AS 4181—2013

AS 4181—2013

Australian Standard®

Repair and off-take clamps for water

industry purposes
This Australian Standard® was prepared by Committee WS-016, Cast Iron Pressure Pipes
and Fittings. It was approved on behalf of the Council of Standards Australia on 19 February
2013.
This Standard was published on 8 April 2013.

The following are represented on Committee WS-016:

• Association of Accredited Certification Bodies

• Australian Chamber of Commerce and Industry
• Australian Industry Group
• Plastics Industry Pipe Association of Australia
• Plastics New Zealand
• Water Industry Operations Group
• Water New Zealand
• Water Services Association of Australia

This Standard was issued in draft form for comment as DR AS 4181.

Standards Australia wishes to acknowledge the participation of the expert individuals that
contributed to the development of this Standard through their representation on the
Committee and through the public comment period.

Keeping Standards up-to-date

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systems. To maintain their currency, all Standards are periodically reviewed, and new editions
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using a current Standard, which should include any amendments that may have been
published since the Standard was published.

Detailed information about Australian Standards, drafts, amendments and new projects can
be found by visiting www.standards.org.au

Standards Australia welcomes suggestions for improvements, and encourages readers to

notify us immediately of any apparent inaccuracies or ambiguities. Contact us via email at
[email protected], or write to Standards Australia, GPO Box 476, Sydney, NSW 2001.
 AS 4181—2013

Australian Standard®

Repair and off-take clamps for water

industry purposes

Originated as AS 4181—1994.
Previous edition 1999.
Third edition 2013.

COPYRIGHT
© Standards Australia Limited
All rights are reserved. No part of this work may be reproduced or copied in any form or by
any means, electronic or mechanical, including photocopying, without the written
permission of the publisher, unless otherwise permitted under the Copyright Act 1968.
Published by SAI Global Limited under licence from Standards Australia Limited, GPO Box
476, Sydney, NSW 2001, Australia
ISBN 978 1 74342 388 2
AS 4181—2013 2

PREFACE
This Standard was prepared by the Joint Standards Australia/Standards New Zealand
Committee WS-016 Cast Iron Pressure Pipes and Fittings, to supersede AS 4181—1999,
Stainless steel clamps for waterworks purposes.
This Standard is the result of a consensus among Australia/New Zealand representatives on
the Committee to produce it as an Australian Standard.
The objective of this Standard is to include design, materials and type tests required for
clamps for the Australian water industry.
The objectives of this revision are the following:
(a) Introduction of a broader range of materials.
(b) Increase in nominal diameters for repair clamps.
(c) Recognition of issues associated with low stiffness pipes, as addressed in WSA 122,
Industry Standard for Flanged Off-take Clamps.
(d) Change of title to better reflect the scope of the Standard.
Key aspects from WSA 122 that have been incorporated into the Standard are the
differentiation between Type R and Type F applications, and the associated type testing
required to demonstrate suitability of a product.
The terms ‘normative’ and informative’ have been used in this Standard to define the
application of the appendix to which they apply. A ‘normative’ appendix is an integral part
of a Standard, whereas an ‘informative’ appendix is only for information and guidance.
Statements expressed in mandatory terms in notes to tables and figures are deemed to be
requirements of this Standard.
 3 AS 4181—2013

CONTENTS

Page

SECTION 1 SCOPE AND GENERAL

1.1 SCOPE ......................................................................................................................... 4
1.2 DEMONSTRATION OF COMPLIANCE ................................................................... 4
1.3 APPLICATION ........................................................................................................... 4
1.4 NORMATIVE REFERENCES .................................................................................... 5
1.5 DEFINITIONS............................................................................................................. 6
1.6 DESIGNATION OF SIZE ........................................................................................... 7
1.7 ALLOWABLE OPERATING PRESSURE (AOP) VALUES ...................................... 7
1.8 DESIGN VARIATION ................................................................................................ 7

SECTION 2 MATERIALS
2.1 REQUIREMENTS ....................................................................................................... 8
2.2 STAINLESS STEEL.................................................................................................... 8
2.3 COATING ................................................................................................................... 9
2.4 ELASTOMERIC SEALS ............................................................................................. 9
2.5 EFFECT ON WATER ................................................................................................. 9

SECTION 3 DESIGN
3.1 CLAMP COMPONENTS .......................................................................................... 10
3.2 CLAMP DESIGN FEATURES.................................................................................. 10
3.3 MEANS OF ATTACHMENT.................................................................................... 10
3.4 BI-METALLIC CONTACT ....................................................................................... 10
3.5 FASTENERS ............................................................................................................. 11
3.6 CLAMP MINIMUM LENGTH ................................................................................. 11
3.7 OFF-TAKE CLAMPS ............................................................................................... 11
3.8 FREEDOM FROM DEFECTS .................................................................................. 11

SECTION 4 TESTING
4.1 TYPE TESTS............................................................................................................. 12
4.2 BI-METALLIC COUPLE .......................................................................................... 14

SECTION 5 MARKING AND PACKAGING

5.1 MARKING ................................................................................................................ 15
5.2 PACKAGING ............................................................................................................ 15
5.3 INSTALLATION INSTRUCTIONS AND PIPE COMPATIBILITY ........................ 15

APPENDICES
A DEMONSTRATION OF COMPLIANCE WITH THIS STANDARD ...................... 16
B ASSEMBLY TEST .................................................................................................... 21
C LEAK-TIGHTNESS TEST DURING APPLICATION OF A BENDING
MOMENT TO THE CONNECTING PIPE ................................................................ 23
D RESISTANCE TO DEPRESSURIZATION AND ROTATIONAL
AND SLIDING MOVEMENT .................................................................................. 26

BIBLIOGRAPHY ..................................................................................................................... 29
AS 4181—2013 4

STANDARDS AUSTRALIA

Australian Standard
Repair and off-take clamps for water industry purposes

S E C T I O N 1 S C O P E A N D G E N E R A L

1.1 SCOPE
This Standard specifies the requirements for the design, materials and in-service
performance of Type R and Type F mechanical clamps for water industry purposes.
In this Standard—
(a) Type R clamps are designated for applications involving rigid pipes, typically ductile
iron (DI), grey cast iron (CI), steel (S), asbestos cement (AC), copper (CU) and
reinforced concrete (RC); and
(b) Type F clamps are designated for applications involving flexible pipes, typically
oriented polyvinylchloride (PVC-O), modified polyvinylchloride (PVC-M),
unplasticized polyvinylchloride (PVC-U) and glass reinforced thermoplastics (GRP).
Clamps complying with this Standard are intended for use in off-take connections on
pressure pipelines of the sizes up to and including DN 600, and repair applications on
pressure pipelines of all sizes, with a maximum operating temperature of 40ºC.
This Standard does not cover the following:
(i) The use of repair or off-take clamps on polyethylene (PE) pipelines.
(ii) Tapping bands/saddles.
NOTE: Tapping bands and saddles area covered in AS/NZS 4793 or AS/NZS 4129.

1.2 DEMONSTRATION OF COMPLIANCE

Demonstration of compliance with this Standard shall be in accordance with Appendix A.

1.3 APPLICATION
1.3.1 General
Repair and off-take clamps have limited ability to accommodate axial deflection and,
therefore, are not intended for use as couplings to join two pipes together.
Repair and off-take clamps are suitable for use in both above-ground and buried
applications.
1.3.2 Repair clamps
Repair clamps complying with this Standard are intended to provide a permanent means of
preventing loss from or contamination of pipelines that have been affected by corrosion or
mechanical damage.
1.3.3 Tapped off-take clamps
Tapped off-take clamps complying with this Standard are intended to provide a permanent
threaded connection into new and existing pipelines. Tapped off-take clamps are suitable
replacements for existing tapped connections that are damaged or where the surface of the
pipeline to be tapped is not suitable for the use of a tapping band.
Tapped off-take clamps may be used in under-pressure connection applications.
© Standards Australia www.standards.org.au
 5 AS 4181—2013

1.3.4 Flanged off-take clamps

Flanged off-take clamps complying with this Standard are intended to provide a permanent
means of making a flanged connection to a pipeline.
Flange off-take clamps may be used in under-pressure connection applications.

1.4 NORMATIVE REFERENCES

The following are the normative documents referenced in this Standard:
NOTE: Documents referenced for informative purposes are listed in the Bibliography.
AS
1112 ISO metric hexagon nuts
1112.1 Part 1: Style 1—Product grades A and B
1199 Sampling procedures and tables for inspection by attributes
1199.1 Part 1: Sampling schemes indexed by acceptance quality limit (AQL) for lot-
by-lot inspection
1646 Elastomeric seals for waterworks purposes
1831 Ductile cast iron
2074 Cast steels
2205 Methods for destructive testing of welds in metal
2205.10.1 Methods 10.1: Corrosion test for welded austenitic stainless steel
4291 Mechanical properties of fasteners made of carbon and alloy steel
4291.1 Part 1: Bolts, screws and nuts
AS ISO
7 Pipe threads where pressure-tight joints are made on the threads
7.1 Part 7.1: Dimensions, tolerances and designation
AS/NZS
1462 Methods of test for plastics pipes and fittings
1462.6 Part 6: Thermoplastics pipes, fittings and assemblies for the transport of
fluids under pressure—Resistance to internal pressure
1462.8 Part 8: Method of testing the leaktightness of assemblies
1554 Structural steel welding
1554.6 Part 6: Welding stainless steels for structural purposes
1594 Hot-rolled steel flat products
3678 Structural steel—Hot-rolled plates, floorplates and slabs
4020 Testing of products for use in contact with drinking water
4087 Metallic flanges for waterworks purposes
4158 Thermal bonded polymeric coatings on valves and fittings for water industry
purposes
ASTM
A240/ Standard Specification for Chromium and Chromium-Nickel Stainless Steel
A240M Plate, Sheet, and Strip for Pressure Vessels and for General Applications
A276 Standard Specification for Stainless Steel Bars and Shapes
A312/ Standard Specification for Seamless, Welded, and Heavily Cold Worked
A312M Austenitic Stainless Steel Pipes
A380 Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel
Parts, Equipment, and Systems
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AS 4181—2013 6

API
5L Specification for Line Pipe
ANSI
B16.3 Malleable Iron threaded Fittings: Classes 150 and 300
AWS
A5.9 Specification For Bare Stainless Steel Welding Electrodes And Rods
ISO
724 ISO general purpose metric screw threads—Basic dimensions
965 ISO general purpose metric screw threads—Tolerances
965-1 Part 1: Principles and basic data
3506 Mechanical properties of corrosion-resistant stainless steel fasteners (all parts)
6507 Metallic materials—Vickers hardness test
6507-1 Part 1: Test method
7089 Plain washers—Normal series—Product grade A
WIS
04-52-03 Specification for anti-corrosion coatings on threaded fasteners
WTIA
TN13 Stainless Steels for Corrosive Environments
WSA
109 Industry Standard for Flange Gaskets and O-rings

1.5 DEFINITIONS
For the purposes of this Standard, the definitions below apply.
1.5.1 Allowable operating pressure (AOP)
The allowable internal pressure, excluding surge, which a component can safely withstand
in service, expressed in megapascals.
1.5.2 Allowable site test pressure (ASTP)
The maximum pressure to be applied on site in a newly installed pipeline, including a safety
factor and allowance for surge, expressed in megapascals.
1.5.3 DN (nominal size)
An alphanumeric designation of size for a component in a pipe work system, which is used
for reference purposes. It comprises the letters DN followed by a dimensionless whole
number, which is directly related to the physical size, in millimetres, of the internal or
external, as applicable, nominal diameter of the pipe.
1.5.4 dn (nominal size of the connecting pipe)
An alphanumeric designation of size of the connecting pipe on an off-take clamp, which is
used for reference purposes. It comprises the letters dn followed by a dimensionless whole
number, which is directly related to the physical size, in millimetres, of the internal or
external, as applicable, nominal diameter of the pipe.
1.5.5 Maximum allowable operating pressure (MAOP)
The maximum internal pressure, including surge, that a component can safely withstand in
service, expressed in megapascals.

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 7 AS 4181—2013

1.5.6 Maximum operating temperature

The maximum internal or external temperature (40°C) to which the clamp is exposed in
service.
1.5.7 Off-take clamp
A clamp with an integral off-take in flange, nipple or socket design which retains the
integrity of the clamp seal.
1.5.8 Pressure classification
A classification of clamp by a PN number based on the AOP, expressed in megapascals
(PN = 10 × AOP).
1.5.9 Repair clamp
An elastomeric-lined metal sheet with an integral clamping system designed for the repair
of pipes and for providing a full circumferential seal.
1.5.10 Size range
The range of outside diameters of pipe for which the clamp is designed.

1.6 DESIGNATION OF SIZE

Off-take clamp size shall be designated by the nominal size of the host pipe followed by the
nominal size of the connecting branch pipe (i.e. DN 100 × dn 80 signifies the fitting as
suitable for a DN 100 pipe with a dn80 connecting pipe).

1.7 ALLOWABLE OPERATING PRESSURE (AOP) VALUES

The AOP values shall be MAOP = 1.2 × AOP and ASTP = 1.25 × AOP.
NOTE: Allowable pressures for commonly used pressure application are given in Table 1.1.

1.8 DESIGN VARIATION

When there is variation in material properties, material thicknesses, fastening mechanisms,
seal material or seal shape, it shall be deemed to be a design variation. Differences in clamp
length or off-take size and type are not considered design variations.

TABLE 1.1
ALLOWABLE PRESSURES FOR COMMONLY USED
PRESSURE CLASSIFICATIONS

Pressure Allowable operating Maximum allowable Allowable site test

classification pressure (AOP) operating pressure (MAOP) pressure (ASTP)
PN MPa MPa MPa
10 1.00 1.20 1.25
16 1.60 1.92 2.00
21 2.10 2.52 2.63
35 3.50 4.20 4.38

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AS 4181—2013 8

S E C T I O N 2 M A T E R I A L S

2.1 REQUIREMENTS
The material for the manufacture of clamps shall be in accordance with Table 2.1.
Alternative materials may be used provided they are equivalent in performance, particularly
with respect to strength, corrosion-resistance, clamp operation and durability.
NOTE: Material equivalence may be considered by a ruling committee of asset owners and
manufacturers selected by the Water Services Association of Australia (WSAA) from standing
members of the relevant Standards Australia Committee(s).

TABLE 2.1
MATERIAL REQUIREMENTS
Materials
Component
Material Standard
Clamp body Coated ductile iron Grade 500-7 AS 1831
or 400-12 AS/NZS 4158
Stainless steel Grade 316/316L ASTM A240/A240M
ASTM A276
ASTM A312/A312M
ANSI B16.3
Coated steel: All products coated to AS/NZS 4158
C3 AS 2074
HA1016 AS/NZS 1594
HXA1016 AS/NZS 1594
250 or 300 AS/NZS 1594
250 or 300 AS/NZS 3678
Grade X42 or X52 ERW API 5L
Seals Elastomer SBR, NBR EPDM AS 1646
Fasteners Stainless steel Grade 316/316L ASTM A240/A240M/ASTM A276
ISO 3506 (All parts)
Carbon steel AS 4291
(coated to WIS 04-52-03)
Washers Stainless steel Grade 316/316L ASTM A240/A240M
ISO 6507-1, hardness 200HV

2.2 STAINLESS STEEL

Stainless steel components that are subjected to welding, including repair welding, during
the manufacture of any component shall either be low carbon or stabilized grade, or shall
meet the carbon requirements specified in WTIA TN13. All stainless steel components shall
be passivated in accordance with ASTM A380.
All welding shall be carried out in accordance with AS/NZS 1554.6 with welding quality
Category 2B. Welding shall be capable of meeting the requirements of the intergranular
corrosion test specified in AS 2205.10.1 and electrodes to AWS A5.9, except inspection.
Inspection shall be carried out by suitably trained persons approved by the manufacturer to
meet its requirements.

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 9 AS 4181—2013

2.3 COATING
The internal and external surfaces of ductile iron and carbon steel clamp components shall
be coated with thermal-bonded polymeric coating in accordance with AS/NZS 4158.

2.4 ELASTOMERIC SEALS

Elastomeric seals shall comply with the requirements of AS 1646, except for flange gaskets
and O-rings which shall comply with WSA 109.

2.5 EFFECT ON WATER

Clamps shall comply with AS/NZS 4020 using a scaling factor of 0.05.

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AS 4181—2013 10

S E C T I O N 3 D E S I G N

3.1 CLAMP COMPONENTS

The clamp shall comprise a body (with or without a branch off-take connection), an
elastomeric seal and a means of attachment to the pipe.

3.2 CLAMP DESIGN FEATURES

3.2.1 Type R clamps
Type R clamps shall be designed for use on ‘rigid’ pipes including DI, CI, S, CU, RC
and AC.
3.2.2 Type F clamps
Type F clamps shall be—
(a) designed for application to flexible pipes including PVC-O, PVC-M, PVC-U, GRP
and other plastics pipes;
NOTES:
1 Type F may be designed for use on Series 1 or Series 2 or both Series 1 and Series 2
flexible pipes
2 PVC-O, PVC-M AND PVC-U pipes are manufactured in two series, Series 1 and Series 2.
The outside diameters of Series 1 and Series 2 pipes for a particular DN are different.
Dimensions for Series 1 and Series 2 are given in the relevant Standards.
3 GRP pipes are manufactured internationally in a number of series, Series A and
Series B1, B2, B3, B4, B5 and B6. The internal and external diameters of the different
series pipes from a particular DN are different. Dimensions for the different series pipes
are given in the relevant Standard. AS 3571.1 lists variations to ISO 10467:2004
forAustralian applications.
(b) full circle design, incorporating a positive stop feature to prevent diametrical
deflection as specified in Clause 4.1.3 and, if spacers or other means are used to limit
the fully tightened position, they shall be captive in the clamp; and
(c) able to accommodate the maximum and minimum tolerances of pipe diameter and
ovality for the material specific pipe Standard(s) for which they are designed.
3.2.3 Type R and Type F clamps
Type R and Type F clamps shall be designed for use on rigid and flexible pipes, provided
the pipes meet the requirements for both Type R and Type F clamps.

3.3 MEANS OF ATTACHMENT

The means of attachment shall ensure that the clamp meets the performance requirements of
this Standard. Where nuts and bolts are used, either the nuts or the bolts, or both, shall be
retained in the clamp.
The clamping system shall be self aligning and locking in its assembly prior to the
tightening of its retaining system.

3.4 BI-METALLIC CONTACT

Where a clamp is intended for use on metallic pipes, electrical insulation shall be
incorporated into the clamp design to prevent bi-metallic corrosion.
NOTE: Coatings may provide suitable electrical insulation.

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 11 AS 4181—2013

3.5 FASTENERS
Clamp fastening systems shall conform to the requirements of ISO 724 and ISO 965.1 for
screw threads, AS 1112.1 for nuts and ISO 7089 for washers. All stainless steel threads
shall be roll-formed. Stainless steel fasteners shall be passivated in accordance with
ASTM A380. Galling prevention compounds shall be factory-applied to the thread of the
fastener or the nut, or both.
Torque requirements for the installation of a clamp shall be specified in the installation
instructions or clamp, or both, in newton metres (Nm).
Graphite greases, graphite packing and graphite compounds shall not be used in contact
with stainless steel.
Washers shall be used where nuts would otherwise contact a coated surface.

3.6 CLAMP MINIMUM LENGTH

Product literature shall specify the minimum clamp length appropriate for a given size of
pipe and off-take (if applicable).

3.7 OFF-TAKE CLAMPS

Flanges shall comply with AS/NZS 4087 or other national Standards (where specified).
Threaded connections shall comply with AS ISO 7.1 or other national Standards (where
specified).
The pressure classification of a clamp shall be not greater than the pressure classification of
its off-take connection.
The bore of the branch of an off-take clamp shall be free from protrusions that could restrict
the free flow of water.

3.8 FREEDOM FROM DEFECTS

The clamp shall be clean, smooth and free from cracks, tears and other defects that could
affect the performance or function of the clamp in service and the safe handling of the
clamp during installation and use.
Small surface imperfections that are not detrimental to the functional quality of the clamp
may be accepted, or may be rectified, provided compliance with all requirements of this
Standard are maintained.
Cracks or tears shall not be repaired as part of clamp manufacture.

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AS 4181—2013 12

S E C T I O N 4 T E S T I N G

4.1 TYPE TESTS

4.1.1 General
Type testing shall be carried out at ambient temperature, unless otherwise specified.
Type R clamps shall be tested in accordance with Clauses 4.1.4, 4.1.5, 4.1.6 and 4.1.7
(resistance to rotation only) and Clause 4.2, where applicable.
Type F clamps shall be tested in accordance with Clauses 4.1.3 to 4.1.7, where applicable.
Type testing of clamps shall be carried out as follows:
(a) Type R clamps shall be tested with pipe samples that conform to the relevant standard
or fabricated metal testing fixtures.
Where a Type R clamp can be applied to a range of pipe diameters, tests shall be
performed on a fixture with an outside diameter equal to the minimum of the clamp
range.
Where a Type R clamp is only applicable to a single pipe diameter, tests shall be
performed on a fixture with an outside diameter equal to the minimum outside
diameter tolerance of RC pipe, as defined by AS/NZS 4058.
Testing fixtures shall be—
(i) rated to withstand 2.4 MPa test pressure or greater; and
(ii) have a long-term pipe stiffness of 20 000 N m/m or greater.
(b) Type F clamps that are designated compatible with Series 1 pipe shall be tested on
PVC-M PN9 Series 1 pipe or other Series 1 PVC pipe of equivalent stiffness.
Type F clamps that are designated compatible with Series 2 pipe shall be tested on
PVC-O MRS400 PN12.5 or PVC-O MRS500 PN16 Series 2 pipe or other Series 2
PVC pipe of equivalent stiffness.
The hydrostatic test shall be performed as per the pressure classifications given in
Clause 1.7.
NOTE: The pipe types chosen as the testing criteria represent the lowest long-term ring
stiffness Series 1 or Series 2 pipe in common use. Any further pipeline developments may
require modification of the specified pipe to be used in the test.
4.1.2 Selection of clamps for type testing
4.1.2.1 General
For off-take clamps, the tests carried out on a particular DN × dn shall qualify all smaller
off-take sizes for that clamp, DN and outside diameter compatibility.
Example:
Type testing a DN 150 Type F Series 1 clamp with dn100 branch qualifies all DN 150
Type F Series 1 clamps with off-take sizes up to and including dn100; however it
does not qualify DN 150 Type F Series 1 clamps with a dn150 off-take or DN 150
Type F Series 2 clamps or DN 150 Type R clamps.
Where the same clamp design and size is produced in different lengths, testing of a
shorter clamp qualifies longer clamps; that is, a 300 mm long DN 150 Type R clamp
qualifies all DN 150 Type R clamps of length ≥300 mm.

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 13 AS 4181—2013

4.1.2.2 Type R clamps

For the purposes of type testing Type R clamps, a successful test of the largest clamp in the
DN sizes listed in Table 4.1 shall qualify all clamps of the same function (repair or
off-take) from that clamp size down to, but not including, the next listed DN size.
For repair clamps greater than DN 600, a successful test qualifies clamps of outside
diameters up to 200 mm less than the outside diameter tested.
Where there is more than one design variation within the same DN, each design variation
shall be tested.

TABLE 4.1
TYPE R TYPE TEST SIZES

Pipe DN sizes
DN 80 DN 300
DN 100 DN 375
DN 150 DN 450
DN 200 DN 500
DN 250 DN 600

4.1.2.3 Type F clamps

For the purposes of type testing Type F repair and off-take clamps, each clamp of a
particular DN and compatible outside diameter size shall be tested.
4.1.3 Assembly test
When tested in accordance with Appendix B, the diametrical deflection of the test pipe shall
be not greater than 2.5%, and any scoring or damage to the pipe induced by the clamp shall
be not greater than 10% of the wall thickness or 0.5 mm, whichever is the lesser.
4.1.4 Leak-tightness test during application of a bending moment to the connecting
pipe—Off-take clamps
This test is only applicable to off-take clamps.
When tested in accordance with Appendix C, no leakage, fracture, crack, defect or other
failure shall occur in the off-take clamp or that section of the pipe on which the clamp is
assembled.
4.1.5 Joint infiltration test
When an assembled clamp and pipe is evacuated to a negative internal pressure of −80 kPa
to −85 kPa for a minimum period of 2 h, in accordance with the principles of
AS/NZS 462.8, the vacuum within the pipe shall not have changed by more than 10% at the
end of the test period.
The vacuum test may alternatively be performed in air, in which case this shall be noted on
the test report.
4.1.6 Hydrostatic leak-tightness test
The minimum hydrostatic type test pressure for clamps shall be 1.5 × AOP for a minimum
test duration of 120 min. When an assembled clamp is hydrostatically tested in accordance
with the principles of AS/NZS 1462.6 and pressures in Table 4.2, the clamp, joints or pipes
shall not leak or develop fractures, cracks or other failures within the clamp or in the pipe
within a distance of DN from the clamp, where DN corresponds to the nominal size of the
pipe used in the assembly.
During the test period, if leakage occurs at the sealing plugs, the test is not valid and shall
be repeated using another test specimen.

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AS 4181—2013 14

TABLE 4.2
TYPE TEST CONDITIONS FOR COMMONLY USED
PRESSURE CLASSIFICATIONS
Pressure Allowable operating Minimum clamp type Minimum test
classification pressure (AOP) test pressure duration
PN MPa MPa min
10 1.00 1.50
16 1.60 2.4
120
21 2.10 3.15
35 3.50 5.25
NOTE: Test pressures are based on a 50 y strain level for PN 16 Class 500 PVC-O
and PN 12 or PVC-M plastics pipe.

4.1.7 Resistance to rotation, longitudinal sliding and depressurization—Off-take

clamps
When tested in accordance with Appendix D, clamps shall not—
(a) show any signs of leakage;
(b) rotate on the pipe as a result of the applied moment;
(c) slide on the pipe as a result of the applied force; or
(d) fail in any other manner.
This test is only applicable to off-take clamps.

4.2 BI-METALLIC COUPLE

When a metallic clamp, intended for use with a metallic pipe, is tested as follows, the
electrical resistance between the clamp and the metallic test fixture shall be not less than
50 000 Ω:
(a) Assemble the clamp centrally on a length of clean metallic pipe, approximately
100 mm longer than the clamp and with an outside diameter compatible with the
nominal diameter of the clamp.
(b) Abrade a small area on the pipe and the clamp not less than 25 mm from the contact
surfaces to provide clean contact points.
(c) Place the assembly on an electrically insulated surface.
(d) Measure the resistance between the abraded areas of the clamp and the pipe with an
insulation resistance tester with a driving voltage of not less than 500 V.

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 15 AS 4181—2013

S E C T I O N 5 M A R K I N G A N D P A C K A G I N G

5.1 MARKING
All clamps shall be clearly and permanently marked with the following information:
(a) The manufacturer’s name or mark.
(b) Nominal diameter of clamp.
(c) Nominal flange off-take or tapping off-take size (where applicable).
(d) Pressure classification.
(e) Pipe outside diameter or diameter range.
(f) Type of clamp (e.g. Type R or Type F or Types R and F).
(g) The number of this Standard, i.e. AS 4181.
NOTE: Manufacturers making a statement of compliance with this Australian Standard on a
product, packaging, or promotional material related to that product are advised to ensure that such
compliance is capable of being verified.
Adhesive labels shall not be used on stainless steel components.

5.2 PACKAGING
Clamps shall be suitably packed to prevent damage to coatings or fasteners prior to receipt
by the purchaser.

5.3 INSTALLATION INSTRUCTIONS AND PIPE COMPATIBILITY

Printed installation instructions, including pipe compatibility, written in plain English shall
be included with each clamp.

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AS 4181—2013 16

APPENDIX A
DEMONSTRATION OF COMPLIANCE WITH THIS STANDARD
(Normative)

A1 SCOPE
This Appendix sets out two means by which compliance with this Standard has to be
demonstrated by a manufacturer:
(a) The use of a product certification scheme.
(b) The use of a minimum sampling and testing frequency plan.

A2 PRODUCT CERTIFICATION
The purpose of product certification is to provide independent assurance of the claim by the
manufacturer that products comply with this Standard.
The certification scheme shall meet the criteria described in HB 18.28 in that, as well as full
type testing from independently sampled production and subsequent verification of
conformance, it requires the manufacturer to maintain effective planning to control
production.
The certification scheme serves to indicate that the products consistently conform to the
requirements of the Standard(s).
The frequency of the sampling and testing plan, as detailed in Paragraph A3, shall be used
by the certifying body for product compliance auditing. However, where the manufacturer
can demonstrate adequate process control to the certifying body, the frequency of sampling
and testing nominated in the manufacturer’s quality plan and/or documented procedures
shall take precedence for the purpose of product certification.

A3 MINIMUM SAMPLING AND TESTING FREQUENCY PLAN

A3.1 General
Table A1 sets out the minimum sampling and testing frequency plan for a manufacturer to
demonstrate compliance of product(s) to this Standard.
A3.2 Retesting
In the event of a test failure, the products manufactured since the previous test(s)
conforming to the requirements outlined in Table A1 shall be quarantined as a batch. A
further set of samples shall be selected randomly from the quarantined batch using a
sampling plan to AS 1199.1 for an acceptable quality level (AQL) of 2.5 and an inspection
level of S3. If the retest requirements are met, the batch may be released and compliance
with this Standard for the quarantined batch may be claimed.
Should a failure on retesting occur, then the quarantined batch shall be rejected and claims
and/or marking indicating compliance to this Standard shall be suspended until the cause of
the failure has been identified and corrected.
A3.3 Rejected after retest
In the event of a quarantined batch being rejected after retesting, it may be subjected to
100% testing for the failed requirement(s), and only those items found to comply may be
claimed and/or marked as complying with this Standard.

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 17 AS 4181—2013

A4 DEFINITIONS
A4.1 Batch
A set of clamps of identical size range, consecutively produced in a single, continuous and
uninterrupted production run.
NOTE: The batch size is determined by the manufacturer.
A4.2 Batch release test (BRT)
A test performed by the manufacturer on a batch of components, which has to be
satisfactorily completed before the batch can be released.
A4.3 Lot
A clearly identifiable subdivision of a batch for inspection purposes.
A4.4 Production shift
A clearly identifiable collection of units, manufactured in a specified time no greater than
8 h, either consecutively or continuously under the same conditions, using material to the
same specification.
A4.5 Sample
One or more units of product drawn from a batch or lot, selected at random without regard
to quality.
NOTE: The number of units of product in the sample is the sample size.
A4.6 Sampling plan
A specific plan that indicates the number of units of components or assemblies to be
inspected.
A4.7 Type test (TT)
A test or series of tests directed towards approval of a design, conducted to determine if an
item is so designed that it is capable of meeting the requirements of the product Standard
and which is done once and repeated only after a change in design, materials, method or
place of manufacture or as otherwise nominated in the product Standard.

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AS 4181—2013 18

TABLE A1
MINIMUM SAMPLING AND TEST FREQUENCY PLAN TYPE TESTS
Characteristic Clause Requirement Test method Frequency
Material 2.1 Conformance or test certificates Verify to relevant material At any change in
properties Standards material composition,
moulding process or, in
2.2 Stainless steel: Verify to relevant material
the case of stainless
Standards and test reports,
– Subjected to welding steel, welding
and low carbon or
procedure or
– Welding procedure stabilized grade or WTIA
passivation treatment
TN13
– Welding electrodes
AS/NZS 1554.6
– Heat treatment Category 2B
– Intergranular corrosion AWS A5.9
resistance AS 2074
AS 2205.10.1
– Passivation ASTM A380
2.3 Polymeric coating AS/NZS 4158 At any change in
coating material,
application method or
substrate material
2.4 Elastomeric seals AS 1646 At any change in
material composition
Flange gaskets and O-rings WSA 109
or moulding process
2.5 Effect on water AS/NZS 4020 At any change in
material composition
or design or every 5 y
whichever occurs first
Design 3.1 Clamp components Verify from component At any change in
and assembly drawings design
3.2 Design of Type F, Type R and
and visual examination—
Types F and R clamps
assess and review
3.2 Fitment of Type F clamps to Measure pipe deflection
flexible pipes and scoring
3.3 Means of attachment Check retention of nuts
and/or bolts
3.5 Fasteners Verify captive At any change in
configuration. supplier
For stainless steel threads,
check thread form and
anti-galling compound
application.
For carbon steel threads,
check thread form and
coatings.
Confirm washer material
where coatings used
(continued)

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 19 AS 4181—2013

TABLE A1 (continued)

Characteristic Clause Requirement Test method Frequency

Design (cont’d) 3.7 Off-take clamps At any change in
flange design or type
Connections:
– Flanged Verify dimensions to
AS/NZS 4087 or other
applicable flange Standard
– Threaded Verify dimensions to
AS ISO 7.1 or other
applicable Standard
Design
– Pressure classification Verify is not greater than
the pressure classification
of its off-take connection
– The bore of the branch of an Verify is free from
off-take clamp protrusions that could
restrict the free flow of
water
Performance 4.1.3 Assembly test—Type F clamps Appendix B At any change in
material or design
4.1.4. Leak-tightness during Appendix C
application of a bending
moment to the connecting pipe
4.1.5 Joint infiltration test AS/NZS 1462.8
4.1.6 Hydrostatic leak-tightness test AS/NZS 1462.6
4.1.7 Resistance to rotation, Appendix D
longitudinal sliding and
depressurization
Marking 5.1 Legibility, durability and Visual examination
accuracy
Packaging 5.2 Suitability of packaging to Visual examination
prevent damage to coatings and
fasteners
Installation 3.6 Content Verify torque requirements At any change in
instructions for the installation of each design
clamp are specified
5.3 Pipe compatibility Verify the minimum clamp
length appropriate for a
given size of pipe and
off-take (if applicable) are
specified.
Review and trial
installation
(continued)

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AS 4181—2013 20

TABLE A1 (continued)

Characteristic Clause Requirement Test method Frequency

BATCH RELEASE TESTS
Material 2.1, 2.2, Conformance or test certificates Relevant Standards Per material type
properties 2.3, 2.4 and/or batch as
and 2.5 applicable
Coatings 2.3 Surface preparation: AS/NZS 4158 In accordance with
AS/NZS 4158
– Adhesion
– Thickness
– Cure
– Continuity
Functionality and 3.1 Check critical dimensions Metrological measurement At start-up then once
design features comply with dimensions on per production shift
design and assembly drawings
Freedom from 3.8 Freedom from defects Visual Each clamp
defects
Marking 5.1 Clear and permanent marking Visual examination Each clamp

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 21 AS 4181—2013

APPENDIX B
ASSEMBLY TEST
(Normative)

B1 SCOPE
This Appendix sets out the method for determining the diametrical deflection of pipes
during the installation of a Type F clamp and assessing whether any damage or excessive
scoring of the pipe occurs during assembly.

B2 RELEVANCE OF TEST
The Type F clamp may be installed on flexible pipe systems and, as such, is required to
minimize the deflection of flexible pipes to ensure excessive stresses and/or excessive
scoring or damage to the pipes, which may induce premature failure, does not occur.

B3 APPARATUS
The following apparatus is required:
(a) A measuring device capable of measuring the internal diameter of the pipes to an
accuracy of ±0.5 mm.
(b) A measuring device capable of measuring the depth of scoring or damage to the pipe
wall to an accuracy of ±0.05 mm.

B4 PROCEDURE
B4.1 Test specimens
Select a test pipe as specified in Clauses 4.1.2.1 and 4.1.2.2. The test pipe shall be of
sufficient length so that the clamp can be assembled at not less than 200 mm from the end.
The testing shall be carried out within the temperature range of 15–25°C.
B4.2 Test procedure
The procedure shall be as follows:
(a) Mark the location on the pipe where the clamp will be assembled, so that the clamp
will be no less than 200 mm from the end of the pipe.
(b) Measure and record the vertical and horizontal internal diameters of the pipe (dv1 and
dh1) at this location. Determine the average internal diameter of the pipe (davg1) by
using the following equation:
d v1 + d h1
d avg1 = . . . B1
2
(c) Assemble the clamp onto the pipe (where an off-take is present the clamp shall be
installed with the off-take vertical). Assemble according to the manufacturer’s
instructions by applying a bolt torque 30% higher than the manufacturer’s
recommended maximum torque.
(d) To determine the initial average internal diameter (Davg1), measure and record the
vertical and horizontal internal diameters of the test pipe (Dv1 and Dh1) at the marked
location, and apply the values to the following:
d v1 + d h1
Davg1 = . . . B2
2

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AS 4181—2013 22

(e) Calculate the actual vertical and actual horizontal pipe percentage deflection (Δdv
and Δdh) using the following equation:
d avg1 − d v2
Δd v = ×100% . . . B3
d avg1

(f) Remove the clamp and inspect the pipe surface for any damage or permanent
deformation to the pipe. Measure the depth of any surface damage.

B5 ACCEPTANCE CRITERA
Where the actual vertical and actual horizontal pipe deflections, as calculated using
Equation B3, and any surface damage is less than that specified in Clause 4.1.3, the pipe
shall be deemed to have passed the test.

B6 REPORT
The following shall be reported:
(a) Complete details of the pipe and clamp tested.
(b) dv1, dv2, dh1, dh2 and davg for each test pipe-clamp combination.
(c) Calculated vertical pipe deflection % (Δdv and Δdh) for each clamp.
(d) The depth of any scoring or damage to the pipe.
(e) Whether each pipe-clamp combination was acceptable.
(f) Reference to this test method, i.e. AS 4181 Appendix B.

© Standards Australia www.standards.org.au

 23 AS 4181—2013

APPENDIX C
LEAK-TIGHTNESS TEST DURING APPLICATION OF A BENDING MOMENT
TO THE CONNECTING PIPE
(Normative)

C1 SCOPE
This Appendix sets out the method for determining leak-tightness during application of a
longitudinal bending moment to the connecting pipe.

C2 RELEVANCE OF TEST
The off-take clamp is required to maintain an effective seal when a load is applied to it
during installation or backfilling.

C3 APPARATUS
The following apparatus is required:
(a) Pressurizing system A hydraulic system capable of producing the test pressure and
of maintaining an accuracy of ±2% of the set value.
(b) End connections Fittings that will make a watertight connection to the test specimen
and to the pressurizing system in accordance with AS/NZS 1462.6.
(c) Loading device for bending moment Device capable of applying the load for the
bending moment with an accuracy of ±2% of the set value.
(d) Timing devices A timing device to register the duration of the test on each test
specimen until the moment of burst, or until the specified time of test has elapsed.
NOTE: An electric contact pressure gauge may be considered for switching the timing device
when used in conjunction with a test gauge.
(e) Reference pressure device A pressure gauge or alternative equipment (e.g. pressure
transducer) accurate to ±1% of the true value used for setting cut-out tolerances.
(f) Testing environment Water or air environment to conduct the test.

C4 PROCEDURE
C4.1 Test specimens
Select a test pipe as specified in Clause 4.1.1 and 4.1.2.
C4.2 Test procedure
The procedure shall be as follows:
(a) Drill a hole, sized within the diameter range given in Table C1 or Table C2 for the
nominal Series 1 or Series 2 or CIOD branch diameter of the off-take (dn), in the pipe
at approximately the centre of the position where the off-take clamp is to be
assembled.
(b) Assemble an off-take clamp, with the branch positioned centrally over the drilled
hole, in accordance with the manufacturer’s instructions, using the maximum outlet
size (dn) for the particular off-take clamp design.

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AS 4181—2013 24

(c) Fix the pipe firmly to a rigid surface, as shown in Figure C1, so that the ends fixed to
the surface are at a set distance from each side of the off-take clamp. The free
minimum length of the test pipe between the test end caps shall be the width of the
off-take clamp plus 2 DN for pipes with an OD ≤315 mm. For pipes with an
OD >315 mm, a free minimum length of test pipe between the test end caps shall be
1000 mm.

TABLE C1
SERIES 1 CUTTER SIZES
FOR OFF-TAKE BRANCHES

Nominal size of Cutter size

off-take branch range
dn mm
100 80–90
125 105–115
150 130–140
175 145–155
200 180–190
225 205–215
250 230–240
300 270–290
375 345–365
400 380–390
450 410–440
NOTE: The cutter size range is based on the
use of appropriately sized gate valves, where
the ID of the valve approximates the nominal
diameter of the off-take branch.

TABLE C2
SERIES 2 AND CIOD CUTTER SIZES
FOR OFF-TAKE BRANCHES

Nominal size of Cutter size

off-take branch range
dn mm
80 60–70
100 80–90
150 130–140
200 180–190
225 205–215
250 230–240
300 270–290
375 345–365
450 410–440
NOTE: The cutter size range is based on the use
of appropriately sized gate valves, where the ID
of the valve approximates the nominal diameter
of the off-take branch.

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 25 AS 4181—2013

(d) Fit a capped outlet steel pipe (branch) to the off-take clamp outlet.
(e) Apply a bending moment to the branch of the off-take clamp outlet connection in the
plane of the test pipe axis, with the centre of moment taken at the base of the branch,
to satisfy the following:
M = 4 dn
where
M = bending moment, in newton metres
dn = nominal size of the branch, in millimetres
(f) Gradually raise the pressure to a value equal to 1.25 × AOP for a minimum duration
of 1 h and inspect for leakage. Gradually depressurize.
(g) Disassemble the off-take clamp and visually inspect the test pipe and the off-take
clamp for fracture, cracking or other defects.

C e n t r e of m o m e n t
FO RCE
B e n di n g m o m e nt

Fl a n g e d t a ke - of f
clamp

Fi x p ip e f i r m l y to r i g i d s u r fa c e

FIGURE C1 FIXING OF PIPE ONTO RIGID SURFACE

C5 REPORT
The following information shall be reported:
(a) Complete identification of the off-take clamp tested.
(b) The identification of the pipe.
(c) Details of any leakage, fracture, crack defect or other failure.
(d) Details of the corresponding test pressures.
(e) Reference to this test method, i.e. AS 4181 Appendix C.

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AS 4181—2013 26

APPENDIX D
RESISTANCE TO DEPRESSURIZATION AND ROTATIONAL AND SLIDING
MOVEMENT
(Normative)

D1 SCOPE
This Appendix sets out the method for determining the resistance to depressurization and
rotational and sliding movement of an assembled clamp that has been installed on a
pressurized main.

D2 RELEVANCE OF TEST
Off-take clamps used in under pressure connections are required to be installed on
pressurized mains that may increase in diameter due to visco-elastic creep. The off-take
clamp is required to maintain an effective seal without movement when the pipe is
depressurized and then re-pressurized for operational and/or maintenance reasons.

D3 APPARATUS
The following apparatus is required:
(a) Pressurizing system A hydraulic system capable of producing the test pressure and
of maintaining an accuracy of ±2% of the set value.
(b) End connections Fittings that will make a watertight connection to the test specimen
and to the pressurizing system in accordance with AS/NZS 1462.6.
(c) Timing devices A timing device to register the duration of the test on each test
specimen until the moment of burst, or until the specified time of test has elapsed.
NOTE: An electric contact pressure gauge may be considered for switching the timing device
when used in conjunction with a test gauge.
(d) Reference pressure device A pressure gauge or alternative equipment (e.g. pressure
transducer) accurate to ±1% of the true value used for setting cut-out tolerances.
(e) Testing environment Water or air environment to conduct the test.

D4 PROCEDURE
D4.1 Test specimens
Select a test pipe as specified in Clause 4.1.2 with a minimum length between end caps of
the width of off-take clamp plus 2 × DN.
D4.2 Test procedure
The procedure shall be as follows:
(a) Fix the pipe firmly to a rigid surface, as shown in Figure C1, Appendix C, so that the
ends fixed to the surface are at a set distance from each side of the off-take clamp.
(b) Gradually raise the pressure in the pipe to the AOP of the pipe (with no off-take
clamp assembled on it) and hold at this pressure for a minimum of 30 min to allow
the pipe to settle.
(c) Assemble the off-take clamp on the pipe in accordance with the manufacturer’s
instructions at approximately the mid-length position whilst the pipe is under
pressure. Once installed, make no adjustments to the off-take clamp bolting torques.

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 27 AS 4181—2013

(d) Gradually reduce the pressure in the pipe to a minimum of 0.2 AOP and carry out an
under-pressure tapping of the pipe in accordance with the manufacturer’s instructions.
(e) After tapping, increase the pressure to 1.25 × AOP and maintain for a minimum of
1 h.
(f) Depressurize the main for a minimum of 1 h.
(g) Carry out resistance to rotational and axial sliding tests in accordance with
Paragraphs D4.3 and D4.4.
(h) Gradually re-pressurize the main in increments of 100 kPa holding the pressure at
these increments for a minimum of 1 min. Increase the pressure to a maximum of
1.25 × AOP. Record any leakage or other failure.
D4.3 Resistance to rotational movement
The procedure shall be as follows:
(a) Calculate the rotation moment (T) to satisfy the following:
T = 0.4 dn
where
M = rotation moment, in newton metres
dn = nominal size of the branch, in millimetres
(b) Apply the rotation moment (T) to the off-take clamp, in a plane perpendicular to the
axis of the plastics pipe, by means of a suitable length of pipe connected to the
off-take branch, for a minimum of 5 min.
NOTE: An illustration is given in Figure D1.
(c) Measure and record any rotational movement of the off-take clamp.

FO RCE

C e ntre of m o me nt

R ot a t i o n a l m o m e n t

FIGURE D1 TYPICAL APPLICATION OF THE MOMENT TO TEST

FOR RESISTANCE OF OFF-TAKE CLAMP TO ROTATION

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AS 4181—2013 28

D4.4 Resistance to axial sliding

The procedure shall be as follows:
(a) Apply a force (F) to the off-take clamp along the axis of the pipe for at least 1 min in
such a way that no moments whatsoever are applied. The force (F) in newtons (N)
shall be equal to the numerical value of the nominal size of the off-take clamp, in
millimetres (e.g. for a DN 100 off-take clamp a force of 100 N shall be applied).
NOTE: An illustration is given in Figure D2.
(b) Measure and record any sliding movement of the off-take clamp.

O f f-t a ke c l a m p

A p p l y fo r c e to
c l a m p s o th at
m o m e nt s a r e
applied

FIGURE D2 TYPICAL APPLICATION OF A FORCE TO TEST

FOR RESISTANCE OF OFF-TAKE CLAMP TO SLIDING

D5 REPORT
The following information shall be reported:
(a) Complete identification of the off-take clamp tested.
(b) The identification of the pipe.
(c) Details of any rotation.
(d) Details of any sliding.
(e) Details of any leakage or other failure and the corresponding test pressures.
(f) Reference to this test method, i.e. AS 4181, Appendix D.

© Standards Australia www.standards.org.au

 29 AS 4181—2013

BIBLIOGRAPHY
AS
3571 Plastics piping systems—Glass reinforced thermoplastics (GRP) systems based
on unsaturated polyester (UP) resin
3571.1 Part 1: Pressure and non-pressure drainage and sewerage (ISO 10467:2004
MOD)
3571.2 Part 2: Pressure and non-pressure water supply (ISO 10467:2004 MOD)
AS/NZS
4129 Fittings for polyethylene (PE) pipes for pressure applications
4793 Mechanical tapping bands for waterworks purposes
HB 18 Conformity assessment
HB 18.28 Part 28: Guidance on a third-party certification system for products
AS 4181—2013 30

NOTES
 31 AS 4181—2013

NOTES
AS 4181—2013 32

NOTES
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