Contech Construction A-2000 Installation Manual
A-2000™
ENGINEERED SOLUTIONS
Unloading, Handling
and Installation Guide
Preface
This instruction book is for your crews. Distribute it
to help them install Contech® A-2000™ correctly.
They are flexible pipes that must be installed
following the trench construction, bedding,
haunching, initial backfill, and other requirements
of ASTM D 2321,“Standard Recommended
Practice for Underground Installation of Flexible
Thermoplastic Sewer Pipe.”
Don’t assume experienced workers know all
the answers. Review these instructions with your
supervisors and crews. It can mean a better job
for you and your customer.
We suggest that you adopt a policy of
performance testing the first few manhole runs.
It will give you an early check that installation
procedures are correct.
If you have any questions about these instructions,
call your Contech Distributor or your Contech
Sales Engineer, or carefully review the installation
guide in the Contech A-2000 catalogs and ASTM
D 2321.
2
Contents
Cold Weather Installation ......................... 5
Unloading and Handling .......................... 6
Trenching ................................................ 8
Installation Tips ........................................ 9
Assembly of Pipe .................................... 10
A. Gasket/Pipe Connection .............. 10
B. Manhole Connection .................... 12
C. Field Cutting Pipe ........................ 14
D. Caps ...........................................14
E. Mechanical plugs ......................... 14
F. Tapping/Saddle Connections ......... 15
Repairs .................................................. 18
Installation of Pipe ................................. 20
A. Pipe Zone/Embedment Material .... 20
B. Deflection Control ........................ 26
Deep Laterals ........................................ 27
Special Notes ........................................ 28
Standard Details ..................................... 30
This safety alert symbol indicates
important safety messages.
When you see this symbol,
be alert to the possibility of
personal injury and be sure you
understand the message that follows.
3
Terms You Should Know
Alerts you to
hazards or unsafe
practices that CAN result in severe
personal injury or property damage.
Messages about
procedures or actions
that must be followed for safe
handling and installation of A-2000
Pipe.
Falling or rolling pipe
can cause severe
personal injury
or death.
Read and follow all safety instructions
before unloading pipe.
4
Cold Weather Installation
1. Handle the pipe with more care in cold
weather. PVC outer walls can become
hardened as temperatures drop. When placing
embedment materials in deep trenches and
temperatures 0° - 32° F, it is required to use
smaller aggregate (3/4- inch max.) and limit
the height of dumping stone, not to exceed
20 feet.
2. Rubber gaskets become harder as the
temperature decreases, gaskets tend to
compress less, and when combined with PVC
bells that become more installation sensitive,
jointing becomes less forgiving. Proper
bell-spigot alignment, adequate bell and
spigot lubrication, and recommended joining
procedures (-i.e. bar and block) all become
more essential as temperature decreases.
In addition, it is recommended to store the
gaskets in a warm place prior to use.
5
Unloading and Handling
The following equipment is recommended for
unloading pipe pallets:
Forklift with full-length forks to engage entire
pallet width, front-end loader or backhoe
with fork adapters full length to engage entire
pallet width.
Nylon lifting slings of sufficient strength and
length to safely handle entire pallet. Do
not stand or ride on the pipe load during
unloading.
NOTE: Pipes sizes 18” and less are palletized with
steel straps around a wood frame. Full trailer width
pallets (21” to 36”) are not framed. Only forks of
sufficient length to engage entire pallet width are
recommended for unloading.
Table 1. A-2000 PVC Handling Weights
Diameter (in) Weight (lbs/ft)
4 1.00
6 1.25
8 2.00
10 3.00
12 4.25
15 7.00
18 10.00
21 13.00
24 17.00
30 25.00
36 34.00
6
Failure to follow these instructions can result in
serious injury or death and/or damage to pipe.
1. Only trained and authorized equipment
operators are to be permitted to unload the
trailer.
2. Wear approved safety hat and shoes, gloves, and
eye protection.
3. Park the truck and trailer on level ground before
you start unloading.
4. Keep all unauthorized persons clear of the area
when the driver releases the binders from the
trailer and during unloading.
5. Do not release steel strapping around the wood
frame until the pallets have been placed on level
ground and will not be moved again as a unit.
6. Know the capabilities and rated load capacities
of your lifting equipment. Never exceed them.
7. Do not stand or ride on the load of pipe while it
is being unloaded. Do not stand beneath or near
the pipe when it’s being unloaded.
8. If unloading at multiple points,
secure pallets between drop
off points. For each unit of
four pallets, always unload the
top pallets first. (See diagram)
9. Never attach chains or wire
rope to the pipe. They could damage the pipe.
10. Do not push pallets off the trailer or permit pipe
to drop to the ground.
11. Do not drag A-2000 Pipe across the ground.
12. Do not stack A-2000 Pipe over two pallets high.
Stacks of three or more pallets can damage
bottom pipes and can become unstable.
13. Handle A-2000 Pipe with extra care in freezing
or cold weather.
7
Trenching
Trenching practice and bedding materials shall be
in accordance with ASTM D2321 and OSHA rules.
1. The excavation needs to be wide enough
and be supported adequately to allow a
person to work safely.
2. Where trench walls are unstable, the contractor
may elect to use sheeting, stay bracing, or
a trench box for stabilization during pipe laying. If
the conditions are severe, sheeting may be left in
place.
3. Excessive groundwater may necessitate dewatering.
4. An unstable trench bottom must be stabilized at the
engineer’s direction. In such cases, install special
foundation and bedding materials in 6-inch layers
and compact.
5. Excavation from 6 inches to 12 inches below the
pipe should be filled with acceptable bedding
material and compacted to a minimum 90%
Standard Proctor Density. Fill areas of over
excavation beyond 12 inches with processed stone
or gravel following standard bedding practices
6. Before installing the pipe, bring bedding material
to grade along the entire length of the pipe.
7. When excavating in Class IV materials (silt, silty
clays, and clays), provide a uniform, undisturbed
foundation.
8
Installation Tips
1. At manholes, flexible manhole connections like
rubber boots, A-Loks, etc. can be used.
With rubber boot manhole connectors, install
either a standard A-2000 double
gasket (8”-10”) or an A-2000 manhole gasket
(12”-36”) on the pipe spigot under the stainless
steel strap (see manhole connection detail on page
12). Where manholes are manufactured with A-Lok
connections, use a Contech PVC manhole sleeve.
2. Do not probe for the pipe with rods, shovels, or
other sharp objects when excavating down to
install laterals, etc. Instead, mark the elevation of
the pipe with stakes or other markers to help locate it.
3. When haunching the pipe or digging down to
install laterals, take care not to damage the pipe
with shovels, or other construction equipment.
4. String only enough pipe to use during the day’s
laying operations.
5. A full line of adapters to other pipes is available. See
Contech A-2000 Fittings Catalogs.
6. After proper assembly, the first load of backfill
should be placed over the middle of the pipe.
While the first load is being placed, the free bell
end should be held safely on line by the pipe layer.
This technique will minimize pipe movement during
backfilling. Subsequent loads of backfill may be
placed in a normal fashion.
9
Assembly of Pipe
A. Gasket/Pipe Connection
1.The double sealing surface A-2000 gaskets
are fitted to the first two full corrugations on the
spigot end of the pipe as shown in the drawing.
The single sealing surface A-2000 Drainage
gaskets are fitted in the first corrugation valley
as shown in the drawing.
Gaskets are shipped loose and require field
installation on the pipe spigot. The leading
(lower) edge of the gasket is marked with the
Contech logo and wording to distinguish it from
the seating (higher) edge.
The low height seal is fitted into the first
corrugation. The double sealing gasket is fitted
into the first two full corrugation valleys.
10
Pipe
end
Spigot
Gasket location
on 4” to 36”
diameter
A-2000
Bell
(plantformed)
Gasket location
on A-2000 pipe
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