Installation Guide
Use this general planning guide to prepare and review the work. It is not a model-specific procedure: the approved product drawing, torque table, project method statement and operator safety procedure always take priority.
Before assembly
Most installation problems begin with the wrong OD, damaged sealing surfaces, poor alignment or uneven bolt loading.
Prepare the work pack
A product name and nominal diameter are not enough for a controlled installation. The crew should be able to identify the exact model, the pipe outside diameter covered by that model, the connection standard and the permitted assembly position. If any of those details conflict with the site condition, stop and return the question to the project engineer or product supplier before work continues.
Issue the current product drawing, bill of materials, gasket and lubricant instructions, bolt-tightening sequence, torque table, project method statement and test procedure. Mark superseded drawings so they cannot be used by mistake.
Confirm that OD measurement tools, cleaning tools, alignment equipment, lifting gear and the specified torque equipment are available and suitable for the range. A nominal pipe label should never replace an actual OD check on the sealing surface.
Verify isolation, drainage, stored-pressure control, lifting access, excavation stability, confined-space requirements and safe access around every bolt. The approved safety procedure controls the job, including any restrictions on live work or tapping.
By product family
The summaries below help a project team plan tools, access and sequence. Always obtain the model-specific drawing before work starts.
Clean and mark the pipe end. Slide the gland and gasket into the correct orientation, position the flange adaptor with the specified end clearance, align the annular gap and tighten gland bolts evenly. Connect the mating flange using the correct gasket and flange-bolt sequence.
View product rangeUse the approved model drawing to mark the required insertion or centre positions on both pipe ends. Fit glands and gaskets, align the pipe axes, maintain the model-specific end gap and centre the sleeve. Move both seals into the sleeve mouths and tighten bolts in the specified sequence.
View product rangeVerify both mating flanges and nominal pressure. Position the joint between the flanges, set the telescopic length, engage the sealing system, tighten gland bolts evenly and lock the tie rods to the approved thrust arrangement.
View product rangeMeasure the OD and defect, clean sound pipe surface beyond the damage and centre the gasket over the leak. Engage the bridge plate correctly, tighten nuts from the centre outward in staged increments and re-check torque before commissioning.
View product rangeConfirm pipe material, OD and outlet orientation. Clean the gasket area, align both saddle halves, tighten bolts evenly and complete tapping only under the utility’s approved procedure.
View product rangeConfirm movement, pressure, temperature and medium. Install anchors and guides first, align flanges without forcing the element, tighten bolts evenly and verify clearance through the complete movement envelope.
View product rangeHold points and handover
A final visual check is easier before the trench, chamber or plant area is closed. Record the checks required by the project and keep the product-specific instructions with the handover package.
Check insertion marks, centre position, flange alignment, gland gaps, available movement and clearance. The connected pipework should not force a component into position or transfer an unplanned load into the joint.
Verify that the correct fasteners, washers and specified lubricant were used. Review the tightening pattern and record final torque where the project procedure requires it. Do not mix a general torque value with a model-specific table.
Fill, vent and pressurize the system in accordance with the approved test method. Observe the complete seal area and supporting pipework during each stage. If leakage or movement appears, isolate and diagnose the cause before applying more torque.
Record the installed model, size, location, drawing revision, inspection result and any approved deviation. Keep photographs where the project requires them, especially before buried work is covered or access becomes restricted.
Use an alternating or cross-pattern sequence. Build torque in stages instead of fully tightening one bolt at a time.
Torque depends on bolt size, gasket, product model and pipe material. Do not copy one value across the full range.
Pressure-test using the project procedure, inspect the complete seal area and correct leakage before returning the pipeline to service.
Troubleshooting
| Observation | Check first | Do not assume |
|---|---|---|
| Leak at gasket | OD, surface, gasket orientation, insertion and bolt sequence | More torque will correct misalignment |
| Uneven gland gap | Pipe centring, angular alignment and alternating tightening | One-sided tightening is acceptable |
| Bolt torque falls | Thread condition, staged tightening and model re-torque guidance | Any bolt lubricant is permitted |
| Movement after test | Tie rods, anchors, guides and restraint design | The seal alone controls pipeline thrust |
Do not work on a pressurized pipeline unless the network owner, product instructions and an approved method statement explicitly allow it. Confirm isolation, stored pressure, lifting, confined-space and live-tapping controls before work begins.
Related technical guides
References and scope
The safety and installation principles above are informed by the official references below. They establish general controls for hazardous energy and ductile-iron pipeline installation; they do not replace the approved Conflex model drawing, torque table, project method statement or network-owner procedure.
Frequently asked questions
Use the approved torque table for the exact product, fastener, gasket and service condition. This general guide does not publish a universal torque because one value should not be copied across different models or sizes.
No. It is a planning and review guide only. The current model drawing, product instructions, project method statement, safety procedure and test plan take priority for the work.
Not without first isolating the system and identifying the cause. Incorrect OD, surface condition, gasket position, alignment, insertion or restraint may not be corrected by additional torque.
Stop when the delivered model, pipe OD, flange drilling, pressure class, installation gap, surface condition, restraint arrangement or approved documents do not agree with the site condition.
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