APP-F

Flange Adaptor

Products / Couplings / Flange Adapter

APP Engineering for Connecting Different Pipe Types to Flanged Equipment

APP Flange Adaptors are designed to securely and leak-tightly connect all types of pipes to flanged equipment such as valves, pumps, flow meters, and pipeline systems. Thanks to their wide tolerance design, they compensate for minor diameter differences on site, ensuring fast and trouble-free installation.

Universal Adaptation: Provides standard flanged connection and valve installation compatibility for all existing pipe types.
Economical Dismantling Solution: Practical and cost-effective design that can be used as a lightweight dismantling joint for valves, flow meters, and similar accessories.
Weld-Free Installation: Ideal for valve and flow meter installation on pipelines where flow cannot be interrupted, thanks to its mechanical, non-welded design.
Full Compatibility: Converts pipes of different materials and diameters into standard flange systems.

KEY ADVANTAGES

  • Compatible with various pipe materials (Ductile iron, Cast iron, AC, PVC, PE, GRP, etc.)
  • Easily integrates different pipe types into flanged systems
  • Facilitates dismantling and maintenance of flanged valves and equipment
  • Compact design suitable for confined spaces and valve chambers
  • Absorbs angular deviations up to 3° and ground movements
  • Expansion and contraction tolerance up to 5 mm
  • Fast installation under harsh site conditions, reducing labor costs
  • Cost-effective solution reducing stock variety
Download Product Data Sheet Download Installation Instructions Download Size Chart
  • Potable water and infrastructure pipelines
  • Industrial pipeline systems
  • Treatment plants and pumping stations
  • Valve and equipment connections
  • Flow meter and instrumentation installations
  • Flange standard conversions (e.g., PN10 to PN16)
  • Transition points between different pipe diameters

This instruction has been prepared for the safe and leak-tight installation of wide-tolerance flange adaptors used to connect different types of pipes (Ductile iron, Cast iron, Steel, PVC, PE, GRP, AC, etc.) to flanged equipment.

  1. Pre-Installation Preparation
  • Product Check:
    Verify the label information on the adaptor (DN size and tolerance range) and ensure it is suitable for the outer diameters of the pipes to be connected.
  • Flange Compatibility:
    Check that the adaptor flange matches the mating flange (PN10, PN16, PN25, etc.) in terms of bolt hole number and pitch circle diameter (PCD).
  • Pipe Cutting:
    Cut the pipes perpendicular (approx. 90°) to the pipe axis. Uneven cuts may prevent proper seating of the sealing gasket.
  • Surface Cleaning:
    Clean rust, dirt, scale, and old coatings from the pipe ends using a wire brush.
    The surface in contact with the sealing gasket must be smooth and clean.
  • Chamfering (If Required):
    Apply an external chamfer of approximately 30° to the pipe end if necessary.
    This prevents damage to the gasket during insertion.
  1. Positioning and Marking
  • Insertion Depth Marking:
    Measure the adaptor body length and mark a reference line on the pipe equal to half of the adaptor length.
  • Pipe Alignment:
    Flange adaptors typically allow up to ±3° angular deviation; however, proper alignment is recommended for optimal performance.
  1. Installation Steps
  • Lubrication:
    Apply a silicone-based lubricant suitable for potable water to the gasket and pipe end.
    (Do not use oil-based lubricants as they may damage the gasket.)
  • Placement:
    Slide the adaptor loosely onto the pipe.
  • Flange Connection:
    Align the adaptor flange with the mating flange (valve or equipment).
    Insert a standard flange gasket between the flanges.
  1. Tightening Procedure (Critical Step)
  • Flange Bolt Tightening:
    First, tighten the flange bolts in a star (crosswise) pattern to fix the adaptor in position.
  • Adaptor Bolt Tightening:
    Tighten the adaptor bolts diagonally (e.g., 12–6 o’clock, 3–9 o’clock).
    This ensures even load distribution on the gasket.
  • Gradual Tightening:
    First hand-tighten all bolts, then tighten gradually in multiple passes using a wrench.
  1. Final Check and Testing
  • Visual Inspection:
    Ensure that the gap between the pressure flanges and the adaptor body is uniform around the entire circumference.
  • Pressure Test:
    Perform a low-pressure leak test before commissioning the pipeline.
    If leakage is detected, recheck and retighten the bolts.

SAFETY NOTES

  • Wear protective gloves and safety footwear during installation.
  • For large-diameter adaptors, use pipe supports or blocking elements to prevent excessive load on the adaptor.
  • Ensure that the protective coating of bolts (galvanized, Dacromet, etc.) is not damaged to maintain corrosion resistance.

No

Component Name

Material and Technical Details

1

Sleeve

ST 37 Steel. High-strength structural body.

2

End Rings

Ductile Iron (GGG40/50) / ST 37 Steel. Pressure end caps applying force to the gasket.

3

Flange

Zinc-Coated ST 37 Çelik. Compatible with various flange standards

4

Tee Bolts/Bolts

Zinc-Coated Grade 8.8 Steel / AISI 304 / 316 Stainless Steel. High corrosion resistance.

5

Conical Gasket

EPDM / NBR. Pressure-responsive sealing technology.

6

Nuts and Washers

Zinc-Coated Grade 8.8 Steel / AISI 304 / 316 Stainless Steel. Secure locking system.

7

Coating

Epoxy / Thermoplastic. Long-lasting protection and durability.
REFERENCE DIAMETER (mm) APP CODE COMPATIBLE PIPE TYPES (mm) Flange Side (mm)
50 APP-F 50 50 Steel, 63 HDPE, 63 PVC 50
80 APP-F 80 80 AC (PN 10), 80 Steel, 90 PVC, 90 HDPE, 80 Ductile, 80 CI 80
APP-F 80/2 110 PVC, 110 HDPE, 80 AC (PN 10) 80, 100
100 APP-F 100 110 PVC, 110 HDPE, 100 AC (PN 10), 100 CI, 100 Steel, 100 Ductile 100
125 APP-F 125 125 AC (PN 10), 140 PVC, 140 HDPE, 125 Steel, 125 CI, 125 Ductile 125
150 APP-F 150/1 160 PVC, 160 HDPE, 150 Steel 150
APP-F 150/2 160 PVC, 160 HDPE, 180 PVC, 180 HDPE, 150 Steel, 150 CI, 150 Ductile, 150 AC (PN 10),
APP-F 150/3 150 AC (PN 12,5), PN12,5, 200 HDPE, 200 PVC
200 APP-F 200/1 225 PVC, 225 HDPE, 200 Steel, 200 Ductile 200
APP-F 200/2 200 AC (PN10), 225 PVC, 225 HDPE, 200 Ductile, 200 CI
APP-F 200/3 200 AC, (PN 12,5) PN 12,5, 250 PVC, 250 HDPE
250 APP-F 250/1 250 Ductile, 250 Steel, 250 CI 250
APP-F 250/2 250 AC (PN 10), 280 PVC, 280 HDPE
APP-F 250/3 250 AC (PN 12,5)
300 APP-F 300/1 315 PVC, 315 HDPE, 300 CI, 300 Steel, 300 Ductile 300, 350
APP-F 300/2 300 Ductile, 300 AC (PN 5)
APP-F 300/3 300 AC (PN 10), 355 PVC, 355 HDPE, 350 Steel
350 APP-F 350/1 300 AC (PN12,5), 350 Ductile, 350 CI, AC (PN 15) 300, 350, 400
APP-F 350/2 350 AC (PN 10), 400 PVC, 400 HDPE, 400 Steel
400 APP-F 400/1 400 Ductile, 400 CI, 400 GRP 400, 450
APP-F 400/2 400 AC (PN 10), 450 PVC, 450 HDPE, 450 Steel
500 APP-F 500/1 500 Steel, 500 HDPE, 500 PVC, 450 AC (PN 10) 500
APP-F 500/2 500 Ductile, 500 CI, 500 GRP
APP-F 500/3 500 AC (PN 10), 560 PVC, 560 HDPE
600 APP-F 600/1 600 Steel, 500 AC (PN15) 600
APP-F 600/2 600 Ductile, 600 CI, 630 PVC, 630 HDPE, 600 GRP
APP-F 600/3 600 AC (PN 10), 600 AC (PN12,5)
700 APP-F 700 AC, Steel, Ductile, GRP, PE, CI 700
800 APP-F 800 AC, Steel, Ductile, GRP, PE, CI 800
900 APP-F 900 AC, Steel, Ductile, GRP, PE, CI 900
1000 APP-F 1000 AC, Steel, Ductile, GRP, PE, CI 1000
1200 APP-F 1200 Steel, Ductile, GRP, PE 1200
1400 APP-F 1400 Steel, Ductile, GRP, PE 1400
1600 APP-F 1600 Steel, Ductile, GRP, PE 1600
1600-3400 APP-F 1600--3400 Steel, Ductile, GRP  
Please specify the pressure classes of the flanges when ordering.
Custom production is available for pipe diameters not listed.
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