Consideration for design and installation 192

Calculation of expansion and contraction 192

Controlled pipework movement 192

191
Pipework expansion Plumbing Engineering Services Design Guide

Consideration
for design and
installation
All pipework will expand and contract
longitudinally and around the
circumference when subjected to
temperature variations.
The temperature variations can occur as
a result of fluids within the pipework
being heated or cooled, or from the
effects of external heat sources, such as
the surrounding air temperatures, solar
heat, etc.
The temperature variations can range
from gradual, such as the increase and
decrease in room air temperatures, to
almost instantaneous, such as when hot
water is discharged from a sanitary
fitting, or when heated water is suddenly
circulated through the pipework.
Calculation of
expansion and
contraction
The change in length of pipework, for
both expansion and contraction, due to
temperature variation can be calculated
using the following formula:
Formula 1
AI = I x a x A t
where:
AI = The change in length of the pipe
due to temperature change.
I = The original length of the pipe.
a = The coefficient of linear expansion
(mm/K) .
At = The change in temperature to
which the pipe is subjected (K).
Example 1
What would be the increase in length and
the final length of a straight copper pipe 15
metres long when subjected to a
temperature increase from 20°C to 80°C.
From Table 1, the coefficient of linear
expansion for copper is 16.9 x 10-6rnm/K.
From Formula 1
AI = I x a x A t
= 15 x 16.9 ~ 1 0x. (80
~ - 20)
= 0.0152m (15.2mm)
Therefore the pipe would expand 0.0152m
and the final length of the pipe would be:
=15m + 0.0152m = 15.0152m.
Upon cooling down the pipe will return to its
original length, unless it has been heated
excessively to such a point where a loss in
form hasoccurred.

Generally the change in diameter of

pipework used for Building Services
Engineering will not require detailed
consideration, other than to ensure that
adequate clearances are maintained
between pipes, pipe supports, joists,
building structures, etc, to allow free
movement of the pipework.
The expansion and contraction along the
length of pipework can however be very
significant, particularly for steam,
condensate, heating, domestic hot water
and certain waste pipework installations.
Expansion and contraction within cold
water pipework systems is minimal and
generally does not require any special
consideration.
It should be noted that the rate of
expansion and contraction varies as a
result of the type of material, as well as
the temperature variation. PVC pipework,
for instance, will expand at over three
times that of copper, for the same
temperature rise.
Damage and failure from stress and
strain can occur to pipework systems,
pipework support systems and building
structures unless careful consideration is
given to the change in pipework length
due to temperature change and the
direction in which the expansion and
contraction will take place.
NOTE
‘ K denotes degrees Kelvin. This is the same
Controlled
as a temperature rise measured in Celsius.
‘I’ can be any metric unit of measurement. pipework
AI will be calculated in the same unit of
measurement as that used for 4: Generally
units of either metres (m) or millimetres (mm)
movement
will be used.
Freedom of movement
Consideration must be given during the
Table 1 Typical coefficients of linear design and installation of all pipework
exoansion for various materials
systems to ensure that they are free to
Material Coefficient expand and contract. The following
fmmK x 1W61 important points should be considered:
ABS 60 to 110.2 a. Pipework passing through structures
Aluminium 25.6 should be provided with sleeves or
Brass 19 installed through neatly formed holes,
Bronze 18 to enable unrestricted movement.
Cast iron 12 This includes walls, floors, ceilings,
Chromium 7 floorboards, floor joists, etc. It must
Copper 16.9 be ensured that the pipework will not
Duralumin 23 come into contact with the sleeve or
Lead 29
wall of the hole. Any mastic or other
material used to fill the gap must
Mild Steel 11.3
permit movement of the pipe.
Nylon 80
Polyethylene High Density 140.2 b. Felt pads, or similar, should be
Polyethylene Low Density 225 provided between pipework and
PVC unplasticised 60 to 100
notched joists, and between adjacent
pipes which may come into close
Tin 21
contact with each other.
Zinc 30
c. Pipe clips, supports and guides must
not restrict the movement of the pipe,
NOTE
1P6indicates that the decimal point of the particularly on long pipe runs.
value being considered should be moved six d. Where it is necessary to bury the
places to the left, eg: 10.2 x 1U6equates to pipework in the screed, provision
0.0000 102.
must be incorporated to prevent
damage to the pipework and screed.
This could take the form of a
proprietary plastic coated pipe
wrapped in fibreglass and the whole
surrounded with expanded metal or
similar.

192

Plumbing Engineering Services Design Guide
- Short length of pipe, taken
Dotted line indicates how the Anchor)<,
pipework will expand away
from anchors
.----- - _ _ _ _ _ ,,
I
Anchor
A
------ - - _ _ _ _ _ !
I
I
I
I
I
I
I
I
I
>(Anchor
-L
Figure 7 Typical anchor positions
e. Ensure that any branches connected
to expanding pipework (eg:
connections to radiators), are of
adequate length to provide natural
flexibility to prevent the connection
shearing.
f. Ensure that expanding pipework will
not clash with structures.
g. The direction of pipework expansion
must always be controlled using
suitable anchors, guides and clips.
Standard pipework clips may be
adequate for short pipework lengths
of small bore copper and plastic.
h. Open type pipe clips must not be
used where there is a possibility of
the pipe springing away from the clip.
The above requirements are also
essential to ensure that excessive
frictional noises do not occur as a result
of expansion and contraction.
Anchors
Where expansion is excessive, pipe
movement must be controlled by
installing anchors. Anchors restrain the
pipework ensuring that any movement
due to expansion occurs in a direction
away from the anchor.
Anchors are usually fixed to the middle of
the pipe to enable the pipe to move in
two directions, therefore effectively
halving the maximum change of
pipework length in any given direction.
Sometimes however, it is desirable to
provide an anchor at one end of a pipe
run, for instance, to prevent a pipe from
coming into contact with an adjacent
wall.
When anchors are installed to control
expansion, forces will be exerted on the
anchor. It is therefore essential to ensure
that:
a. The anchor is adequately secured to
the pipe
b. The anchor itself is structurally
adequate
~~
I
Pipework expansion
Pipework provided with additional bends to
rom original of 'carryin accommodate expansion shown in solid line,
, iipe' (the length split with 4 anchor positions.
J
I
I
I
I
/ I
Originally intended pipework route
solder
shown dotted. .;,
Figure 2 Typical anchor for copper pipework Figure 5 Providing additional bends to
accommodate pipework expansion
Plastic coated
Socket saddle strap
channel ~ I/ \I Socket LAnchor AnchorA
Figure 3 Typical anchor for steel pipework Figure 6 Expansion loop/horseshoe section
(light load)
Pipework expansion
devices
Heavy mild steel strap
welded to pipe; bolt
to support
1 Angle or channel
support
dependent on If expansion and contraction of pipework
cannot be controlled with the use of
anchors alone, then consideration must
Locking be given to providing additional devices
channel/an to enable movement to take place. These
not require include:
for lightly
loaded a. Routing pipework with additional
anchors
bends or offsets
b. Providing purpose designed
loop/horseshoe sections in the
This anchor may be used for copper pipes
pipework
using brass strap.
c. Installing expansion bellows or
comDensators
Figure 4 Typical light to medium load anchor
d. Providing expansion couplings for soil
and waste pipework systems.
c. The anchor fixings to the building The provision of additional bends, offsets
structure are adequate or loop/horseshoe pipework systems
d. The building structure itself, to which must provide adequate natural flexibility
the anchor is fixed, is adequate to to accommodate the pipework
accept the forces. expansion.
Where necessary, the advice of a Expansion bellows or compensators are
structural engineer should be obtained to proprietary manufactured devices,
ensure the anchor and support designed to accommodate or absorb
arrangements are adequate for the expansion and contraction.Various
anticipated forces which may be exerted. different types of these devices are
available. It is essential that the
manufacturer be consulted for their
particular recommendations regarding
the most suitable type for the situation
and for their requirements for anchors
and guides.
193
Pipework expansion
The following points should be noted
when using expansion bellows or
compensators:
a. Axial type bellows must not be used
where the pipe is hung or suspended
freely. The pipe supports must guide
the pipe and allow only axial
movement along the entire length of
the pipe.
b. It is essential to ensure that the pipe
is guided carefully on each side of
the bellows. The guides must allow
only axial movement onto the
bellows.
c. It is essential to ensure that the pipe
is guided carefully at the necessary
intervals along the whole pipe run.
d. Only the bellows unit should be
installed between two pipe anchors.
e. The line between two anchors should
be straight, in plan and in elevation,
with no sets or bends.
f. Pipe anchors must be of adequate
strength.
g. Bellows must be stretched by half the
total expansion movement (cold-
draw). This does not apply to special
applications or ‘pre-cold drawn’ units.
h. Screwed end units must be held firm
when installing to prevent twisting of
the bellows.
The most common method of providing
the facility for expansion and contraction
in plastic soil and waste pipe systems is
the use of proprietary expansion
couplings incorporating socket and spigot
joints having rubber sealing rings. The
couplings should be of the same
manufacture as the pipework system.
The expansion couplings should be
introduced at 1.8 metre intervals or as
recommended by the manufacturer, to
connect pipes together.
Plastic pipework should be anchored and
supported in accordance with the
manufacturer’s recommendations.This
will depend on the system employed.
194
Plumbing Engineering Services Design Guide
Supports and pipe guides
The purpose of a support is to transfer
the load of the pipe and the contents
within the pipe safely to a structure. The
pipe support should reduce deflection of
bending of the pipe.
The purpose of a pipe guide is to control
the direction in which a pipe will move
when it expands. A pipe guide is any
form of constraint which allows the pipe
true axial movement along its length but
prevents offset movement whether
horizontal or vertical. Pipe guides can,
however, be designed to also provide a
support facility. Some typical pipe guides
are indicated in Figures 7 to 11.
Figure 7 Strap-type guide
(c,
I 7
Figure 8 Strap-typeguide with tube roller
Figure 9 Strap-typeguide with roller and chair
figure 10 Tube-type Guide
Figure 11 Slip-on Flange Type Guide
Clearance
For guides nearest the bellows, the
clearances between the outside pipe and
inside guide walls should not be greater
than 1.6mm for pipe diameter up to
IOOmm and not greater than 3.2mm for
larger pipes. For the guides along the
pipe run, maximum clearances of 3.2mm
and 6.4mm respectively should be used.
Guides nearest
the bellows
The function of guides closest to the
bellows is to ensure true axial movement
on to the bellows. This can be achieved
by using a tubular type guide (as Figure
10) of such length that the necessary
clearances to permit axial movement do
not allow appreciable offset movement.
Generally a tubular guide having a length
to diameter ratio of 6:l will be adequate.
Tubular guides are generally only fitted to
small pipes. For larger sizes (50mm and
over), proprietary straps and roller guides
are normally employed. Straps and roller
guides are short and individually cannot
control angular movement of the pipe. To
ensure alignment of the pipe onto the
bellows, an additional set of guides is
required as follows.
I-IYz pipe
lllllllt
r diameters
l-----I
Tubular guides 5-6 pipe
diameters
Figure 12 Guide near bellows
I I
I/ Guides as
necessary
7
I - I pipe
~
diameters
BeIIow s 15-20 pipe
diameters
Figure 13 Installation of additional strap and
roller guides
Figure 14 Pipework failure may occur without
pipe guides
I Bowing force
Correct guides
1 Anchor
1 Andhor No ghdes
Plumbing Engineering Services Design Guide Pipework expansion

A
It is essential to ensure that the complete
pipe run is adequately guided and not
just local to the bellows. If this is not
carried out, the pipework may bow
outwards as a result of the compressive
forces imposed on it.
It is essential that all support
Ci = 0.3
arrangements, except for purpose
designed anchors, enable controlled
pipework movement. If the pipework is ~~

incorrectly restrained, damage to the Figure 18a Point contact Figure 186 Line contact
pipe supports or structure may result,
due to excessive friction or forces.

Cold draw of bellows

It is normal for bellows to be ‘cold drawn’
(eg. stretched) by half the total calculated
expansion when installed into a pipe. The
bellows will then absorb the total
expansion, half in tension and half in
compression from the neutral position.
This keeps the stress in the bellows
material to a minimum for a given
expansion and provides maximum
bellows life.
In steam and high temperature heating
applications, it is not necessary to allow
for ambient temperature variation
(dayhight, summer/winter) when
installing the bellows, since this variation
is very small compared with the working
temperature range. However, on low
temperature applications, allowances
must be made when calculating cold
draw. Where very small movements,
vibration or subsidence are to be
absorbed, the bellows manufacturers
often recommend that cold draw is not
used.
U Ci = 0.25
Figure 18c Line contact
Cold draw can be achieved by:
a. for flanged bellows:
Leaving a gap internally between the
bellows and pipe flange at one end of
the unit and then tightening up the
flange using over-sized flange bolts.
b. for screwed bellows:
Under-cuttingthe length of an
adjacent pipe section and allowing
the thread of a connecting union to
expand the bellows. Care must be
taken that the bellow is not twisted
during the tightening process.
c. for welded end bellows:
Installing a pair of flanges in the
pipework adjacent to the bellows with
a gap initially between the flange
Ci = 0.4
Figure 18d Face-to-face contact
Calculating forces
on anchors
The following main factors have to be
taken into consideration when
determining forces on anchors:
a. The effect of test pressure on the
cross-sectional area of any bellows
installed within the pipework system.
b. The elasticity force to stretch and
compress bellows installed through
the working movement.
c. Frictional forces between the pipe
and pipe supports, acting against the
direction of movement.
d. The slope of the pipe, affecting the

,
,
II II I ,1
II I 1 I I I I
I Bellows - cold draw

1 Bellows - neutral I
faces and then tightening up the
flange using over-sized flange bolts.
d. for all bellows:
lower anchor (vitally important if the
pipe is vertical).
e. Fluid pulsation and flow effects in the
I I Bellows-
By purchasing pre-cold drawn pipe.
hot bellows.
I f. Differential forces due to changes in
Total expansion
Cold draw movement pipe diameter.
Quoted friction coefficients between
pipework and supports vary considerably
Figure 15 Cold draw in expansion bellows but the values shown in Figures 18(a),
(b), (c), and (d) may be used as a
general guide for steel on steel.
The frictional resistance (kg) = dead load
at point of support (kg) x coefficient of
friction.

Figure 16 Taking up cold draw on flanged bellows

Figure 19
Figure 17 Taking up cold draw on welded end bellows

Anchor BeIIow s
Anchor
Guide at necessary
intervals

~~

195
Pipework expansion Plumbing Engineering Services Design Guide

This resistance acts against the direction
of movement e.g. it can act either way,
depending on whether the pipe is
warming up or cooling down.
Should the above figures give
unacceptably high forces consideration
could be given to using special PTFE
support pads which gives figures as low
as 0.02.
Example 2
The following example illustrates the
calculation to determine the force imposed
on an anchor under normal working and
test conditions on a pipework installation
indicated in Figure 19, which incorporates
axial type bellows.
The designer must obtain the relevant data
from the bellows manufacturer.
Pipe weight = 22kg/m
Water weight = 19.5kgh
Lagging weight = 6kgh
Effective area of bellows = 0.023m2
Thrust to compress or extend bellows
through full movement = 6700N
from manufacturer’s data (Newtons)
Coefficient of friction between
pipe and supports = 0.3
System working pressure = 550kPa
(550 x 1 0 3 ~ 4
System test pressure = 830kPa
Length of pipe = 42.5
Pipework system under
normal working conditions
Thrust due to internal pressure on bellows
= working pressure x effective area
= 550 x 103x 0.023N
= 12650N pushing outwards on anchors
Force due to bellows stiffness (bellows
compressed in working platform)
= 6700N pushing outwards on anchors.
Frictional resistance to pipe movement over
its supports:
= coefficient of friction x (total weight of
pipe + water + lagging)
= 0.3 x [(22 x 42.5) + (19.5 x 42.5)
+ (6 x 42.5)Ikg
= Converted to Newtons (1kg = 9.807N)
= 0.3 x [(22 x 42.5 + (19.5 x 42.5)
+ (6 x 42.5)] x 9.807N
= approximately 6000N against the
direction of movement, eg. pushing
outwards on anchors.
Total Thrust on Anchor
= 12650 + 6700 + 6000
= 25350N (Newtons) pushing outwards
on anchors.
Pipework system under test conditions vi. The pipe between bellows and
anchors is frequently in compression
Thrust due to internal pressure on bellow
and unless the pipe is guided
= test pressure x effective area carefully, and runs accurately in a
straight line from anchor to anchor,
= 830 x 1O3 x 0.023N
the pipe may bow out sideways. This
= 190909 pushing outwards on anchors will pull the bellows with it and may
Force due to bellows stiffness (bellows cause failure.
stretched in cold-draw position) vii. Never use axial bellows in pipework
= 6700N pulling inwards on anchors systems incorporating suspended
hanger supports or any other support
Frictional resistance systems which can readily swing.
= NIL as pipe only moves under
viii. Confirmation should always be
temperature effect obtained from the bellows
Total thrust on anchor manufacturer regarding any special
requirements they may have
=19090-6700
regarding the position of anchors and
= 12390N pushing outwards on guides.
anchors.
It can be seen in this instance that the
greatest force acting on the anchor is under
normal working conditions, this however is
not always the case.
The following important points should be
considered when installing bellows:
I. When a fitting such as a bend, valve
or distance piece is installed into a
pipe and subjected to internal
pressure. The fitting will act just like a
pipe itself, holding the internal
pressure, but not pushing or pulling
on the pipe.
ii When an axial bellows is fitted into a
pipe and subjected to internal
pressure, it reacts to the internal
pressure by trying to open out
lengthways. An outward pressure is
therefore exerted by the bellows.
iii, When a pipe restrained by an anchor
at one end, but otherwise free to
move longitudinally, is subjected to
heat, it will expand away from the
anchor position, exerting an outward
force away from the anchor.
iv. When a pipe anchored at two points
and provided with a bellows between
the anchor points is subjected to
heat, pressure is exerted by both
pipework sections towards the
bellows. Meanwhile the pressurised
bellows is exerting pressure outwards
towards the two anchor points.
V. When the pipe gets hot, it expands
towards the bellows and tries to
compress it. Meanwhile, the
pressurised bellows is trying to open
out lengthways. The expanding pipe
therefore has to overcome this
pressure force as well as the stiffness
of the bellows and the friction of the
pipe supports. Hence the need for
firm anchors at each end of the pipe
run, and careful guiding not only on
each side of the bellows but also
along the pipe run.

196