensured that the
sealing capability. bolt holes are arranged in such a way that they are symmetrical
to both main axes of the pipe (Fig. 10).
The outside diameters of seals are standardised (e. g. DIN EN
1514-1). The minimum thicknesses of flat seals are given in
Table 3. The thicknesses of profiled seals are specified by the 3.2 Alignment of the parts
manufacturer. Ideally, the welding neck, the neck bush or the integral flange, the
seal and the loose flange should be aligned centrally with the
Table 3. Minimum thicknesses of flat seals. pipe axis. When aligning the seal, it must be checked whether the
seal dimensions conform to the outside and inside diameters of
the welding neck or neck bush.
Nominal width Thickness of flat seals
Before the bolts are tightened, the sealing faces of the welding
Up to d 90 / DN 80 s ≥ 2 mm neck, the neck bush or the integral flange must be located paral-
≥ d 110 / DN 100 s ≥ 3 mm lel to each other and must be in close contact with the seal.
Adjusting the position of the sealing faces by means of bolt
pretensioning using a spanner is not permissible.
2.7.3 Seal materials
In the case of piping sections with a horizontal course, the bolt
When choosing a seal material, it is necessary to take account of alignment shown in Fig. 10 is recommended since the medium
the medium, the operating conditions, the properties of the seal being transported would not run directly over the bolts if there
material, the shape and surface finish of the sealing face as well were any leaks at the flanged joint.
as the loads on the flanged joint.
In plastic piping, preference should be given to the use of seals
made of elastomer materials such as EPDM, CSM or FPM with a
Shore A hardness up to 70°. Seal materials with a higher hard-
ness (e. g. as used in metallic piping) are often not suitable for
thermoplastic piping.
If seals with a particular chemical resistance (e. g. made of PTFE)
and whose preliminary deformation requires bolt-tightning
torques above the values specified in Table 5 are to be used, it is
recommended to consult the moulding manufacturer. If in doubt,
the operational safety of the flanged joint must be proven. Figure 10.
Alignment of the bolts outside
An operationally-safe seal with effective chemical resistance can
both the main axes.
be achieved by using modified PTFE seals. The properties of
multidirectionally-oriented seals made of expanded PTFE (ePTFE)
allow good conformity to the sealing faces with low bolting forces. 3.3 Bolt assembly
Seals with reinforcement can only be used if the load-bearing The length of the bolts must be chosen in such a way that the bolt
part is completely surrounded by the seal material. Due to their thread protrudes over the nut by no more than two to three thread
high preliminary deformation forces, fabric-reinforced elastomer turns. Washers must be placed not only at the bolt head but also
seals tend to be unsuitable for flanged joints in plastic piping. at the nut.
642
In order to aid the smooth tightening of the bolts as well as loos- Table 5. Bolt-tightening torques for assembling flanged joints using
ening after being in service for a long time, the thread and all elastomer seals and a friction coefficient, ges µ = 0.15.
friction faces must be provided with an anti-seizing agent (e. g.
molybdenum sulphide). Bolt-tightening torque [Nm]
The bolts must be tightened diagonally and uniformly, ideally Nominal
diameter Flat ring Profiled ring O ring
using a torque-controlled mechanical or impact screwdriver. (guide values) (guide values) (guide values)
DN
zul p ≤ 10 bar zul p ≤ 16 bar zul p ≤ 16 bar
3.3.1 Bolting force
15 10 10
After the assembly of the flanged joint, the bolting force and the
resulting torque, under the influence of setting and creep 20 15
phenomena, must not be less than the minimum value in order to
ensure that a seal is achieved. The tightening process deter- 25
15 15
mines the scatter of the bolting force [FM] between FM min and 32 20
FM max (Table 4).
40 30
FM min = lower value of the bolting force
FM max = upper value of the bolting force 50 35
Scatter = difference between the lower and upper values of the
bolting force 65
20 20
Due to the significant scatter during the tightening processes 80 40
according to Classifications III and IV, it is not recommended that 100
these are applied to a flanged joint.
125 50 30 25
Table 4. Guide values for the scatter of the bolting force. 150 60 35 30
200 70 40 35
Classi- Scatter Tightening process
fication 250 80 50 40
I ±5% Mechanical screwdriver, controlled accord- 300 100 60 45
ing to the rotating angle, motor-driven or
350 100 70 50
manual
400 120 80 60
II ± 20 % Mechanical screwdriver, torque-controlled
500 190 90 70
III ± 40 % Impact screwdriver, manual, with torque
control 600 220 100 80
IV ± 60 % Impact screwdriver, manual, without torque zul p = permissible operating overpressure
control
= zul p ≤ 6 bar
3.3.2 Bolt-tightening torques
Remarks about Table 5:
The necessary bolt-tightening torque is dependent on the shape
and material of the chosen seal as well as on the friction in the The specified bolt-tightening torques result in compressive
screw thread and at the nut contact face [ges µR]. A friction coef- stresses in the seal, Qeff, up to 8 N/mm2. If the guide values for
ficient, ges µR = 0.15, may be expected for average (normal) the flat ring seal are exceeded (scatter) by > 20 %, this may lead
conditions. to permanent damage of the flanged joint.
The bolt-tightening torque to be applied during the preliminary If the seal manufacturer stipulates lower torques than those in
deformation of the seal must generate a compressive stress of Table 5, these should not be exceeded. Using the correct proce-
Qmin ≥ 0.5 N/mm2 in the elastomer seal. Below this minimum dure and torque-controlled tools, leak tight flanged joints can be
compressive stress, the leak rate may be exceptionally high and achieved using only 80 % of the guide values specified in Table 5.
non-uniform.
If excessive torques are applied, not only may the seal be dam- 4 Tests and inspections
aged but the welding neck, the neck bush and the loose or inte-
gral flange may also be subjected to unacceptable stresses. The 4.1 Manufacturers' tests and inspections
guide value for the maximum compressive stress in an elastomer
The components of a flanged joint must satisfy the quality re-
seal is approx. Qmax = 10 N/mm2, depending on the width-to-
quirements according to the respective standards. In addition to
thickness ratio of the seal (DIN EN 1591-2).
the single-part tests and inspections, the tests and inspections on
In most cases, the consequence of excessive compressive the completed flanged joint must also be carried out. The require-
stress in the elastomer seal is long-term deformation on the neck ments of the tests and inspections, for the different plastics used,
or the neck bush, resulting in a reduction in operational safety. can be taken from the standards listed in Section 5. The loading
limits generated from the tests and inspections must be docu-
Upper limiting values for bolt-tightening torques when using elas-
mented.
tomer seals and as-new bolts provided with anti-seize agent are
given in Table 5. 4.2 Visual inspection of the flanged joint
The visual inspection is concerned with the condition of the
flanged joint parts before and after installation. Particular atten-
tion must be paid to the following:
– undamaged and flat sealing faces
– parallel faces of the attached welding necks or neck bushes
– gap dimension between the sealing faces before the seal is
inserted
643
– checking the integrity of the seal 5.2 Flange standards

– concentricity of the loose flange and the seal DIN 2501-1 Flanges and connecting dimensions
– dimensional congruence between the seal and the inside DIN 16872 Pipe joints and piping parts for piping made of
diameter of the pipe thermoplastics; flanges made of glass-fibre-
– correct bolt length reinforced polyester resins (UP-GF); dimen-
sions
– use of plain washers at the nut and bolt head
DIN EN 1092-1 Flanges and their joints – Circular flanges for
– checking that an anti-seize agent has been used pipes, valves, fittings and accessories, PN
– isolated checking of the bolt-tightening torques designated – Part 1: Steel flanges
DIN EN 1514-1 Flanges and their joints – Dimensions of gas-
4.3 Internal pressure testing of the pipe system kets for PN-designated flanges – Part 1: Non-
The completed pipe system must be tested according to the metallic flat gaskets with or without inserts
DVS 2210-1 technical code, Supplement 2. All flanged joints DIN EN 1514-8 Flanges and their joints – Dimensions of gas-
must be included. If necessary, the bolts must be retightened kets for PN-designated flanges – Part 8: Poly-
after the internal pressure has been relieved. meric O-Ring gaskets for grooved flanges
DIN EN 1515-2 Flanges and their joints – Bolting – Part 2:
Classification of bolt materials for steel flanges,
5 Standards, technical codes and regulations that are also
PN designated
applicable
DIN EN 1591-1 Flanges and their joints – Design rules for
5.1 Material-related standards gasketed circular flange connections – Part 1:
Calculation method
DIN 8063-4 Pipe joints and piping parts for pressurised pip-
ing made of unplasticised polyvinyl chloride DIN EN 1591-1 Flanges and their joints – Design rules for gas-
(PVC-U); necks, flanges and seals; dimensions Supplement 1 keted circular flange connections – Back-
ground information
DIN 8063-5 Pipe joints and fittings for pressurised piping
made of unplasticised polyvinyl chloride DIN EN 1591-2 Flanges and their joints – Design rules for gas-
(PVC-U) – Part 5: General quality requirements, keted circular flange connections – Part 2:
tests and inspections Gasket parameters
DIN 16832-1 Pipe joints and fittings for pressurised piping
made of chlorinated polyvinyl chloride (PVC-C) – 5.3 DVS technical codes and technical bulletins
PVC-C 200 – Part 1: Dimensions DVS 2205-4 Calculation of tanks and apparatus made of
DIN 16962-4 Pipe joints and piping parts for pressurised pip- thermoplastics – Flanged joints
ing made of polypropylene (PP); Types 1 and 2; DVS 2205-4, Calculation of tanks and apparatus made of
necks for heated tool butt welding, flanges and Supplement thermoplastics – Welding flanges and welding
seals; dimensions necks – Design-related details
DIN 16962-12 Pipe joints and fittings for pressurised piping DVS 2210-1 Industrial piping made of thermoplastics – De-
made of polypropylene (PP), PP-H 100, PP-B 80 signing and execution – Above-ground pipe sys-
and PP-R 80 – Part 12: Necks, flanges and seal- tems
ing rings for sleeve welding; dimensions
DVS 2210-1, Industrial piping made of thermoplastics – De-
DIN 16963-4 Pipe joints and piping parts for pressurised pip- Supplement 1 signing and execution – Above-ground pipe sys-
ing made of high-density polyethylene (PE-HD); tems; calculation example
necks for heated tool butt welding, flanges and
seals; dimensions DVS 2210-1, Industrial piping made of thermoplastics – De-
Supplement 2 signing and execution – Above-ground pipe sys-
DIN 16963-11 Pipe joints and fittings for pressurised piping tems; recommendations for the internal pressure
made of polyethylene (PE), PE 80 and PE 100 – and leak tests
Part 11: Necks, flanges and sealing rings for
sleeve welding; dimensions DVS 2210-1, Industrial piping made of thermoplastics – De-
Supplement 4 signing and execution – Above-ground pipe sys-
DIN EN ISO Plastics piping systems for industrial applica- (under prepa- tems; calculation according to yield strengths
10931 tions – Poly(vinylidene fluoride) (PVDF) – Speci- ration)
fications for components and the system
DIN EN ISO Plastics piping systems for industrial applica- Remark: Only the essential standards are listed here, in order to
15493 tions – Acrylonitrile-butadiene-styrene (ABS), supplement the complexity of subjects dealt with. For any individ-
unplasticized poly(vinyl chloride) (PVC-U) and ual case, it may be necessary to comply with more detailed stan-
chlorinated poly(vinyl chloride) (PVC-C) – Speci- dards, guidelines, technical codes and regulations.
fications for components and the system; Metric
series
DIN EN ISO Plastics piping systems for industrial applica-
15494 tions – Polybutylene (PB), polyethylene (PE) and
polypropylene (PP) – Specifications for compo-
nents and the system; Metric series
644
File:
D:\Eigene Dateien\Kunden\DVS\Ri+Me\2210\teil2_englisch\e2210-2.fm
October 2007
DVS – DEUTSCHER VERBAND Industrial Piping made of Thermoplastics

FÜR SCHWEISSEN UND Design, Structure and Installation Technical Code
VERWANDTE VERFAHREN E.V. of Two-pipe Systems DVS 2210-2
Contents: 5.3.7 Kinking

5.4 Proof of the stresses
1 Scope of application 5.4.1 Proof of the stresses for straight pipe sections
1.1 Areas of application 5.4.2 Proof of the stresses for fittings
1.2 Definitions of terms 5.5 Proof of the strains
1.2.1 Terms 5.5.1 Strain in the X-direction
1.3 Materials 5.5.2 Strain in the Y-direction
1.3.1 Material selection 5.5.3 Safety margin to the limiting strain
1.3.2 Material properties 5.6 Application of Miner's rule
2 Regulations and remarks about applications 5.7 Hydraulic calculations
2.1 European Pressure Equipment Directive 5.8 Explanation of the designations used in Section 5
2.2 Fundamental authorisation and construction principles 6 Structural desig
2.2.1 Two-pipes ystems for the transport of combustible 6.1 Straight pipe pieces
substances 6.1.1 Spacers
2.2.2 Two-pipe systems for the transport of water-polluting 6.1.2 Annular gap
substances 6.1.3 Locking discs
3 Loads on two-pipe systems 6.1.4 Modification of straight pipe pieces

3.1 Loads caused by internal overpressure or an internal 6.2 Bend pieces
partial vacuum 6.2.1 Bend pieces with fixed points
3.1.1 Loads on the internal pipe caused by operating 6.2.2 Bend pieces with supporting shells
overpressure 6.3 Branch pieces
3.1.2 Loads on the internal pipe caused by overpressure in the 6.3.1 Branch pieces with fixed points on all sides
annular space 6.3.2 Branch pieces without fixed points in the main line
3.1.3 Loads on the internal pipe caused by a partial vacuum in 6.3.3 Branch pieces without fixed points in the main or
the annular space connecting line
3.1.4 Loads on the external pipe caused by overpressure or a 6.3.4 Special fittings
partial vacuum in the annular space 6.3.5 Stresses at the internal pipe cut-out
3.1.5 Loads on the external pipe due to overpressure in the 6.4 Reducers
annular space in the event of leaks in the internal pipe 6.5 Adapters and end pieces
(failure case) 6.6 Fittings that limit length changes
3.2 Loads caused by the action of the temperature 6.6.1 Fixed point on the internal pipe (Type A length
3.2.1 Action of the temperature on the internal pipe restriction)
3.2.2 Action of the temperature on the external pipe 6.6.2 Supporting shell on the internal pipe (Type B length
3.3 Loads caused by effects from the transported substance restriction)
3.3.1 Loads caused by swelling-inducing transported 6.6.3 Fixed point on the external pipe (Type C length
substances restriction)
4 Designing criteria and system classification 6.6.4 Fixed point on the internal and external pipes
4.1 Calculated loading duration (Type D length restriction)
4.2 Calculated temperature 6.7 Nozzles in the external pipe
4.3 Assumptions for the loads in the event of failure 6.8 Flanged joints
4.4 System classification and loading categories 6.9 Valves and measuring facilities
4.4.1 Application of the loading categories 6.10 Special fittings
4.4.2 Example of a category classification with identification 7 Processing, preassembly and identification
5 Calculation fundamentals 7.1 Initial products
5.1 Strength calcuations 7.2 Preassembly
5.1.1 Determination of the permissible stress 7.2.1 Prerequisites for preassembly
5.1.2 Determination the pipe wall thickness 7.3 Transport and storage
5.1.3 Determination of the wall thicknesses of mouldings 7.4 Identification
5.2 Elasticity calculations 8 Installation (laying and assembly)
5.3 Proof of the stability 8.1 Laying type
5.3.1 Buckling stress in the circumferential direction 8.2 Laying methods
5.3.2 Buckling stress in the longitudinal direction 8.3 Joining processes
5.3.3 Compressive stresses from an internal partial vacuum or 8.3.1 Welding of piping parts made of PE, PP, PB, PVDF and
external overpressure in the circumferential direction ECTFE
5.3.4 Compressive stresses from loads in the longitudinal di- 8.3.2 Process variants of heated tool butt welding
rection 8.3.3 Adhesive bonding of piping parts made of ABS and PVC
5.3.5 Interaction for circumferential and longitudinal 8.3.4 Hot gas welding
compressive loads 8.4 Fastenings
5.3.6 Critical buckling pressure 8.4.1 Pipe spans
645
8.4.2 Distances between guides demand, extend or restrict the application of this technical code.
8.4.3 Fastening of the external pipe in the region of expansion Remarks about this are included in Section 2.
bends
8.4.4 Fixed points 1.1 Areas of application
8.5 Modifications and repairs to the two-pipe system
Examples of areas of application are:
8.5.1 General measures
8.5.2 Replacement of a defective pipe piece – installations in waste water engineering
9 Quality management, tests and inspections – installations in electroplating technology
9.1 Elements of quality management – industrial and chemical installations
9.1.1 Quality requirements on the fabrication The scope of application does not exclude the extension of the
9.1.2 Quality requirements on the installation technical code to areas not listed above. The contracting parties
9.1.3 Records must reach an agreement on any extended application of the
9.1.4 Training and education technical code.
9.2 Tests and inspections
9.2.1 Visual inspections 1.2 Definitions of terms
9.2.2 Non-destructive test procedures
9.2.3 Destructive test procedures Two-pipe systems within the scope of this technical code are
9.2.4 Inspection of the devices and machines concentric pipe sections that are pushed one inside the other.
9.2.5 Internal pressure test The annular space between the pipes must be gas-tight and
9.2.6 Leak test liquid-tight and should only be used for monitoring purposes.
10 Leak inspection, checking and indicating equipment Pipe systems that are provided with a splash guard or are operat-
10.1 Leak indicators acting without pressure ed in a protective pipe are not covered by the term "two-pipe
10.1.1 Visual inspection equipment systems".
10.1.2 Electrical checking equipment The "two-pipe system" term encompasses all of the elements
10.2 Pressure-triggering leak monitoring systems that are used for constructing a relevant piping installation.
10.2.1 Differential pressure method Double piping can be erected not only using units prefabricated
10.2.2 Gas rinsing procedure in the factory (preassembled) but also by assembling the compo-
10.3 Requirements on inspection, checking and leak nent parts on the building site.
monitoring equipment
10.3.1 Monitoring sections Two- pipe systems are characterised by the fact that the longitu-
11 Commissioning and inspections dinal mobility of the internal pipe section is restricted in the event
11.1 Initial commissioning of a temperature change. In the region of the bend sections, limit-
11.2 Initial inspection ed length changes may be accommodated, depending on the
11.3 Repeated inspection type of two-pipe system used.
12 Documentation
13 Standards, technical codes and regulations 1.2.1 Terms
13.1 DVS technical codes and technical bulletins Internal pipe Internal pipe section for the transport of liquid or
13.2 Regulations (piping) gaseous substances
13.3 Literature references
External External pipe section for the protection of people
14 Appendix
pipe (piping) and the environment in the event of unplanned
leaks in the internal pipe
1 Scope of application Annular Space between the internal and external pipe
space or which, in the event of failure, collects the sub-
This technical code includes fundamentals for the design, dimen- monitoring stances escaping from the internal pipe
sioning and installation of two-pipe systems as well as for the de- space
sign and manufacture of two-pipe components made of thermo- Inspection Part of the two-pipe system according to Section
plastics. Prerequisites for the application of the technical code facility 10.1, which offers the possibility of visually in-
are experience in plastics processing and general piping con- specting the integrity of the internal pipe
struction as well as knowledge about the materials used.
Leak Facility according to Section 10.2 which perma-
The two-pipe systems dealt with in this technical code may be monitoring nently monitors the annular space and auto-
used to transport liquid and gaseous substances. They may be matically signals any leaks in the internal pipe
laid not only inside buildings, ducts and shafts but also outdoors.
The dimensioning of buried two-pipe systems is not dealt with in
1.3 Materials
this technical code as far as external loads are concerned.
With regard to the material selection, consideration must be
This technical code should be consulted during the installation of
given to the following:
two-pipe systems laid both above and below ground, especially
whenever the use of a two-pipe system is specified because of – area of application
particular dangers to people and the environment. Therefore, in – operating conditions
the case of piping for the transport of environmentally-hazardous – the influence of installation and ambient conditions
or toxic substances, an explicit agreement does not have to be – chemical resistance to the substances to be conveyed
made between the customer and the company with regard to the – compatibility of the materials
application of this technical code. – type of joints
Two-pipe systems that serve process engineering purposes If necessary, the suitability of all materials in the system, includ-
(e. g. with coolant in the annular space) are not covered by this ing adhesives, seal materials, and similar items must be proven.
technical code. With regard to the loads on the internal and exter-
The scope of application includes the following pipe materials1):
nal pipes, this application requires a different approach. Separate
attention must be paid to any regulations, fundamental construc- – acrylonitrile butadiene styrene (ABS)
tion, testing and authorisation principles or official conditions that – polybutene (PB)
It should be understood that the material designations are generic terms for one group of thermoplastics in each case. Thermoplastics with abbrevia-
tions according to DIN, EN and ISO standards may be assigned to the material groups according to their properties (e. g. PE includes PE 63, PE 80 and
PE 100 types and PVC-U the -HI, -NI and -RI types). The information provided corresponds to the status of the standardisation at the time of printing.
646
– polyethylene (PE) 2.2.1 Two-pipe systems for the transport of combustible

– polypropylene (PP-H), (PP-B) and (PP-R) substances
– polyvinyl chloride (PVC-C) and (PVC-U)
Two-pipe systems for conveying combustible liquids according to
– polyvinylidene fluoride (PVDF)
the Operational Safety Ordinance (BetrSichV) must be built
– ethylene chlorotrifluoroethylene (ECTFE)
according to the construction regulations in TRbF 50.
This technical code may also be applied to other thermoplastics.
Two-pipe systems for conveying combustible liquids must comply
The prerequisites for the use of the above materials are that the
with the guidelines concerning explosion protection. In general,
characteristic values required for dimensioning and the neces-
the requirements of the Rules of the Employers' Liability Insur-
sary fabrication parameters are available.
ance Association for Health and Safety at Work (BGR 132:
1.3.1 Material selection "Avoiding ignition dangers caused by electrostatic charges") are
applicable.
The material selection for the internal pipe, subjected to the
transported substance (medium), is influenced by the application In the following cases, two-pipe systems must be produced in a
concerned and by the anticipated operating conditions. If the conductive or dissipative form:
double piping is operated outdoors, the external pipe must be – if combustible liquids are conveyed, in order to prevent any
sufficiently resistant to weathering. Moreover, it must, in the ignition danger during filling and emptying
event of failure, be capable of reliably withstanding the action of
the transported substance for a limited duration. – if insulating liquids are conveyed, in order to avoid any damage
to the piping caused by breakdowns due to charging of the
The materials must be chosen by the user in agreement with the liquid
manufacturer of the two-pipe parts or with the fabricator of the
two-pipe system. The agencies that arrange the construction or – where piping is erected within non-explosion-proof areas in
operate a two-pipe system are regarded as the users of the two- Zone 0 or Zone 1 or when crossing them, in order to avoid any
pipe system. ignitions due to charging of the piping
Two-pipe systems are conductive or dissipative if the piping parts
1.3.2 Material properties
are manufactured from corresponding materials and the joint
With regard to the material properties, it makes no difference between the piping parts is also conducting and properly earthed
whether this constitutes a two-pipe system or single pipe system. (see Chapter 3.6, BGR 132).
Therefore, the material properties of the plastics listed in Section
1.3 are not dealt with in this technical code but reference is Crucial variables for the classification of conductive and dissipa-
instead made to Section 3.3 of DVS 2210-1. The information tive materials are the volume resistivity (DIN IEC 60093) and the
from the manufacturers and other relevant literature must be surface resistance (DIN IEC 60093 and DIN EC 60167). The
incorporated into the calcuations for special applications. following assignment is made according to BGR 132:
A substance or material is regarded as conductive if its volume
resistivity is ≤ 104 Ohm ⋅ m or its surface resistance is > 104 Ohm
2 Regulations and remarks about applications
at 50 % relative air humidity and 23°C.
The manufacturers of pipes, fittings, equipment parts etc. as well A substance or material is regarded as dissipative if its volume
as the fabricators of two-pipe systems must check which of the resistivity is > 104 Ohm ⋅ m and ≤ 109 Ohm ⋅ m or its surface
regulations specified below apply to the application concerned or resistance is > 104 Ohm and ≤ 109 Ohm at 50 % relative air
whether other regulations or sets of rules must be complied with. humidity and 23°C.
The respective procedures of the various regulations are not
dealt with in any greater detail in this technical code. If explosion protection can be ensured in a different way (e. g. by
means of suitable inerting, shielding or similar measures), a
2.1 European Pressure Equipment Directive conductive or dissipative two-pipe system is not necessary. The
planning and implementation of explosion protection measures
According to European Directive 97/23/EC (Pressure Equipment
require in-depth expertise and their effectiveness must therefore
Directive (PED)) the manufacturer of a pressure device is, for a
by evaluated and approved by specialists.
permissible internal pressure p > 0.5 bar, required to subject the
device or sub-assemblies to a conformity assessment procedure For underground two-pipe systems buried at depths ≥ 40 cm, the
(PED, Art. 10). A named agency is responsible for carrying out fire protection requirements can be regarded as satisfied.
the conformity assessment procedure (PED, Arts. 12 to 14). Detachable joints and valves in two-pipe systems must be kept
accessible while preserving the double-wall design.
Tanks, piping and equipment parts are covered by the PED. The
piping includes, in particular, pipes, fittings, expansion pieces
and other pressure-maintaining parts. Equipment parts are 2.2.2 Two-pipe systems for the transport of water-polluting
valves, measuring and regulating devices as well as miscella- substances
neous facilities (e. g. leak monitoring), which influence the safety As well as the regulations specified in Section 2.2.1, the legislator
of the system. demands additional measures during the manufacture and
With the Ordinance Concerning the Device and Product Safety construction of piping installations for the transportation of water-
Act (Pressure Device Ordinance - 14. GPSGV), PED is imple- polluting substances (Water Resources Act, WHG, Section 19).
mented in the national law of the Federal Republic of Germany. The following remarks are intended to give an overview of these:
Two-pipe systems that are used in installations for the storage or – The distance between the walls of the internal and external
transportation of water-polluting liquids must be subjected to spe- pipes must be sufficient to guarantee that enough of the leak
cial authorisation conditions if necessary or their suitability must indicating medium passes through and that the substances
be established by a recognised, independent testing agency. escaping in the event of failure are conveyed. The monitoring
space must be equipped with at least one connection each for
2.2 Fundamental authorisation and construction principles the leak indicator and the functional test.
If special authorisation and construction principles that describe – No nozzles or passages that affect the double-wall design may
the particular protection needs of installations for the transport of be fitted in the monitoring space. The leak-tightness of the
combustible and/or water-hazardous substances must be consid- external pipe must ensure a minimum service life as specified
ered in the manufacture and installation of two-pipe systems, in Table 1, Section 4.1.
these must be taken into consideration to a corresponding extent
– It must be ensured that, under basic operating conditions, a
(e. g. fundamental DIBt authorisation principles).
leak at any position in the internal or external pipe is recogn-
Basic regulations are included in Sections 2.2.1 and 2.2.2. ised and indicated by a leak indicating device. It is necessary
647
to use leak indicating devices that have a general construction 3.1.2 Loads on the internal pipe caused by overpressure in
supervisory approval for the applications concerned. the annular space
If a planned overpressure exists in the annular space for the pur-
3 Loads on two-pipe systems pose of permanent leak monitoring, the critical buckling pressure
of the internal pipe must be determined mathematically and
The material properties relating to the action of operational and compared with the operating overpressure in the annular space
external influences must be taken into account during the plan- (proof of the stability).
ning of thermoplastic two-pipe systems. These influences may
result in mechanical, thermal and chemical stresses. During the The permissible overpressure in the annular space is dependent
calculational design of double piping (dimensioning), it is neces- on the wall-thickness-to-diameter ratio (SDR) of the internal
sary to record the loads generated during the testing, assembly, piping. Thin-walled pipes (higher SDR value) are particularly at
operating and failure of the system and their effects. risk from buckling. With Regarding the critical load case, it is nec-
essary to prove a safety margin for the buckling pressure of the
Buried two-pipe systems are exposed to additional external loads internal pipe with Sbeul ≥ 2.0 as well as sufficient stability from the
(soil pressure, traffic load and ground water) whose effect on superimposition of the axial and radial pressures (interaction).
the external pipe requires consideration according to the
ATV-DVWK-A 127 guideline. 3.1.3 Loads on the internal pipe caused by a partial vacuum
in the annular space
3.1 Loads caused by internal overpressure or an internal
partial vacuum If a planned partial vacuum exists in the annular space for the
purpose of permanent leak monitoring, the internal pipe is
The utilisation duration (calculated service life) of the two-pipe subjected to loads from the superimposition (addition) of the
system is mainly influenced by the operating pressure (overpres- operating overpressure and the monitoring partial vacuum. The
sure or partial vacuum) that acts on the internal pipe, together dimensioning of the wall thickness of the internal pipe must be
with the operating temperature. The external pipe may be based on this load case. Lowering of the operating overpressure
subjected to loads due to an overpressure or partial vacuum may be necessary in this case.
existing in the monitoring space. The loading level is dependent
on the type of leak monitoring used. The individual load cases for 3.1.4 Loads on the external pipe caused by overpressure or
the internal and external pipes are described in the following a partial vacuum in the annular space
sections.
If a planned overpressure or partial vacuum exists in the annular
3.1.1 Loads on the internal pipe caused by an operating space for the purpose of permanent leak monitoring, the external
overpressure pipe must be dimensioned according to the loads concerned. In
the case of partial vacuum loads, the external pipe is at risk from
As a rule, the planned overpressure in the internal pipe must not short-term buckling. The proof of buckling resistance must be
exceed the temperature-dependent and time-dependent operat- provided according to Section 3.1.2.
ing overpressure specified in the generic standards for pipes.
Attention must be paid to the safety factors on which the service For a buried two-pipe system, the internal partial vacuum in the
life determination is based. If the permissible limiting values are annular space is superimposed on the external overpressure
exceeded (i. e. in the event of persistant internal pressure over- from the earth and traffic loads as well as, if applicable, from the
loading), this may cause the accumulative expansion of the pipe, ground water pressure in such a way that there is a greater
which may lead to a fracture in the long-term. danger of external pipe instability. This load case must be investi-
gated separately according to ATV-DVWK-A 127.
It must also be borne in mind that the operating overpressures
specified in the generic pipe standards, classified according to 3.1.5 Loads on the external pipe due to overpressure in the
SDR series, only include the pipe mouldings (fittings) if they are annular space in the event of a leak in the internal pipe
designated for the overpressure. In the case of fittings that are (failure case)
not manufactured by injection moulding but instead from semi-
finished products with wall thicknesses according to the SDR If the transported substance enters the annular space in the
series, geometrical influences and fabrication-induced imper- event of a leak in the internal pipe, it must be proven that the
fections may lead to a decrease in the internal pressure loads external pipe can withstand the operational loads for a limited
permissible according to the SDR series. period.
Another restriction on the permissible operating overpressure The loading assumptions and calculation coefficients for the
may result from the bending and thermal stresses (tensile and failure case are given in Section 4.3, Table 3. The dimensioning
compressive) whose effect is superimposed on the longitudinal of the wall thickness of the external pipe should be based on the
stresses from the internal pressure. Their influence on the instal- most severe load case from Sections 3.1.4 and 3.1.5.
lation safety must be determined mathematically and must be Remarks: The investigation into the loads in case of a failure is a
used as the benchmark for the actual permissible operating over- safety consideration and must not be interpreted as
pressure. proof for the continued operation of the two-pipe sys-
It is also necessary to take account of the fact that the internal tem. Corresponding remarks must be attached to the
pipe is often not exposed to a steady operating overpressure but calculations of the required wall thickness or the theo-
instead to a fluctuating operating overpressure. The loading level retical service life.
and duration concerned must be subjected to a separate analy- In the event of a failure in the internal pipe, the piping
sis. Over time, the individual loading sections (average statistical installation must be shut down as quickly as possible.
loads) result in the definitive long-term stresses that permit a In any case, the operating loads must be reduced as
statement about the expected service life for the internal piping soon as the failure is detected and corresponding
(see Section 5.6 and Miner's rule in DVS 2205-1). repair and replacement measures must be taken.
Pressure surge loads may also arise in the internal piping and
these must be investigated mathematically and their effect on the 3.2 Loads caused by the action of temperature
operational safety of the system must be assessed. Priority
The permissible internal or external overpressure on the two-pipe
should be given to reducing or avoiding pressure surges by tak-
parts caused by the temperature-dependent strength behaviour
ing design-related measures.
of thermoplastics falls as the operating temperature rises. During
Example: Two-pipe systems whose internal piping is operated the dimensioning of the pipe system, particular consideration
using a pump should not contain any quick-acting must be given to length of time the system is at each tempera-
shut-off valves (e. g. ball cocks). ture.
648
3.2.1 Action of temperature on the internal pipe 3.3.1 Loads caused by swelling-inducing transported
substances
Assuming that the internal piping in the two-pipe system is not
mobile in the longitudinal direction (axiall- clamped condition), the Subject to certain prerequisites, two-pipe systems made of ther-
operationally-induced temperature changes lead to tensile or moplastics are suitable for the transport of swelling-inducing
compressive stresses in the pipe wall cross-section. If compres- substances. In order to ensure that the pipe system operates
sive stresses arise, the compression of the internal pipe is without any problems, this case must be considered in detail
combined with the danger of buckling vertical to the longitudinal before the application, supported by investigations into the long-
pipe axis. term effect on the material behaviour.
The application limits of the axially-clamped internal piping are
stipulated by the permissible tensile or compressive stress as In particular, it must be determined what influence the solvent
well as by the critical strain or compression. In addition to the has on the pipe guides, the distances between them and on the
stress analysis, it is also necessary to prove stability against stability of the internal piping. The characteristic mechanical
buckling, with Sk ≥ 2.0 (see Section 5.3). values reduced by swelling (strength and creep modulus) must
be used in the calculational proof.
3.2.2 Action of temperature on the external pipe In order to establish the strength values, investigations must be
The effect of temperature on the external pipe is dependent on conducted on two-pipe parts using the transported substance
whether the two-pipe system is operated inside or outside build- concerned. For example, two-pipe parts can be installed in an ex-
ings. For a buried two-pipe system a generally consistent temper- isting pipe system in order to record their behaviour in operating
ature of the external pipe should be expected. conditions. If there are no adequate test results or information
about the effect of the transported substance on the material
In the case of a two-pipe system, it cannot be ruled out that the
properties, it is not possible to prove that the application is safe.
temperature of the external pipe will not have an effect on the
Here, it is definitely advisable to carry out immersion tests in
internal pipe. For each particular application, the extent the oper-
order to establish the saturation curve as well as the influence of
ational safety of the two-pipe system is influenced by tempera-
the substance on the strength, strain and elastic modulus of the
ture differences between the internal and external pipes must be
plastic concerned.
checked. In this respect, attention must also be paid to the
temperature differences when two-pipe parts are stored or when The calculated effects of swelling on the operational safety of
the double piping is not in operation. double piping are dealt with in Sections 5.2 and 5.3 as well as in
Unless any particular proof must be provided, the dimensioning DVS 2210-1, Section 4.1.3. Design-related data regarding the
of the external pipe can be based on the temperature information effects of solvents are given in Section 6.
in Table 2, Section 4.2.
3.3 Loads caused by effects from the transported 4 Design criteria and system classification
substance
Thermoplastics are more resistant to a large number of transport- Two-pipe systems must be designed for the required service life.
ed substances, particularly chemicals, than metallic materials. This applies to all the parts of the system. This includes not only
However, some transported substances (e. g. solvents) may the periods where the system is in operation but also times where
cause changes to the material properties of some thermoplastics, the system is not under load (e. g. shut-downs). The effects of
for example, a reduction in strength and/or stability resulting from the transported substance on the material behaviour must be
oxidation or swelling. related to the effective overall service life.
Furthermore, stress cracking may occur due to the simultaneous The effective service life of double piping is not the same as the
influence of certain transported substances and mechanical theoretical service life, which is specified as 25 years in
loads. Information on transported substances that generate DVS 2210-1, Section 4.2. This relates exclusively to the definition
stress cracking are included in the documents from the manufac- of the material parameters and the difference between short-time
turers of the raw materials and the semi-finished products. and long-term behaviour.
The relevant supplements to the generic pipe standard con-
cerned provide an initial indication of the resistance of the material During thecalculations for two-pipe components, either uniform
to the transported substances. loads must be assumed over the required effective service life or
different loads and their effective duration (cumulative consider-
Dimensioning of the plastic piping requires a term that takes ation) must be taken into account.
account of the effect on the strength behaviour of the material
(reduction factor for the transported substance). Data about this For reasons relating to operational safety, it is necessary to
are included in DVS 2205-1, the DIBt media list or information assume a mathematical minimum loading duration (minimum
from the manufacturers. service life). Recommendations about this are given in Table 1.
649
4.1 Calculated loading duration
Table 1. Minimum service life for double piping.
Loads Operating Monitoring pressure Temperature Failure case

overpressure
Remarks about The maximum value Overpressure or partial Operating temperature or Full loads3) Reduced
the loads >>> must be estimated1) vacuum ambient temperature loads4)
Internal pipe Min. loading duration Min. loading duration Min. loading duration 4.4 . 104 h – –
4.4 . 104 h (≥ 5 years) 4.4 . 104 h (≥ 5 years) with calculated wall temperature
according to Table 2
External pipe – Min. loading duration Min. loading duration 4.4 . 104 h ≥ 72 h ≥ 3 months
4.4 . 104 h (≥ 5 years) with calculated wall temperature
according to Table 22)
Explanations:
Fluctuations between min. and max. values may only be taken into consideration in the case of service lives ≥ 10 years.
Assuming the operating temperature in the internal pipe has an influence on the external pipe temperature, it is necessary to assume the worst-case
average statistical temperatures in each case.
The full loads correspond to the operating conditions of the internal pipe.
Reduced loads exist when, for example, the operating temperature is lowered by adding cold water. The specified service life also applies to two-
pipe systems whose leak indicating device is linked to the pump generating the operating overpressure in such a way that this device switches off
the pump immediately after the alarm signal and thus relieves the loads on the external pipe.
Table 2. Minimum loading temperatures for double piping.
System application Calculated wall temperature Calculated wall temperature

Internal pipe1) External pipe1)
Type of design >>> Strength Stability Strength Stability
Column (i = internal, a = external) >>> 1i 2i 3i 1a 2a 3a
theroretical service life >>> ≥ 5 to > 10 years Independent ≥ 5 to > 10 years Independent
10 years 10 years
Above-ground two-pipe systems outdoors max. TB mittl TB max. TB 0.5 x max. TB 0.5 x mittl TB 0.5 x max. TB
min. 30°C min. 20°C min. 30°C min. 50°C min. 30°C min. 50°C
Above-ground two-pipe systems in frost- max. TB mittl TB max. TB 0.5 x max. TB 0.5 x mittl TB 0.5 x max. TB
free rooms min. 30°C min. 20°C min. 30°C min. 40°C min. 20°C min. 40°C
Buried two-pipe systems max. TB mittl TB max. TB 0.6 x max. TB 0.6 x mittl TB 0.8 x max. TB
min. 25°C min. 20°C min. 25°C min. 20°C min. 20°C min. 20°C
Two-pipe systems laid in a concrete duct max. TB mittl TB max. TB 0.6 x max. TB 0.6 x mittl TB 0.8 x max. TB
or partially covered min. 25°C min. 20°C min. 25°C min. 30°C min. 25°C min. 30°C
Explanations:
mittl T = average operating temperature of the transported substance = 0.5 (max T + min T )..
4.2 Calculated Temperatures effect the operating temperature has on the mean long-term wall
temperature of the external pipe surrounded by the earth.
When designing two- pipe systems, it is necessary to take
account of the effective wall temperatures of the internal and If the information available about the variation of temperature
external pipes. Due to the poor thermal conduction of plastics, a with time is not very precise, the calculated wall temperatures
short-term increase in the operating temperature does not lead to specified in Table 2 can be used.
an equivalent change in the pipe wall temperature. A similar
situation applies to the calculated wall temperature of the exter-
nal pipe. 4.3 Assumptions for the loads in the event of failure
For extremely fluctuating operating temperatures (∆ϑ ≥ 30 K), it With regard to failure of the internal pipe, the assumptions for the
is recommended to make a separate heat transfer calculation in proof of the strength of the external pipe according to Table 3
order to establish the effective pipe wall temperatures. Particular- may be made in association with the information in Sections 4.1
ly in the case of buried double-piping, it must be determined what and 4.2.
650
Table 3. Calculation coefficients for the failure case.
Loading duration t(Leck) T(Leck) ∆ϑ(Leck) p(Leck) SB(Leck) A2(Leck) A4(Leck)

t(Leck) ≤ 72 h max. TB min. 40°C max. TB – TU1) max. pB 1.0 1.0 1.0
72 h < t(Leck) < 3 Months 0,5 . max. TB min. 40°C max. TB – TU1) max. pB 1.25 1.12) 3)
Explanations:
For the ambient temperature, T ≤ 5°C must be used with above-ground two-pipe systems outdoors and T ≤ 10°C for two-pipe systems in frost-
free buildings.
A = 1.0 may be used if A < 1.20.
A according to DVS 2205-1, Table 2 or supplements.
If stability considerations are to be made for the laying of the external pipe (e. g. in the case of axial clamping), 2.0 must be used instead of
S =S . The values specified in Table 3 apply to A .
Table 4. Classification of the two-pipe systems according to loading categories.
Column A Column B Column C

Loading Operating mode Permissible operating Permissible operating Temperature difference
category overpressure temperature during operation
pü TB ∆ϑ 1)
I After commissioning, According to the information According to the information According to the information
quasi-steady temperature from the manufacturer; from the manufacturer; from the manufacturer;
and internal pressure min. 0.1 bar and max. 0,5 bar min. 20°C and max. 40°C min. 10K and max. 20 K
loads
II After commissioning, According to the information According to the information According to the information
alternating temperature from the manufacturer; from the manufacturer; from the manufacturer;
and internal pressure min. 0.5 bar and max. 10 bar min. 20°C and max. 50°C min. 10 K and max. 30 K
loads
III According to the information According to the information
from the manufacturer; from the manufacturer;
min. 40°C and max. 90°C min. 30 K and max. 60 K
Explanations:
In the short-term, the loads arising during the starting and stopping of the two-pipe system as well as during shut-downs must be established from
the temperature difference (∆ϑ) between the ambient temperature and the maximum or minimum operating temperature. ∆ϑ = 20 K must be used
for unintentional temperature differences, e. g. caused by the unprotected storage of two-pipe components outdoors.
4.4 System classification and loading categories combination of the minimum value according to Column A and
the maximum value according to Column B may be regarded as
In order to ensure that two-pipe parts are adequate for the appli-
the permissible loads. The permissible loads according to
cation concerned, it is recommended that the two-pipe systems
Column C correlate with the minimum and maximum tempera-
are classified into loading categories. The loading category
tures according to Column B.
should allow the diverse requirements on two-pipe systems to be
applied in a meaningful way. The category concerned may influ- In order to complete the information about the permissible loads
ence (amongst others): from the internal overpressure or partial vacuum, the correspond-
– the scope of the mathematical proof ing identification field must be extended by the amount of pü(20°C)
– the design and manufacture of the two-pipe parts (see the following example).
– the choice of joining process
– the quality assurance measures 4.4.1.2 Dependence of the loads on the leak monitoring
– the scope of tests and inspections system
– the documentation
Particular attention must be paid to the difference in the operating
Table 4 is intended to illustrate that the requirements must also pressure, ± ∆p, if the leak monitoring of the annular space uses
be suitably adjusted as the operating loads increase. For exam- an overpressure or a partial vacuum. If necessary, the informa-
ple, greater temperature differences result in constraining forces tion about the permissible pressure difference ∆p at TB or at
that must be borne using special structural parts. On the other T = 20°C must be integrated into an additional Column D (see
hand, simple structures and processing methods may be suffi- the identification option in the following example in Section 4.4.2).
cient to guarantee the safe operation of double piping subjected
to low loads.
4.4.1.3 Dependence of the loads on the material
4.4.1 Application of the loading categories
The materials that the manufacturer must use to ensure the
The manufacturer may assign his two-pipe system to a loading applicationof the system for loads according to Table 4 is deter-
category, including the application limits, specified in Table 4. mined mainly by the transported substance. If necessary, Table 4
This makes it possible to limit the dimensioning to certain operat- must be extended to include a new column (Column E) in which
ing conditions. On the basis of this information, the user can iden- the manufacturer includes transported substances with A2 = 1.0.
tify the loads that the two-pipe system can support.
4.4.1.1 Dimensioning depending on the loading category 4.4.1.4 Information required by the manufacturer
If such an assignment has been made, all parts of the two-pipe The manufacturer must inform the operator of the two-pipe sys-
system must be dimensioned for the loads specified in the tems in a suitable form that any stresses beyond the specified
respective Category Lines I to III and their suitability must be application limits are not permissible or that a different loading
proven mathematically. Unless the manufacturer specifies other- scenario may restrict the effective service life. As far as possible,
wise, the combination of the maximum value according to overloading should be prevented by taking operational measures
Column A and the minimum value according to Column B or the (e. g. by means of pressure or temperature monitoring).
651
4.4.2 Example of a category classification with identification, according to Table 4
Category/column = permissible loads >>> I/A = 0.1..0.5 I/B = 30 I/C = 20 (I/D = ± 0.3..0.5)
∆p(B..20°C) [bar]
∆ϑ(B) [K]
Τ(B) [°C]
pü(B..20°C) [bar]
The example shows the systematic information about the permis- 5.1.3 Determination of the wall thicknesses of mouldings
sible loads on a two-pipe system according to the comments in
The calculated wall thicknesses of the mouldings subjected to
this section. The type of identification for the loading limits is left
internal pressures is dealt with in more detail in DVS 2210-1.
to the manufacturer but the details of Table 4 should be incorpo-
Therefore, this does not have to be repeated for the internal
rated. For details about the identification of two-pipes, see Sec-
piping of a two-pipe system. The application of the equations to
tion 7.4.
the external pipe relates only to two-pipe systems laid above
ground.
5 Calculation fundamentals The constraints between the internal and external pipes arising in
addition to the internal pressure loads and their effect on the
5.1 Strength calculations stress in the pipe moulding concerned must be assessed
separately during the wall thickness dimensioning. It is always
Strength calculations predominantly serve to establish the wall
necessary to take account of the worst-case loading or a
thicknesses of pipes and fittings as a result of loads from internal
combination of the various loads. For the determination of the
overpressure. The thermal stresses are not taken into consider-
wall thickness of the external pipe in a buried two-pipe system,
ation in the standard strength calculation. In contrast, double
reference must be made to the ATV-DVWK-A 127 guideline.
piping must be designed for a calculated minimum service life
according to Table 1, Section 4.1, taking account of all of the
5.2 Elasticity calculations
stresses. Load-reducing variations in the operating overpressure
may only be taken into account if the calculated service life is Elasticity calculations must be carried out if the two-pipe system
≥ 10 years. The operator and the fabricator of the pipe system is exposed to temperature changes. A change in length in the
may agree on a different service life if this does not lead to any straight pipe sections, resulting from a temperature difference
conflict with statutory regulations or formal requirements. De- can be accommodated using compensation elements (e. g.
pending on the operating temperature in each case, the strength expansion bends). The elasticity of the compensation element
parameters may be taken from the creep rupture curves, the has an important effect on the level of stresses in the longitudinal
generic pipe standards or DVS 2205-1, including its supple- pipe direction.
ments. The strength calculations (calculated proof) may be made
For two-pipe systems, the length change of the internal pipe is
not only by the system manufacturer but also by the fabricator of
limited by the space in the external pipe. Therefore, compensa-
the two-pipe system.
tion using bend pieces (bending legs) is only possible to a small
extent. If the change in length is restricted, this results in tensile
5.1.1 Determination of the permissible stress
or compressive stresses whose effect on the service life of the
The permissible stress must be determined similar to the calcula- pipe system may be significant.
tions in to DVS 2205-1. This requires the circumferential and lon-
In order to establish the internal pipe stresses in the longitudinal
gitudinal directions of the pipe to be considered separately.
direction, it is advisable to divide the two-pipe system into straight
sections and bend sections and then to calculate the forces
5.1.1.1 Permissible stress in the circumferential direction
acting in each section and the stresses (tensile, compressive and
σV bending) resulting from these.
zul σ u = ---------------------------
- [1]
A2 ⋅ A4 ⋅ S The longitudinal stresses determined during the elasticity calcula-
tions must be added to the axial stress generated from the oper-
5.1.1.2 Permissible stress in the longitudinal direction ating overpressure. The sum of these individual stresses must
not exceed the permissible stress in the longitudinal direction
σ V ⋅ f LZ (Equation [2]).
zul σ l = -------------------------- [2]
A2 ⋅ A4 ⋅ S
Elasticity calculations must be made for both the internal pipe
and the two-pipe combination. This applies, in particular, to
5.1.2 Determination of the pipe wall thickness systems that are laid above ground and are subjected to weath-
The minimum wall thickness of the pipe subjected to internal ering. It must be taken into account that, compared with the
pressure loads is: single pipe, the elasticity of the double-pipe may be restricted
due to the effect of the external pipe or due to the design of the
p ⋅ de bend pieces.
min e R = ---------------------------------- [3]
20 ⋅ zul σ + p Simplified elasticity calculations for L-shaped and Z-shaped
After the calculated pipe wall thickness, eR, has been deter- expansion bends are given in DVS 2210-1. Attention must be
mined, the effective wall thickness eeff must be determined from paid to the increase in stiffness of the expansion bend due to the
the generic pipe standard concerned, taking into account the pipe simultaneous deformation of the internal and external pipes (e. g.
series. Consideration must be given to particular required addi- increase in the moment of inertia). Due to their complexity,
tions to the wall thickness, e. g. for using PP external pipes out- detailed elasticity calculations on two-pipe systems require the
doors. use of a computer program.
652
In addition to establishing the stresses, the following calculations Table 6. Material-dependent factor α for determining σ .
for the internal and external piping must be made within the
scope of the elasticity calculations: αk PE 0.35
– determine the fixed-point forces for axially-clamped pipe Established according to Equation [6] PP-H, PP-B 0.34
sections with ELZ for an effective service life of
25 years PP-R 0.38
– determine the fixed-point forces for axially-mobile pipe
sections (predominantly for the external pipe, but also in PVC-U 0.47
special cases for the internal pipe)
PVDF 0.42
– establish the distances between the supports and guides
– check the deflection between the individual fastening points Remarks: The SDR dependence of αk can be neglected for
practical purposes. In other cases, or for calculations
5.3 Proof of the stability with a service life other than 25 years, the calculation
coefficient αk must be determined as follows:
Proof of the stability must be provided if the two-pipe system
(external and/or internal pipe) is exposed to an internal partial 5.3.3 Compressive stresses from an internal partial vacuum
vacuum or external overpressure. Moreover, it must be deter- or external overpressure in the circumferential
mined what effect the restriction of the thermal expansion (axial direction
pressure) has on the safety of the system. The proof of the stabil-
ity must demonstrate sufficient safety against buckling in the The compressive stress acting in the circumferential direction of
circumferential and longitudinal directions as well as against the the pipe during operation is given by:
interaction of loads in both directions.
p u ,p a 2 ⋅ ( d e /d i ) 2
The following equations have been developed using DIN 18800-4 vorh σ u ( p ) = --------------- ⋅ ------------------------------ [7]
(Stability – Analysis of safety against buckling of shells) in order 10 ( d /d ) 2 – 1e i
to establish the buckling stresses and the safety against instabili-
ty. The comparison of the critical buckling pressure and the effec- 5.3.4 Compressive stresses from loads in the longitudinal
tive outside pressure or partial vacuum loads was added in order direction
to be able to explain the current approach for establishing a
buckling safety factor. The application of the equations was, as The compressive stresses acting in the longitudinal direction of
far as possible, related to the SDR value of the piping parts. the pipe during operation can be determined according to the
following equations. If several loads arise at the same time during
5.3.1 Buckling stress in the circumferential direction operation, the stresses resulting from these must be added
together.
Equation [4] below is based on Element 413, DIN 18800-4, and
has been simplified considerably with the incorporation of the 5.3.4.1 Compressive stresses caused by an internal partial
equation parameters in Table 5 (for the original form of the equa- vacuum or external overpressure in the longitudinal
tion, see the appendix). During the simplification, it was assumed direction
that, with LR/rm ≥ 10, Term 2 in the original equation could be
treated as negligible. This applies to all piping. p u ,p a ( d e /d i ) 2
vorh σ i ( p ) = --------------- ⋅ ------------------------------ [8]
Solving the individual terms in the equation results in the follow- 10 ( d /d ) 2 – 1
e i
ing ideal (critical) buckling stress of thermoplastic pipes subject-
ed to loads due to radial pressure in the circumferential direction
with a Poisson's ratio, µ = 0.38: 5.3.4.2 Compressive stresses caused by restricted thermal
expansion in the longitudinal direction
σ u ( i ) = E KZ ⋅ f SDR [4]
vorh σ l ( dT ) = α ⋅ ∆ϑ ( KZ ) ⋅ E KZ [9]
Table 5. SDR-dependent factors, f , for determining σ . 5.3.4.3 Compressive stresses caused by a bending moment
in the longitudinal direction
SDR 7,4 9 11 17,6 26 33 41
e/rm 0.318 0.252 0.222 0.122 0.091 0.064 0.050 q ⋅ L A2
vorh σ l ( b ) = ----------------- [10]
8 ⋅ WR
fSDR 0.0295 0.0185 0.0144 0.0044 0.0024 0.0012 0.0007
The short-term elastic moduli [EKZ] are given in DVS 2205-2, 5.3.5 Interaction of circumferential and longitudinal
Table 6. compressive loads
5.3.2 Buckling stress in the longitudinal direction 5.3.5.1 Utilisation of the strength in the circumferential
direction
The ideal (critical) buckling stress of circular pipes that are
subjected to axial loads and have deflection rates f ≤ LA/500 can S ⋅ A 2 ⋅ Σeff σ u ( d )
η u ( i ) = ---------------------------------------------- ≤ 1.0 [11]
be determined as follows: σu ( i )
e
σ l ( i ) = α k ⋅ 0.62 ⋅ E KZ ⋅ ------ [5]
rm 5.3.5.2 Utilisation of the strength in the axial direction
0.7 S ⋅ A 2 ⋅ Σeff σ l ( d )
α k = -------------------------------------------------------------------- [6] η l ( i ) = -------------------------------------------- ≤ 1.0 [12]
σl ( i )
E KZ20 C rm 
---------------------- ⋅ 1 + ---------------- -
E  100 ⋅ e 
LZ20 C 5.3.5.3 Interaction condition
The short-term and long-term elastic moduli for T = 20°C are 1.25 1.25
ηi = ηu ( i ) + ηl ( i ) ≤ 1.0 [13]
given in Tables 6 and 7 of DVS 2205-2.
653
5.3.6 Critical buckling pressure 5.4.1 Proof of the stresses for straight pipe sections
For longitudinally-mobile piping that is subjected only to stresses 5.4.1.1 Stress caused by internal overpressure in the
from an internal partial vacuum or external overpressure or for circumferential direction (Y-axis)
thick-walled pipes in which the influence of the axial pressure is
negligible, the stability criterion can be reduced to the proof of the p ü ( d e /d i ) 2 + 1
buckling safety Sbeul. The following applies to these cases: σ u ( p ) = ------ ⋅ ------------------------------- [18]
10 ( d /d ) 2 – 1
e i
p krit
S beul = ---------- ≥ 2.0 *) [14]
p eff 5.4.1.2 Stress caused by internal overpressure in the
longitudinal direction (X-axis)
*) If the proof is provided without taking pipe ovality into consideration, the pü
buckling safety, S , must be increased to ≥ 2.5. Attention must be 1
σ i ( p ) = ------ ⋅ ------------------------------ [19]
paid to this safety aspect, especially in the case of pipes with 10 ( d /d ) 2 – 1
d > 400 mm or with a high SDR (thin-walled pipes). e i
The critical buckling pressure of long pipes (pipe sections) sub- 5.4.1.3 Stress caused by internal overpressure in the radial
jected to loads from a partial vacuum or external overpressure direction (Z-axis)
can be determined fairly accurately using the equation according pü
to [MISES]: σ r ( p ) = ------ [20]
10
20 ⋅ E KZ e 3 5.4.1.4 Stress caused by pipe deflection in the longitudinal
p krit = --------------------- ⋅  --- [15]
2  d direction (X-axis)
1–µ
q ⋅ L A2
5.3.7 Kinking σ l ( b ) = ----------------- [21]
8 ⋅ WR
In the case of long cylinders subjected to axial compressive
loads, the buckling turns into the kinking of the pipe bar according 5.4.1.5 Stress caused by resticted thermal expansion in the
to [EULER]. Therefore, restriction of the axial mobility (clamping) longitudinal direction (X-axis)
of the internal and/or external pipe requires not only proof of the
σ l ( ∆ϑ ) = ± 0.5 ⋅ α ⋅ ∆ϑ ( t ) ⋅ E ( t,TB ) [22]
buckling safety but also calculation of the critical kinking length.
Equation [22] is intended to define the long-term tensile or
During the calculation, the distances between the guides of the
compressive stresses that result from the median load between
internal and external piping must be specified while observing the
max TB and min TB. The factor of 0.5 takes account of the 50%
critical kinking length. The safety margin for the critical kinking
relaxation of stress that may be assumed to occur in the time
length must be SK ≥ 2.0.
between the temperature interval from max TB to min TB.
Using twice the kinking safety margin and assuming pipe The short-term stress peaks must be considered not only during
sections guided in pipe clips, the required distance between the proof of the stability (see Section 5.3) but also during a
fastenings LF is: service life analysis (see Section 5.6).
JR 5.4.1.6 Total stress in the longitudinal direction (X-axis)

erf L F = 3.17 ⋅ -------------- [16]
ε ⋅ AR The addition of all the longitudinal stress components results in
the total stress in the longitudinal direction as follows:
5.4 Proof of the stresses σ l ( ges ) = σ l ( p ) + σ l ( b ) ± σ l ( ∆ϑ ) [23]
The proof of the stresses should document that the stresses that 5.4.2 Proof of the stresses for fittings
arise in a component as a result of long-term loads do not exceed
the permissible stress when superimposed on the medium-term The stresses generated in fittings due to internal pressure loads
loads. Short-term stresses must be taken into consideration as deviate considerably from those in the straight pipe. The dimen-
part of a cumulative service life investigation (see Section 5.6). sioning of common fittings is dealt with in DVS 2210-1. There-
fore, this does not have to be referred to in any great detail here.
In order to establish the overall stress condition in a two-pipe However, it must be pointed out that the additional forces
system, the individual stress components from the multiaxial originating from the two-pipe combination (e. g. from restricted
loads must be calculated for both the internal pipe and external thermal expansion) sometimes require modified proof of the
pipe. Since the material parameters were established using stresses.
uniaxial loads, the component stresses can only be directly
Due to the different systems and geometries of fittings as well as
compared with the strength parameter of the material with the aid
the different arrangement of spacers between the internal and
of strength hypotheses. Details about the various strength
external pipe parts, it is not possible to generalise the calculation
hypotheses are given in the literature.
operations. Instead of the calculational proof, the manufacturers
Remark: If the comparative stress (σV) was established from of two-pipe parts can provide suitable experimental proof in
creep rupture internal pressure tests on pipes or was which the testing conditions must be equivalent to the operating
taken from creep rupture curves (e. g. DVS 2205-1), loads.
the following proof is sufficient:
5.5 Proof of the strains
σv Stresses in the pipe system generate strains, which must not
– In the circumferential direction: σ u ≤ -------------------- [17a] increase beyond a material-dependent limiting strain. If this is not
A ges ⋅ S
borne in mind, this may, over time, lead to damage at the position
subjected to the stress (e. g. cracking).
σ v ⋅ f LZ
– In the longitudinal direction: σ i ≤ -------------------- [17b] For the normal applications (biaxial stress condition), the strain in
A ges ⋅ S the pipe and fitting may be calculated as follows:
654
5.5.1 Strain in the X-direction fLZ, (fs) = Long-term joining factor (–)
100 JR = Moment of inertia of the pipe (mm4)
ε σ ( x ) = ----------------- ⋅ ( σ x – µ ⋅ σ y ) [24]
E ( t,T ) LA = Distance between supports (mm)
LF = Distance between guides (mm)
5.5.2 Strain in the Y-direction LR = Pipe length (mm)
100 Mb = Bending moment in the pipe (Nmm)
ε σ ( y ) = ----------------- ⋅ ( σ y – µ ⋅ σ x ) [25] section
E ( t,T )
p = Internal pressure loads, general (bar)
5.5.3 Safety margin for the limiting strain pü = Internal overpressure (bar)
In order to guarantee a sufficient safety margin for the limiting pu, pa = Internal partial vacuum or (bar)
strain, the proof of the strains can be provided as follows: external overpressure
pkrit = Partial vacuum or external (bar)
ε grenz overpressure at which the pipe
S ε = --------------- ≥ 1.3 [26]
ε eff begins to buckle
peff = Partial vacuum or external (bar)
5.6 Application of Miner's rule overpressure which subjects the
The intermittent loads in the case of double piping, predominantly piping to effective loads
from temperature fluctuations, require the cumulative recording q = Line load from the pipe, filling (N/mm)
of the stress level over time. This has particular significance in and additional weights
the case of piping made of thermoplastics since the permissible rm = Mean radius of the pipe cross- (mm)
stress values correlate directly with the respective operating tem- section
peratures.
S, (SF) = Safety coefficient or safety factor (–)
The quasi-steady internal pressure loads with the thermal stress- (see DVS 2205-1)
es (min. and max. values) superimposed may be viewed as the
t = Time factor (minutes [min], hours
standard calculation model. If the temperature differences are
[h] and years [a])
great, the short-term stress peaks in the longitudinal direction
may greatly exceed the permanent circumferential stress from TB = Operating temperature (°C)
internal pressure. Operating conditions lasting several hours can WR = Pipe resistance moment (mm3)
also be considered to be short-term loads.
∆ϑ = Temperature difference (K)
In this case, it must be determined what effect the succession of µ = Poisson's ratio (–)
short-term stress peaks exerts on the calculated utilisation (0.38 for thermoplastics)
duration or service life of the two-pipe systems. This is possible
using the theory of linear damage accumulation according to σ(u, l) = Stress value, in relation to the (N/mm2, MPa)
[MINER]. cause or the effective direction
σV = Comparative stress from the (N/mm2, MPa)
The DVS 2205-1 technical code includes a series of application
creep rupture internal pressure
examples which relate to this subject and provide valuable help
test
with the calculations for two-pipe systems. The clear treatment in
the examples makes any further explanation of the approach zul σ(u, l) = Permissible stress in the (N/mm2, MPa)
unnecessary. If any users want to deal with Miner's rule in more circumferential or longitudinal
detail, they can find further information in DIN EN ISO 13760. direction
α = Coefficient of linear thermal (1/K)
5.7 Hydraulic calculations expansion
(temperature-dependent)
The hydraulic calculations required for a two-pipe system are the
same as those for single pipe systems. Approaches for establish- εgrenz = Strain-limiting value according to (%)
ing the pressure losses in a practical way are dealt with in DVS 2210-1, Supplement 5
DVS 2210-1 and, as an example, in DVS 2210-1, Supplement 1. εeff = Calculated strain (%)
εσ(x), = Strain, depending on the stress (%)
5.8 Explanation of the designations used in Section 5
εσ(y) direction
A1..n = Reduction factors (–) (For further designations, see
(see DVS 2205-1) DVS 2210-1)
A2 = Reduction factor for the effect of (–)
the transported substance 6 Structural design
A4 = Reduction factor for the influence (–)
of the material viscosity The operational safety and effective service life of thermoplastic
Ages = Influence of all the reduction (A2 x A4 x An) two-pipe systems are mainly influenced by the properties of the
factors plastic concerned, and the design and quality of manufacture of
the parts. The following section should serve to specify the
AR = Annular surface of the pipe wall (mm2)
components of two-pipe systems with regard to the structural
de, De = Pipe outside diameter (mm) design and the loads acting on the parts.
(also da or Da)
Components of two-pipe systems are:
di, D i = Pipe inside diameter (mm)
= Pipe or fitting wall thickness (mm) – straight pipe pieces
e, eR,
(also s, sR or sF) – bend pieces
eF
– branch pieces
eff = Effective value (–) – reducers
EKZ, LZ = Elastic modulus (N/mm2, MPa) – adapters and end pieces
KZ, LZ = Short-term or long-term value (–) – fittings, to limit the length change (fixed points)
655
– nozzles in the external pipe the gap between the internal and external pipe beads during
– flanged joints simultaneous HS welding.
– valves and measuring, inspection and checking facilities If the annular gap is < 5 mm for system-related reasons (this may
– special fittings be the case for double piping where the internal pipe has an
outside diameter de ≤ 160 mm), the user must include this detail
6.1 Straight pipe pieces in his/her report.
Straight two-pipe pieces (Fig. 1), consisting of internal and exter- This applies especially for two-pipe systems whose transported
nal pipes, must allow the proper construction of two independent substances contain coarse particulates, which may block the
pipe systems, which are each self-contained. The internal pipe annular gap in the event of failure.
must be guided concentrically inside the external pipe by suitable
spacers. 6.1.3 Locking discs
6.1.1 Spacers The protrusion of the ends of the internal and external pipes [LÜ]
as well as fastenings between the internal and external pipes
As a rule, spacers are not welded on to the internal pipe apart produced during manufacture (e. g. locking of the internal pipe at
from when they cannot be secured against axial displacement in the distance [Lx]) must be specified depending on the joining
any other way. The distance between the spacers (LA or LF) must process used.
be chosen in such a way as to exclude any unacceptable deflec-
tion or lateral buckling of the internal pipe. If a locking disc is needed (this is the case during simultaneous
HS welding at both pipe ends), this must be designed to with-
The shape of spacers must not cause any damage to the pipe stand the effective loads [Fa]. Further remarks about this are
surfaces or any deformation of the pipe cross-section. Spacers given in Section 8.3.
must be designed in such a way that, in the event of a failure in
the internal pipe, the medium can flow in the external pipe to the Locking discs must be designed in such a way that, in the event
next leak detection position without hindrance. of failure of the internal pipe, the medium can flow in the external
pipe as far as the next leak detection position without hindrance.
If spacers are fabricated in the form of discs that are cut from The disc cut-outs for this purpose must be manufactured using a
plates, the openings for leak passage must be manufactured tool that does not generate notches.
using a tool that does not generate notches.
The width or thickness [b] of spacers must primarily be based on 6.1.4 Modification of straight pipe pieces
their weight loading, i. e. the chosen distances. the smaller the
If it is necessary to shorten preassembled two-pipe pieces during
distance between the spacers is, the narrower the spacer width
pipe laying, the installer must ensure that the distances between
can be. Guide values for the minimum width of pipe spacers can
the spacers comply with the permissible values. Any spacers or
be found in DVS 2210-5, Table 5.
internal pipe locking pieces that have been removed must be
replaced such that the conformity of the system is retained.
6.1.2 Annular gap
The ratio of the external pipe diameter to the internal pipe diame- 6.2 Bend pieces
ter is dependent, amongst other factors, on the joining process.
If at all possible, internal and external injection moulded pipe
For example, attention must be paid to the maximum outside
fittings must be used for bend and elbow pieces in two-pipe
dimension of an electrofusion fitting on the internal pipe such that
systems. Bend and elbow pieces must be capable of accommo-
a sufficient annular gap is ensured at this position. If possible, the
dating any length changes ∆L arising in the bend apex without
free annular gap [x] should be ≥ 5 mm throughout.
overloading. It must be ensured that, in the case of the maximum
Attention must be paid to the minimum annular gap dimension at temperature change or depending on the loading category
all joints and fittings. This includes not only the bead height according to Table 4, Section 4.4, the internal pipe bend does not
during the HS welding of the internal pipe but also, in particular, come into contact with the external pipe bend (x > ∆L).
or Annular gap Spacer (e. g. skid)
See Tables 13..20. DVS 2210-1
Locking of the internal pipe when

simultaneous HS welding is applied
Openings for leak passage in

the event of failure
Thickness of the locking disc

according to static requirements Spacer, disc-shaped,
see Table 5, DVS 2210-1
As small as possible,
see Section 8.3.2.1.1 (e. g. for HM welding
or adhesive bonding)
Figure 1. Straight two-pipe piece.
656
The standard version of bend and elbow pieces does not permit The supporting shells must not have a detrimental effect on the
any length change from the connected pipe section. With regard operational safety or on the gap in the monitoring space.
to the fixing and protrusions at the ends of the mouldings, the
same requirements apply to bend and elbow pieces as to the One fundamental difference between the fixed-point element and
pipes sections. the supporting shell is that the connections to bend and elbow
pieces must be made with supporting shells on both sides using
6.2.1 Bend pieces with fixed points a cascade joint. Details about this are given in Section 8.3.1.2.
The bend section between the fixed-point fittings (Fig. 2a) is sub-
jected to longitudinal and circumferential bending stresses whose 6.3 Branch pieces
levels are determined by the elastic length of the bend piece [RB]. If at all possible, internal and external branch pieces in double
One condition for the design of fixed points on both sides of the piping should be injection moulded. If unreinforced branch pieces
internal pipe bend is that the compressive, tensile and transverse are installed, their influence on the operation limits must be taken
forces [Fa and Fq] should not cause any deformation of the cross- into account according to Table 4, Section 4.4.
section or any unacceptable rise in stress. In turn, the reaction
forces delivered to the external pipe must not have a detrimental Bend and elbow pieces with fixed points on both sides are
effect on the operational safety of the double piping. suitable for simultaneous heated tool butt welding since the
necessary joining pressure can be applied to the wall cross-
Further details about limiting the length change using fixed points section of the internal pipe bend with the aid of the fixed-point
are described in Section 6.6. discs. The fixed-point discs must have openings that guarantee
Openings in the discs for the discharge free passage in the monitoring space.
of a leak in the event of failure
The same applies to branch pieces that are manufactured by
segmenting pipes or using a welded-in nozzle. Due to the stress-
es on the branch pieces in two-pipe systems, it is recommended
to use such branches only for pipe systems that are not subject-
ed to any pressure or to limit their use to the loads in Category I,
Table 4.
6.3.1 Branch pieces with fixed points on all sides

Branch pieces are usually fixed points in two-pipe systems. This
applies not only to the main line but also to the connecting line. In
the standard version, provision is made for fixed-point fittings at
all connecting intersections of the branch piece. Details about the
loads on the internal pipe branch can be found in Section 6.3.3.
Disc thickness [h] Openings for the discharge
according to static of a leak in the event of failure
requirements
Fixed-point element (ring or disc)

as an integrated fitting if at all possible.
Fa and Fq from static calculation
Figure 2a. Pipe bend with fixed points on both sides.
6.2.2 Bend pieces with supporting shells

In the case of the bend piece shown in Fig. 2b, supporting shells
on both sides serve as fastening points. There are merely trans-
verse forces [Fq], which are spread over the length of the sup-
porting shell [LSchale] without allowing unacceptable deformation
of the cross-section of the internal and external pipe bends.
or
See Tables 13..20, DVS 2210-1
Figure 3a. Pipe branch with fixed points at all connecting intersections.
Supporting shells 6.3.2 Branch pieces without fixed points in the main line
in the installed condition If a branch piece is installed in a pipe section between two fittings
(e. g. bend, elbow, end pieces etc.), which are themselves
equipped with fixed points, no further axial locking is necessary in
the main line.
Supporting shell for the external pipe
The fixed-point fitting must remain at the outlet to the connecting
Supporting shell for the internal pipe line in order to minimise the extent of length change acting trans-
(before installation) verse to the main line. Thus, two fixed-point fittings are not
necessary at the branch piece and can be replaced by spacers or
Figure 2b. Bend piece with supporting shells on both sides. supporting shells.
657
6.3.4 Special fittings

In addition to injection moulded branch pieces, it is also possible
to manufacture branch pieces using machining processes. One
example of this is shown in Fig. 3d. Advantages of these compo-
nents include the integrated internal pipe fixed point and that
each fitting can be designed with a specific wall thickness. The
function of the double-wall design must be retained in all cases.
Spacer or supporting shell

L see Tables 13..20, DVS 2210-1
(if necessary, as close as possible on both sides of the branch nozzle)
Boreholes for leak passage
Figure 3b. Pipe branch without any fixed points in the main line.
Figure 3d. Pipe branch as a special fitting.
6.3.3 Branch pieces without fixed points in the main or
connecting line 6.3.5 Stresses at the internal pipe cut-out
If neither the main line nor the connecting line has a fixed-point 6.3.5.1 Circumferential stresses
fitting, the length changes and the loads resulting from these [Fq]
The nozzle cut-out in the internal pipe causes a rise in the
can act directly on the connecting intersections As indicated in
circumferential stresses due to internal overpressure. The
Fig. 3b, not only support pressures [FA] but also bending
increase in stress is independent of the type of construction. The
moments arise, in the case of supporting shells, at the internal
cut-out diameter and the wall thickness at the edge of the cut-out
pipe outlet with Mb(1) = Fq x LB as well as at the internal pipe
have a critical effect on the stress level.
passage with Mb(0) = 0.25 x Fq x LA.
6.3.5.2 Longitudinal stresses
If distinct tensile stresses are generated due to temperature
fluctuations and a restricted length change in the main line, the
longitudinal stresses are higher at the internal pipe cut-out than
elsewhere in the internal pipe cross-section. This can be ex-
plained by the fact that the tensile forces acting in the longitudinal
pipe direction must be borne by a reduced cross-sectional pipe
area, which also causes a bending moment. In the case of alter-
nating temperature loads (e. g. Loading Category III, Table 4), it
must be checked whether annular wall thickness reinforcement
of the internal pipe is necessary in the cut-out region.
6.4 Reducers
Reducers are available in various types. In this respect, an
essential distinction must be made between concentric and
eccentric reducers. Not only injection-moulded reducers but also
Internal supporting shell machined reducers may be used. Longitudinally-welded reducers
External supporting shell
are not allowed in two-pipe systems subjected to internal pres-
sure.
Concentric reducers distribute the axial loads (tensile or com-
Figure 3c. Pipe branch without any fixed points in the main or connec- pressive forces) more uniformly around the stress cross-section
ting line. than eccentric reducers. This applies particularly in the case of a
substantial reduction in the pipe diameter, during which the high-
In order to decrease the bending moments, the supporting shells er axial force must be transferred from the larger pipe via the
or spacers on the internal pipe must be arranged as close as reducer to the smaller pipe.
possible to the branch nozzle. The supporting width of the spac- In such cases, it is recommended to install internal pipe fixed
ers or supporting shells should be as large as possible in order to points upstream and downstream of the reducer, as shown in
minimise the surface pressure and to increase the supporting Fig. 4.
effect. The tensile or compressive forces from the connecting line
The use of reducers with a short design length (reduction angles
act on the internal pipe like an internal or external overpressure,
> 45°) are not recommended, both for strength reasons and from
which is limited to the outside diameter of the connecting line. If
a hydraulic viewpoint. This does not concern reduction sleeves,
the internal piping is subjected to planned loads due to external
e. g. those used in PVC piping.
overpressure or an internal partial vacuum, the safety against
buckling decreases at the nozzle cut-out of the internal pipe. With Eccentric reducers should predominantly be used if a constant
regard to the fixing, the protrusions and the longitudinal mobility, base level is required (e. g. drainpipes and buried two-pipe sys-
the same requirements apply to the branch pieces as to the tems) or if it is more efficient to carry out the laying with a uniform
pipes, irrespective of their type,. fastening height.
658
With regard to the fixing, the protrusions and the longitudinal

mobility, the same requirements apply to reducers as to the
pipes.
Locking disc when HS welding is applied Elastomer sealing elements
Fixed-point element Figure 5b. Adapter that can be slipped on the internal pipe.
(see Fig. 8a)
End pieces of double piping must be designed in such a way that
the annular flat base with the thickness [hB(i)] withstands the
Figure 4. Concentric reducer with optional fixed points.
internal overpressure of the internal pipe. If there is also an inter-
nal overpressure or partial vacuum in the monitoring space, this
6.5 Adapters and end pieces must be taken into consideration when calculating the thickness
Connections between a double pipe and a single pipe, as well as of the base [hB(a)].
end pieces, must be designed in such a way that the loads are
transferred safely. Because of their arrangement in double pipes,
in most cases adapters and end pieces are also internal pipe
fixed points. Loads are caused by:
– internal overpressure or partial vacuum in the monitoring
space
– thermal stresses from the temperature change in the internal
and external pipes
Adapters can be combined with a fixed point on the external pipe
in order to suppress length changes in the double piping (Fig. 5a,
Shape B with an annular groove for pipe clip locking).
Shape A Shape B
Figure 6. End piece of double piping.
Connections for leak warning facilities as well as venting or emp-

tying devices for the monitoring space can also be integrated into
adapters or end pieces. With regard to protrusions etc., the same
requirements are applicable as in the case of the pipes.
6.6 Fittings that limit length changes

The structure of double piping means that the length change in
the internal pipe must be limited or suppressed by special fittings
(e. g. fixed points) because there are few expansion possibilities
Figure 5a. Adapters with an annular flat base.
in the bend piece of the external pipe.
Connections between double pipes and single pipes may also be In the vast majority of applications, the manufacturers arrange
equipped with a slip-on facility, where the long-term leak-tight- internal pipe fixed points upstream and downstream of the bend
ness of the internal pipe bushing is ensured by using elastomer pieces (on this subject, see Fig. 2a).
sealing elements and a suitably-dimensioned external pipe base
All structural types must be capable of reliably transferring the
thickness [hB].
forces in the internal pipe to the external pipe without altering the
Axial loads [FA] result from the friction between the internal pipe cross-section of the internal pipe. In the external pipe, the loads
and the adapter subjected to internal pressure [FR]. Adapters caused by the internal pipe may only give rise to deformations
with a slip-on facility are not suitable for simultaneous HS weld- and stresses that do not jeopardise the safe operation of the leak
ing. monitoring system. Rib-shaped or welded-on locking devices in
659
the longitudinal axis are not allowed since cracks may arise in the
internal pipe if there is insufficient weld penetration.
In order to guarantee the function of the leak monitoring system,
provision must be made for a suitable pathway between the
internal and external pipes (annular space) at the joining discs of
the fittings so that, in the event of a failure, the transported
substance that has entered the annular space will reach the next
monitoring point without hindrance. One exception to this is
where the monitoring space is divided into safety sections. In this
case, the fittings also serve as bulkheads.
Those openings in the joining disc shown in Fig. 7 must be locat-
ed at the base of the annular space. A symmetrical arrangement
around the main axes is appropriate. The size and number of the
openings affect the load-bearing capacity of the joining disc and
this must be taken into consideration at the design stage.
Figure 8a. Fixed point on the internal pipe.
6.6.2 Supporting shell on the internal pipe

(Type B length restriction)
Another possibility of bearing the tensile and compressive forces
is to use a shell structure to support the end of the internal pipe
bend on the opposite side of the connected straight pipe section
in each case, as shown in Fig. 2b.
This support causes not only bending stresses but also trans-
verse loading on the internal pipe bend which is essentially
determined by the length of the supporting shell.
6.6.3 Fixed point on the external pipe

(Type C length restriction)
In the case of double piping laid above ground, the fastening
Figure 7. Examples of openings in the joining disc between the internal system is the same as that of single piping. If greater length
and external pipes to allow for leak passage in the event of changes in areas where the direction changes are to be restrict-
failure.
ed by axial clamping of the external pipe, it is necessary to
arrange corresponding external pipe fixed points. The internal
Fixed points must bear the tensile and compressive forces from pipe is not affected by this, i. e. the fixed-point loads from the
the internal pipe section due to a restricted length change. internal pipe are Fa(i) = 0 (see Fig. 8b).
Furthermore, it is necessary to provide the external pipe with
fixed points in order to limit the length change in the double Every external pipe fixed point includes a torsionally-stiff fasten-
piping or to selectively guide it in certain directions. ing structure, which must be adapted to the local conditions. The
dimensioning and manufacture of the fastening structure are the
The fixed points on the external pipe must be arranged to comply tasks of the installer.
with the elasticity conditions. If there are any deviations from the
approach described in DVS 2210-1, Section 4.3.2 for the design
of expansion bends, the bending stresses generated in the exter-
nal pipe must be proven.
There are various methods for restricting the length change.
Type A: Fixed point on the internal pipe with a joint to the exter-
nal pipe.
Type B: Shell on the internal pipe with positive locking to the ex-
ternal pipe.
Type C: Fixed point on the external pipe with a joint to a fasten-
ing structure.
Type D: Combination of Variants A and C (double-pipe fixed
point).
6.6.1 Fixed point on the internal pipe Figure 8b. Fixed point on the external pipe.
(Type A length restriction)
6.6.4 Fixed point on the internal and external pipes
The fixed-point fitting shown in Fig. 8a can be used in order to
(Type D length restriction)
bear the tensile and compressive forces acting on the internal
pipe and to transfer them to the external pipe. The joining disc In the case of a special double-pipe fixed point, which fixes the
between the internal and external pipes must be designed such internal and external pipes at the same position, it is not possible
that it doesn’t move under the maximum system loads [Fa(i)]. This to choose the fastening point on the external pipe. Unless it is
relates to the disc thickness [LFP(i)] in particular. Openings in the detrimental to the laying of double piping, the double-pipe fixed
joining disc for the leak passage in the event of failure are man- point can be prefabricated in the factory in order to simplify instal-
datory. lation (see Fig. 2a).
660
With regard to its double sealing function, the flanged joint impos-
es considerably more stringent requirements on the stiffness of
the neck and loose flange than for single piping.
Moreover, the ability to seal during assembly or testing must be
maintained during operation. As a result of this, the operationally-
induced axial forces must be taken into consideration not only in
calculational and structural respects but also with regard to
testing technology.
6.9 Valves and measuring facilities

Valves and measuring facilities are subject to the same require-
ments as have already been described for the double-pipe
fittings. The structural details must be specified by the system
manufacturer concerned.
Within the scope of application-related requirements on valves
and measuring facilities, their unrestricted usability for the usual
joining processes should be named in particular. Furthermore, it
must be borne in mind that the valve housing should be designed
based on the overpressure or partial vacuum loads existing in the
Pipe clip of the fixed-point structure
monitoring space as well as the test pressure.
Figure 8c. Double-pipe fixed point. Valves or measuring facilities should be removed and reinstalled
without disconnecting the double piping.
With regard to the shape of fixed-point fittings, it must be ensured
that pipe clips appropriate for the length [LFP(a)] and diameter 6.10 Special fittings
[DRS] are available. In the case of greater fixed-point loads [Fa(i) If the range of a manufacturer includes special fittings (e. g. slip-
or Fa(a)], it is advisable to increase the wall thicknesses of the on compensators), the same requirements with regard to the
fitting [eFP(i) or eFP(a)] to create a more favourable stress distribu- double-wall design apply to these parts as to the pipe. The use of
tion. special fittings must not result in any reduction of the safety of the
The remarks in DVS 2210-1, Section 5.7.3 as well as the infor- two-pipe system or on its load-bearing capacity. The particular
mation from the manufacturers about the load-bearing capacity structure of special fittings requires clear identification with
according to DVS 2210-2, Table 4, Section 4.4 apply to the oper- information about the loading category according to Table 4,
ation of fixed-point fittings. Section 4.4.
6.7 Nozzles in the external pipe

7 Processing, preassembly and identification
The installation of nozzles is allowed only in the external pipe.
Nozzles in the external pipe are used for leak monitoring, for
This section deals with the processing, preassembly and identifi-
emptying and for the ventilation and venting of the monitoring
cation of double-pipe fittings. The processing involves the manu-
space. Nozzles may also be needed for internal pressure or leak
facture of parts using mechanical processes such as turning,
testing of the external pipe.
planing and sawing as well as other fabrication processes (e. g.
The monitoring space may have to be divided into several welding and thermoforming).
sections, which may require the installation of additional nozzles
Preassembly covers all the work which assists the direct assem-
(see Section 10.3.1). The monitoring space must be emptied
bly of individual double-pipe parts. This includes, for example, the
after a failure in order to make a repair. So that the joining work is
fixing of the internal pipe parts in the external pipe or the closing
not affected by residual moisture during a repair, it is necessary
of straight pipe pieces using a fixed-point moulding or an end
to ensure that the monitoring space can be emptied completely.
cap.
Nozzles must only be installed where absolutely necessary and
at accessible positions (e. g. emptying or venting devices in 7.1 Initial products
inspection shafts for buried double piping). In particular, it must
be borne in mind that nozzles should only be positioned outside Initial products for two-pipe systems are pipes, fittings and
zones in need of protection. During operation, nozzles must be accessories, which mainly come from the fabrication of semi-
closed in order to prevent the uncontrolled escape of substances finished products for single pipe systems. Only special fittings,
in the event of failure. This applies especially to screw connec- such as fixed points, adapters, end bases and similar parts
tions and other detachable connections (e. g. couplings). require manufacture specific to two-pipe systems. The initial
products are subject to the quality assurance of the product
6.8 Flanged joints manufacturer.
Flanged joints must satisfy the same requirements with regard to 7.2 Preassembly
the double-wall design as pipes and fittings. Exceptions are
permissible if the flanged joints are poitioned in special collection In order to minimise the cost of erecting two-pipe systems, the
containers The flanged joint must have a passage so that, in the manufacturers offer preassembled double-pipe fittings. These
event of a failure, the substances that have entered the monitor- parts consist of the internal pipe element, which is already joined
ing space can be detected or can travel as far as the next moni- with the external pipe part in such a way that only the joints must
toring point without hindrance. be produced during assembly.
In the case of flange joints in double piping, suitable structures With regard to the preassembled double-pipe fittings, the manu-
must ensure the safe sealing during operation between the inter- facturers must guarantee not only the initial products but also the
nal pipe and the monitoring space and also between the monitor- correct processing. The manufacturers are required to provide
ing space and the environment. In order to decrease the wrench clear information about the load-bearing capacity of the double-
torque for screws, it is recommended that O-ring seals or profiled pipe fittings, which indicates their operational limits (identification
flat seals made of elastomer materials are used. requirement).
661
Since the installation of a two-pipe system requires parts that are Table 7. Identification recommendations.
not preassembled (e. g. single pipe bends for the internal and ex-
ternal pipes), the guarantee and the operational limits are Identification DP parts DP system
required for only the initial product concerned. In any case, the To be carried out by the: (manufacturer) (installer)
party that carries out the preassembly must guarantee the quality
and load-bearing capacity of the double-pipe product. Manufacturer's name or
manufacturer's symbol
7.2.1 Prerequisites for preassembly Manufacturing date
Any party that manufactures or preassembles double-pipe fittings (month/year)
must have at its disposal corresponding machines and fabri- or code
cation facilities as well as qualified personnel. The requirements Authorisation number and
on the manufacturers, the processors and the installers have
certificate of conformity
already been described in DVS 2210-1, Sections 6.1 and 6.2,
and are therefore not dealt with here. Material of the internal pipe 1)
With regard to the preassembly, there is a need for special [DIN EN identification]
facilities and fabrication processes that have been developed Nominal outside diameter of 1)
based on experience. Therefore, it is not possible to use the the internal pipe [de]
same fundamental principles for the prefabrication of single pipe
parts to the preassembly of double-pipe fittings. The quality Nominal wall thickness of the 1)
requirements are described in Section 8. internal pipe [ei]
(also SDR identification)
7.3 Transport and storage
Material of the external pipe
The packing, transport and storage of preassembled double-pipe [DIN EN identification]
fittings frequently requires approaches different from those for
single pipe parts. General rules exist for the careful handling of Nominal outside diameter of
the parts with regard to the particular properties of the plastics. the external pipe [De]
Details about this are included in DVS 2210-1, Section 6.3. Only
Nominal outside diameter of
the features relating to the double-pipe fittings are described
the external pipe [ea]
below.
(also SDR identification)
Double-pipe fittings must be transported and stored in such a
way that no objects can enter the monitoring space and that Permissible operating condi- 2)
soiling is minimised. The measures to be taken to meet this tions or loading category
requirement are left to the manufacturer concerned (e. g. block- (e. g. identification according to
ing the pipe ends with protective caps). the example in Section 4.4.2)
Regarding the need to protect the monitoring space, it must be ) Identification only on the internal pipe
borne in mind that, in general, this should be completely dry and Identification by the installer only in the case of fabrication by the
measures should be taken to ensure that condensation or the installer
penetration of moisture do not occur.
Attention must also be paid to the roundness of the ends of
8 Installation (laying and assembly)
double-pipe fittings. This is more important depending on the
choice of joining process to be used, for example simultaneous
heated tool butt welding (Section 8.2.2.1.1) requires a joining The laying and assembly encompass all the activities associated
with the installation of a two-pipe system using piping parts,
face misalignment of ≤ 0.1 x pipe wall thickness. The storage and
valves, monitoring facilities and similar items, and including join-
stacking must be carried out to maintain the roundness of the
ing. The system-specific requirements for the proper installation
pipe ends since any subsequent re-rounding of the pipe ends is
difficult. of two-pipe systems are described in the following sections in
order to give the user an insight into the complexity of the
In order to avoid unacceptable deformation of double-pipe fittings subject.
and any excessive loads on the joints between internal and exter-
nal pipes due to thermal stresses, pipe fittings should be stored The approaches and fundamental principles for laying plastic
pipes as well as for assembling fastenings and similar items are
where there are not extreme variations in ambient temperature.
only described if these are different than for single piping. The
In particular, the storage of the double-pipe fittings equipped with
procedures according to DVS 2210-1 must be applied in all other
fixed points is not permissible at ambient temperatures ≤ 5°C
without taking special protective measures. cases.
8.1 Laying type

7.4 Identification
Manufacturers and installers of double-pipe parts are obliged to Double piping can be laid both above and below ground. In the
case of underground laying (buried double piping), the external
permanently identify the parts. A recommendation about the type
pipe is laid on a continuous pipe support. When the double piping
and scope of the identification on double-pipe parts (DP parts) or
on the double-pipe system (DP system) is included in Table 7. is installed in the earth (back-filling and compaction), attention
must be paid to the required minimum compaction of the soil
around the piping. DPr = 95 % is regarded as the minimum com-
paction.
The above-ground laying of double piping requires the use of
load-bearing structures and fastening elements. The fastening el-
ements must support or guide the external pipe at suitable dis-
tances and, depending on their function, may oppose the axial
movement of the external pipe.
662
8.2 Laying methods The joining process suitable for double piping is determined by
the following factors:
In the case of double piping, the laying method means the type of
fastening of the external pipe. If it is a buried pipe system, the – process variants
linear expansion of the external pipe is generally restricted by the – material of the internal and external pipes
friction with the earth and resistance at bend and branch pieces. – pipe dimensions
Both the "axially-mobile" and "axially-clamped" laying methods – system components
can be applied to above-ground two-pipe systems. – laying method
The following combinations are possible for the external piping:
8.3.1.1 Heated tool butt and socket welding
Pipe section Bend section Branch section Heated tool butt welding is applicable to all the pipe dimensions
Axially-mobile Axially-mobile Axially-mobile that can be supplied. Heated tool socket welding has limited
application due to the available fitting dimensions and, in the
Axially-clamped Axially-mobile Axially-clamped case of two-pipe systems, is restricted to the joining of the inter-
nal pipe parts only. The high joining factors attainable with
Axially-clamped Axially-clamped Axially-clamped heated tool welding guarantees the high operational safety and
long-term durability of the piping.
Other combinations, not given in the table, are also possible.
However, attention must be paid to the consequences (e. g. 8.3.2 Process variants of heated tool butt welding
fixed-point loads) that the laying method concerned has on the
double-pipe part or the fastening. – Simultaneous joining, abbreviation: (-S)
– Cascade joining, abbreviation: (-K)
Axially-mobile bend sections permit a geometrically-dependent
length change between the fixed points in the system. Axial 8.3.2.1 Simultaneous joining
clamping of bend sections requires a greater scope of fastening
and, as experience has shown, leads to greater stresses. In simultaneous joining, the external and internal pipe parts are
joined in one operation. If the joining is carried out by means of
The axial clamping of external pipe sections results in greater butt welding, it is imperative that the internal pipe cannot be
loads on the fixed points than axially-mobile systems. In addition displaced in relation to the external pipe and that all the parts to
to the fixed-point loads, it must be borne in mind that tensile or be welded are made of the same material. Visual inspectio

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DVS – DEUTSCHER VERBAND Adhesive bonding of plastics

Contents: concerning Section 45 of the Skilled Trades Code are specified in

1 Scope of application 4 Evaluation of adhesive-bonded joints

DVS – DEUTSCHER VERBAND

Contents: 2.1.2 Fittings/mouldings

4 Manufacture of adhesive-bonded joints 5.5 Leak test

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DVS – DEUTSCHER VERBAND Testing of semifinished products Directive D

Contents: Table 1. Materials and letter symbols.

1 Scope Letter symbol material naming

4.2 Behaviour under thermal stress

2.2 Thermal behaviour

DVS, Technical Committee, Working Group “Plastics, Welding and Bonding”

4.2.3 Thermal ageing 5 Standards and directives

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Kurzzeichen / Abbreviation Werkstoffbezeichnung / Material

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PVC-HI Polyvinylchlorid hoch schlagzäh / Polyvinyl chloride high impact resistant

DVS, Ausschuss für Technik, Arbeitsgruppe „Fügen von Kunststoffen“

Prüfen von Halbzeug aus Thermoplasten;