avk repair-clamps brochure

7/26/2019 AVK Repair-clamps Brochure

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AV K R e p a i r c l a m p s

A V K I N T E R N A T I O N A L A / S

Te c h n i c a l b r o c h u r e



Whenever a leakage in a water mains occurs due to a crack, it

is essential that the repair is done quickly and efficiently so that

the consumers and surroundings experience a minimum of

disturbance.

As most cracks occur without any prior notification it is of

greatest importance that the repair products are available

ex-stock either at the waterworks, the contractor or as minimum

at the wholesaler. To make this possible the repair products

must have multi functionality, flexibility and wide tolerances.

Furthermore the key demands when conducting repairs are

easy and fast installation and reliable functionality.

For all these specific purposes and demands AVK offers a

comprehensive range of products specially designed for all

sorts of cracks in the most common pipe materials.



3

Typical pipe cracks

PVC pipes have for many years been used for potable water

pipelines as well as for sewage.

The material has proved to be very stable because of the low

weight and relatively high pressure class. If a crack appears it

might be caused by earth settlements or increased traffic load.

A typical crack will be unstructured and can move in both

longitudinal and circumferential direction.

The best way to repair a cracked PVC pipe is to cut out and

replace by a new piece connected with couplings. In this way

the stress in the pipe will be neutralised and new cracks

prevented. If for some reason there is no possibility to use

couplings, the AVK stainless steel repair clamps can be used.

Ductile iron has been in use for 30 - 35 years. It is more

resistant to impact and settlement forces.

The most common failure mode is longitudinal cracking caused

by cathodic attack i.e. a puncture in the pipe coating which will

create a location for an electric cell from stray currents picked

up from overhead power cables, adjacent railways or fromalcaline soil.

The longitudinal cracking can be quite dramatic - the pipe can

virtually unzip. Common corrective action is to drill a small hole

at both ends of the crack to prevent it from travelling further,

and then mount a repair clamp on the pipe.

In the northern part of Europe PE is one of the most used

materials for water networks. Normally there are very few leak

problems and very often the leaks are due to external damages

such as digging. When repairing PE pipe systems the part to be

repaired is cut out and replaced by a new piece of pipe, which

is directly welded into the PE pipe system by using socket

fusion welding.

With minor damages repair clamps of stainless steel can be

used due to the fact that no stress relieve is required for PE

pipes.

The application of ductile repair clamps is seldom seen but can

however be used in line with stainless steel repair clamps.

Cast iron was widely used in water and gas systems in the past

and today forms 90 - 95 % of all ferrow pipe failures.

The most common leakage is circumferential cracking

caused by:

A. Differing soil types causing earth settlement.

B. Increased road traffic resulting in settlements and cracking

Cast Iron pipes can be repared with ductile repair couplings

since stress relief is essential.

Asbestos Cement is used mainly in water systems. Failure

mode is similar to cast iron pipes, a circumferential crack

caused by earth settlements or increased road traffic.

Pipe dimensions are only reliable at the pipe ends. It is therefore

essential to use e.g. a sliding caliper to determine the suitability

of repair fitting as to tolerances. Also here AVK ductile repair

clamps are to be preferable.

Typical longitudinal crack in a pipe typicaly caused by earth settlement or

increased traf fic load.

Easy and fast neutralization of the crack is essential in order to minimize

disturbance for consumer. Here AVK universal supacollar repair fitting is

mounted.



PE-pipes:

1. Cracks most often appear because of mechanical impact onthe pipe

2. Repair o f big PE cracks is done by cutting out the damaged

piece and inser ting a new piece by means of socket fusion

welding

Asbestos cement pipes:1. Pipe cracks typically app ear circumferentially because of

stress in the pipe

2. Often the crack zone is in the middle of the p ipe, where the

external diameter fluctuates the most

3. The tolerance area of the repair clamp is important

4. Stress re lief is required

Ductile i ron pipes:

1. Direct pip e cracks, where the pipe cracks in two, appear very

seldom

2. Most of ten leaks appear in connection with wrong pipe f itting,

resulting in galvanic corrosion

3. Longitudinal cracks are stopped by d rilling the pipe at both

ends of the crack

Cast iron pipes:

1. Cracks typically appear circumferentially on the pipe

2. The cracks are most often caused by stress in the pip e

3. The pipe should be stress relieved before repair

4. With minor earth settlements par t of the p ipe is cut out and

replaced by a new piece of pipe and coup lings

PVC-pipes:

1. The pip e is typically deteriorated because of ozone and

UV-radiation

2. Crack zone longitudinal and circumferent ial of the pipe

3. The pipe should be releived from stress before repair

Typical pipe cracks

XDefective AC (asbestos

cement) coupling

XCracks in AC, steel, cast

iron or PVC

XPipe ends angled

XHoles in AC, steel or cast

iron

XDamage caused by service

crane or breaking-off ofbranching section

XSeal of AC coupling is

damaged

XBreaks in AC and cast iron

pipes

XCorrosion leaks

X

Pipes do not join upPipe ends do not lie in the

same plane



5

Mounting instructions for AVK repair clamps

1. Excavate pipe allowing sufficient clearance to fit The Repair Clamp.

2. Clean area of pipe where the fitting is to be installed.

3. Measure and check diameter of pipe against tolerance of fitting.

4. Ensure that proper tools are used, i.e. spanner.

5. Open the clamp and place it on the pipe next to the leak.6. Hook the clamp together and slide it over the leak.

7. Tighten the bolts/nuts in a cross diagonal sequence.

Making the repair

Stainless Steel Repair Clamps

-Series 729S/D

The AVK Rewag series 729 is a widely used clamp when dealing

with leaky pipes or complete ruptures in the pipe system. The

clamp construction ensures a cost effective and reliable

solution for quick repairs of pipes in any pipe material. The

clamps can be used for permanent repair of punctures,

longitudinal and circumferential cracks.

The functional principle of the repair clamp rests on a stainless

steel, pre-rolled plate, which is clamped round the pipe and

fastened with lugs and nuts. The clamp has a rubber lining. The

tensile force applied by the clamp fastening is converted to a

radial pressure on the rubber lining.

AVK offers stainless steel clamps in following variants:

•Single band, standard or with threaded outlet. To be used

exclusively as repair clamp and/or as tapping saddle due to

the outlet. This type is recommended for cost effective repair

on primarily pipes where small tolerances are required.

Diameter range from 48 mm to 360 mm.

•Double band, standard or with threaded or flanged outlet. Tobe used exclusively as repair clamp and/or tapping saddle.

This type is recommended for cost effective repairs on pipes

where bigger tolerances are required. Diameter range from 88

mm to 650 mm. An advantage of the double band repair

clamp is a high degree of a tight equally distributed sealing

pressure due to the double band.

Main areas of use are for water, gas and sewage covering a

temperature range from -30° C to +110° C.

The single and double band repair clamps can be supplied in

lengths from 100-600 mm with an interval of 100 mm.

The repair clamp is made of stainless steel AISI 304 with teflon

coated stainless steel A2 bolts, bolts and washers. Gasket is

made of NBR rubber as standard. Optional gaskets can be

supplied in EPDM or SBR rubber.



AVK external repair clamp

Repair of large pipes is costly in terms of excavation and traffic

diversion. Companies focus on minimizing repair time and

resources when repairs are needed. It is therefore essential to

have a product on the market that is easy to install and is

expected to last for many years.

We consider the AVK Series 729 the optimal solution for this

task.

The AVK Rewag external repair clamp series 729 primary area

of use is for repair of cracks, holes and open joints in large

dimension pipelines. The clamp is made of two shells that are

fastened with lugs and nuts. The sealing pressure is equally

distributed when tightening the lugs.

Covering angular deflection up to maximum 4 degrees the

clamp is a versatile and user friendly product that is made of

high quality materials to ensure long lifetime.

Major advantages of the AVK Rewag repair clamp series lie inthe fact that all possible parts are made of stainless steel.

Furthermore it is to be mentioned that all welds are chemically

passivated that ensures optimal resistance to corrosion.

Large internal and external repair clamps

-Series 729

Installation of large pipes is costly

in terms of transpor tation,

excavation and installation.

The external repair clamp is easily

mounted by one or two workers in

spite of the large dimension

pipes.

Repairs can be done quickly. No

problem with non-round pip es.

The clamp absorbs the form of

the pipe.

Allround Repair



7

AVK internal repair clamp

The internal repair clamp is made of several segments

(depending on size). Using a key spanner the couplings are able

to expand. The special rubber profile is placed at the edge of

the clamp and it seals off the leakage of the pipe when

expanding the clamp.

The advantages of using the internal clamp is primarily based

on the fact that no excavations or traffic diversion are needed

before installing the clamp. This is time and money saving and

furthermore the installation can be done by using a key spanner

only.

The AVK Rewag Internal Repair Clamp technical features are

identical with the external edition of the clamp.

The internal/external clamps are made of stainless steel AISI316

with teflon coated stainless steel A2 bolts, nuts and washers.

The clamps are also available in AISI314. A4 bolts are

recommended in especially aggressive soil. Gasket is made of

NBR rubber or EPDM rubber approved for drinking water.

The standard sealing range of the repair clamps is 400 mm to

3000 mm. Lengths can be supplied in 200 mm and 400 mm. On

request any diameter and length can be supplied.

The clamps are suitable for water, gas and sewage covering a

temperature range of -30° C to +110° C.

Due to the large dimension of the

pipes a person can move around

inside the pipe without d ifficu lty.

The clamp weight has been kept

very low for easy handling.

The internal repair clamp is

mounted using only a spanner.

The special rubber sealing

ensures that the repair clamp shuts off the leakage permanently.

Time from detecting the leakage

to fulfilled installation is minimal

and with no external

disturbances.

Allround Repair



The AVK Universal couplings are used for mechanical assembly of pipes. Quick and easy assembly

of different pipe materials and different outside diameters is possible using only one coupling

suitable for all types of piping materials including cast iron, ductile iron, PVC and asbestos cement.

The system includes adaptors that can be connected to any flanged object, valves or pipes.

In renovation or repair situations the flexibility of the Supa Coupling System facilitates a fast

assembly of the needed AVK product and the operation can be commenced with short notice.

The system includes:

Series 601 universal Supa coupling DN 40-400 PN 16 and series 602 universal stepped Supa

coupling: accepts angular deflection of ±8 degrees in total

Series 603 universal Supa adaptor: accepts angular deflection of ±4 degrees in total

The unique gasket design of EPDM (DVGW/KTW approved) for water with moulded ribs ensures

that any minor imperfection in the pipe is absorbed by the gasket thus securing a safe mounting

on all pipe materials regardless of size and condition of the pipeline.

The coupling features a maximum tolerance of up to 26 mm on the pipe diameter. Sleeve and

brackets are in ductile iron GGG-40 with epoxy coating to DIN 30677. Bolts/nuts are of mild steel

with rilsan coating, alternatively stainless steel. The use of high quality materials ensures long lifetime of the coupling.

AV K Supa coupl ing

- series 601, 602 and 603

1. Excavate pipe allowing

sufficient clearance to fi t the supa coupling

2. Clean area of pipe where the

fitting is to be installed

3. Measure and check diameter

of pipe against tolerance offitting

4. Lub ricate are a of pipe where

fitting is to be installed. Use

soap b ased lubricant or simi lar.

5. All couplings and adaptors are

pre-assembled to a llow a q uick and ef ficient installation. Within

few minutes mounting is

completed by the use of a

torque wrench.

6. Tigthen bolts in a cross

diagonal way according to the label on the product.

7. The coupling in place.Two

different types of pipes have

been bridged and are now

ready fo r use.

Mounting instructions



9

Mounting instructions

AV K Universal supacol lar repair f i t t ings

-series 52

1. Excavate pipe allowing sufficient clearance

to fit the repair clamp.

2. Clean area of pipe where the fitt ing is to be

installed.

3. Measure and check d iameter of pipe against

toleance of fitting.

4. Lubricate a rea of p ipe where fitting is to be

installed. Use soap based lubricant or

similar.

5. All b olts are fitted with O-rings to p revent

the bolts dropping in the trench.

Furthermore the domed head square neck

bolts automatically stay in position dur ing

installat ion/tightening.

6. Split fitting into two halves by removing

nuts.

DO NOT remove bolts

DO NOT remove seals

DO NOT remove seal assembly or flexibility

ties

The AVK universal supacollar repair Fitting series 52 consists of two identical halves fitted with

rubber seals. Only four bolts are used on all sizes to seal and tighten the fitting. This ensures an

easy and very convenient installation process.

The universal tapping tee/universal collar has a unique sealing system consisting of:

• rubber coated triangular bars sealing along the pipe.

• a rubber gasket encircling the pipe effectively.

The tapping tee’s are available with branch outlets from 80 mm and up to the

diameter of the main pipe itself max. 300 mm. On the tapping flange a shut-off valve can be

mounted directly in order to drill under pressure.

The universal collars with 1/2" - 2" threaded holes are suitable for use as tapping saddles. The

universal supacollar repair system is suitable for repairing all types of leaks under pressure. If the

pipe is completely broken, a maximum 4° angular deviation of the pipe ends can be covered. The

coupling is designed to meet the requirements of British Gas BG/PS 8, part 4.

7. Mount the fitting half complete with bolts on

downside of pipe and supp ort manually.

Locate other half of the fitting over bolts.

Loosely tighten nuts and bolts.

If necessary, rotate fitting carefully on pipe

to required position.

8. Cross tighten to the recommend ed torque

indicated on the fitting.

Use torque wrench.

Ensure fitting is level along axis of pipe

during installation.

9. Pressure test fitting.



0

Recommended field of application

Each product group has its own colour indicating field of application. The statement

of dimensions is a guideline based on our experience and refers to the external pipe

diameter. The application table below is a recommendation but in reality all AVK

repair products can be used regardless of their ability to accept angular deflection.

User guide for

AV K repair equipment

AVK universal suparcollar repair fi ttings

- series 52

The AVK universal supacollar repair fitting is

available in a 1/2" to 2" BSP drilled and

tapped version or as a flanged branch

connection from DN 80 to DN 300.

PVC

560

630

N/A

50

63

75

75

90

110

125

160

200

225

250

280

315

355

400

N/A

DN

40

50

60

65

80

100

125

150

175

200

225

250

300

350

375

400

450

500

600

Steel

355,6

N/A

48,3

60,3

76,1

76,1

88,9

114,3

139,7

168,3

193,7

219,1

244,5

273,0

323,9

406,4

508

610

N/A



The philosophy behind the existing product programme is

to cover the need of our customers in the most efficient

and comprehensive way without compromising quality and

price.

We steadily improve and develop our product programme in

order to offer state-of-the-art products and services. The AVK

repair programme for every possible repair and renovating

situation that demands for prompt and effective handling.

The AVK Ranges of Repair Clamps

AVK Rewag repair fitt ings

series 729 S/D

Single or double band repair fit-

ting with or without flange. Light

weight and cost effective solution

for long lasting repair of pipe

systems.

AVK Rewag internal/external

repair clamps series 729

Easy to mount repair clamp for

large pipe systems. Made of high

quality materials and ensures

optimal corrosion resistance due

to passivated stainless steel.

AVK universal supacollar repair

fitting series 52

Can be used as tapping saddle or

repair fitting. The patented rubber

seal function with ductile iron in-

serts allow up to 30mm tolerance

on the pipe diameter. Suitable for

A/C, cast iron, ductile iron and

steel pipes.

AVK Supa coupling series 601,

602 and 603

Use for quick assembly purposes

of pipes. Able to join different

piping materials in different sizes.

Absorbs a high degree of angular

deflection due to unique gasket

design.

41729XEB/2011-10-07

AVK INTERNATIONAL A /S

Bizonvej 1, Skovby

DK-8464 Galten, Denmark

Tel.: +45 87 54 21 00

Fax: +45 87 54 21 20

E-mail: [email protected]

www.avkvalves.com

avk repair-clamps brochure

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