vonRoll hydro (suisse) Ltd - Water Services Association of Australia

Transcription

WSAA Product Appraisal 1430
1
vonRoll hydro (suisse) Ltd
PRODUCT APPRAISAL REPORT 1430
vonRoll Ductile Iron Pipes and Fittings for Water Supply and Sewerage
applications
BS EN 545:2010 Ductile iron pipes, fittings, accessories and
their joints for water pipelines. Requirements and test
methods
BS EN 598:2007 Ductile iron pipes, fittings, accessories and
their joints for sewerage applications - Requirements and
test methods
Publication Date: 15 December 2015
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Document History
The following information indicates the changes made to this document.
Date
15 July 2015
15 July 2015
12 October 2015
15 December 2015
Version
File Location
Peer Review
U:\PP1 Industry Performance and Regulation\PP1-012
Product Appraisals\Civil Asset Infrastructure\2014\PA 1430
VonRoll Hydro - Ductile Iron Pipes for Water Supply
applications\vonRoll PA 14_30 VonRoll DI pipe 15-715.docx
Peer Review
applications\vonRoll PA 14_30 VonRoll DI pipe
1772015.docx
Peer Review final
applications\Peer Review Draft\vonRoll PA 1430 VonRoll DI
pipe-Peer Review final.docx
Publication
applications\Peer Review Draft\Final\vonRoll PA 1430
VonRoll DI pipe-Peer Review final2.docx
Peer Reviewers
Name/Title
Organisation
Date
Infrastructure Product and Material Network
WSAA
11/11/2015
Carl Radford, Product Appraisal Manager
WSAA
12/10/2015
Name/Title
Signature
Date
Carl Radford, Product Appraisal Manager
Carl Radford
15/12/2015
Approvals
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Overview of WSAA
The Water Services Association of Australia (WSAA) is the peak industry body that supports
the Australian Urban Water Industry. Its members and associate members provide water and
sewerage services to approximately 20 million Australians and many of Australia’s largest
industrial and commercial enterprises.
The Association facilitates collaboration, knowledge sharing, networking and cooperation
within the urban water industry. It is proud of the collegiate attitude of its members which
has led to industry-wide approaches to national water issues.
WSAA can demonstrate success in the standardisation of industry performance monitoring
and benchmarking, as well as many research outcomes of national significance. The WSAA
Executive retains strong links with policy makers and legislative bodies and their influences,
to monitor emerging issues of importance to the urban water industry. WSAA is regularly
consulted and its advice sought by decision makers when developing strategic directions for
the water industry.
WSAA was formed in 1995 as a non-profit organisation to foster the exchange of information
relating to the provision of urban water services between industry, government and the
community, and to promote sustainable water resource management.
The Association’s main activities focus on four areas:
1. Influencing national and state policies on the provision of urban water services and
sustainable water resource management;
2. Promoting debate on environmentally sustainable development and management of
water resources and the community health requirements of public water supplies;
3. Improving industry performance and establishing benchmarks and industry leading
practices for water service processes; and
4. Fostering the exchange of information on education, training, research, water and
wastewater management and treatment and other matters of common interest
Copyright
This document is copyrighted. Apart from any use as permitted under the Copyright Act
1968, no part of this document may be reproduced or transmitted in any form or by any
means, electronically or mechanical, for any purpose, without the express written permission
of Water Services Association of Australia Limited.
© Copyright 2015 by WATER SERVICES ASSOCIATION of Australia Limited All rights
reserved.
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CONTENTS
1 EXECUTIVE SUMMARY ........................................................................................................................................... 7
1.1 Recommendation ................................................................................................................................................ 8
2 THE DISTRIBUTOR AND MANUFACTURERS ......................................................................................................... 9
2.1 The Distributor ....................................................................................................................................................... 9
2.2 The Ductile Iron Pipe Manufacturer ..................................................................................................................... 9
2.3 The Ductile Iron Fitting Manufacturer .................................................................................................................. 9
2.3.1 ECOFIT ductile iron fittings ........................................................................................................................... 9
2.3.2 Derwent Industries ductile iron fittings ........................................................................................................ 10
3 THE PRODUCT ....................................................................................................................................................... 10
3.1 Polyurethane Internal Lining and External Coating ........................................................................................... 14
3.1.1 Polyurethane Internal Lining ....................................................................................................................... 14
3.1.2 Polyurethane External Coating ................................................................................................................... 14
3.2 Types of Joints and interconnection .................................................................................................................. 14
3.3 Elastomeric and Thrust-Resisting Joint Sealing Rings ...................................................................................... 21
3.3.1. Unrestrained Joint ........................................................................................................................................ 21
3.3.2 Restrained Joint ............................................................................................................................................ 21
3.4 vonRoll ISO sized ECOFIT DI fittings ................................................................................................................ 22
3.4.1 Types of Joints and Interconnections.......................................................................................................... 23
3.4.2 Restrained Joints for DI Fitting .................................................................................................................... 23
3.4.2.1 Internal Restrained Joint Single Chamber DN 80 – 700 ....................................................................... 23
3.4.2.2 External Restrained Joint Single Chamber DN 80 – 700...................................................................... 24
3.5 DI Fittings ISO sized – Configurations, Size and Class ................................................................................. 25
3.6 Elastomeric and Thrust-Resisting Joint Sealing Rings ISO sized .................................................................. 25
3.6.1 Unrestrained Joint ......................................................................................................................................... 25
3.6.2 Restrained Joint ............................................................................................................................................ 25
3.7 DI Socketed Fittings to AS/NZS 2280 ............................................................................................................ 25
4 SCOPE OF THE APPRAISAL ................................................................................................................................. 25
5 APPRAISAL CRITERIA ........................................................................................................................................... 26
5.1 Quality Assurance Requirements ...................................................................................................................... 26
5.2 Performance Requirements............................................................................................................................... 26
5.2.1 Product Manufacturing Standards ................................................................................................................ 26
6 COMPLIANCE WITH APPRAISAL CRITERIA......................................................................................................... 27
6.1 Compliance with Quality Assurance Requirements ........................................................................................... 27
6.1.1 Distributor ................................................................................................................................................... 27
6.1.2 Manufacturers ............................................................................................................................................. 27
6.1.2.1 vonRoll DI pipes ................................................................................................................................... 27
6.1.2.2 ECOFIT DI fittings and DI components for external restrained joints ................................................... 28
6.1.2.3 TYTON® elastomeric seals ................................................................................................................... 28
6.1.2.4 Internal Restrained thrust-resisting rings .............................................................................................. 29
6.1.2.5 Jointing lubricant for vonRoll DI pipes and ECOFIT DI fittings ............................................................. 29
6.1.2.6 Bolts and Nuts for use with external restrained joints ........................................................................... 29
6.1.2.7 Elastomeric joint seals - ......................................................................................................................... 29
6.2 Compliance to the Appraisal Requirements ...................................................................................................... 30
6.2.1 Material properties ...................................................................................................................................... 30
6.2.1.1 Ductile iron tensile and hardness properties ........................................................................................ 30
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6.2.2 Wall thickness ............................................................................................................................................. 30
6.2.3 Performance test requirements to EN 545 and EN 598 .............................................................................. 30
6.2.3.1 Type tests and audit reports for vonRoll DI pipes ................................................................................. 31
6.2.4 Pressure ratings .......................................................................................................................................... 31
6.2.5 Pipe class designation ................................................................................................................................ 32
6.2.5.1 Pipe Classes for Water Supply Application .......................................................................................... 32
6.2.5.2 Pipe Classes for Sewerage Application................................................................................................ 34
6.2.5.3 Flanged pipes for water supply and sewerage application ................................................................... 34
6.2.6 Joints .......................................................................................................................................................... 34
6.2.7 Elastomeric Seals for push-in socket joint connections .............................................................................. 35
6.2.7.1 Elastomeric seals for use on vonRoll hydro DI pipes and ECOFIT DI fittings ...................................... 35
6.2.7.2 Transition elastomeric seals – for use on DI pipe manufactured to EN 545 / EN 598 and AS/NZS 2280
manufactured Socketed DI fittings ..................................................................................................................... 36
6.2.8 Restrained joints ......................................................................................................................................... 39
6.2.9 Linings for DI pipes ..................................................................................................................................... 39
6.2.10 External Coatings...................................................................................................................................... 41
6.2.10.1 Polyurethane coating for ECOPUR® ductile iron pipes....................................................................... 41
6.2.10.2 Zinc and finishing layer for DUCPUR® and GEOPUR® DI pipes ........................................................ 41
6.2.11 Polyethylene sleeving ............................................................................................................................... 41
6.2.12 Contact with drinking water ....................................................................................................................... 42
6.2.12.1 EPDM Elastomeric Seals ................................................................................................................... 42
6.2.12.2 Special Adaptor Elastomeric Seals .................................................................................................... 42
6.2.12.3 Jointing Lubricant ............................................................................................................................... 42
6.2.12.4 Internal coating of ECOFIT DI fittings ................................................................................................. 42
6.2.13 Flanged joints and flanged pipe ................................................................................................................ 42
6.2.14 Angular joint deflection of pipes and fittings .............................................................................................. 42
7 FITTING INSTRUCTIONS, TRAINING AND INSTALLATION ................................................................................. 43
7.1 Installation Instructions .................................................................................................................................. 43
7.2 Ductile iron fittings ......................................................................................................................................... 43
7.3 Tapped connections....................................................................................................................................... 43
8 MAINTENANCE ....................................................................................................................................................... 43
9 PIPE LAYING TRAINING AND DEVELOPMENT OF TECHNICAL LITERATURE.................................................. 43
10 PRODUCT MARKING ........................................................................................................................................... 43
10.1 vonRoll DI pipes for water supply and sewerage ............................................................................................. 43
10.2 ECOFIT DI fittings ........................................................................................................................................... 45
10.3 Polyethylene sleeving ...................................................................................................................................... 46
10.4 Elastomeric joint seals ..................................................................................................................................... 46
10.4.1 Elastomeric seals – supplied by Hultec for use on vonRoll DI pipe and ECOFIT DI fittings ...................... 46
10.4.2 Special Transition Elastomeric seals – for use on vonRoll DI pipe and AS/NZS 2280 manufactured
socketed fittings ..................................................................................................................................................... 46
11 TRACEABILITY ..................................................................................................................................................... 47
12 PACKAGING AND TRANSPORTATION ............................................................................................................... 47
13 PRODUCT WARRANTY ........................................................................................................................................ 48
14 WATER AGENCY EXPERIENCE WITH THE PRODUCT OR FIELD TESTING REPORT ................................... 48
14.1 Long Term ....................................................................................................................................................... 48
14.2 Short Term ...................................................................................................................................................... 49
15 AVAILABILITY OF PRODUCTS ............................................................................................................................ 49
16 REPAIRS TO POLYURETHANE COATING .......................................................................................................... 49
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17 DISCUSSION......................................................................................................................................................... 49
18 OUTCOMES OF EXPERT PANEL PRODUCT REVIEW....................................................................................... 50
19 LIFE EXPECTANCY .............................................................................................................................................. 50
20 FUTURE WORKS .................................................................................................................................................. 51
21 DISCLAIMER ......................................................................................................................................................... 51
21.1 Issue of Report ................................................................................................................................................ 51
21.2 Limits on Reliance on Information and Recommendations.............................................................................. 51
21.2.1 Disclaimer of liability ................................................................................................................................. 51
21.2.2 Need for independent assessment ........................................................................................................... 52
21.2.3 No Updating ................................................................................................................................................. 52
21.2.4 No Warranty ................................................................................................................................................. 52
APPENDIX A – GERMAN ACCREDITATION SYSTEM ............................................................................................... 53
A1 - vonRoll Flanged Pipe ......................................................................................................................................... 53
A2 - vonRoll ECOFIT Socketed and Flanged DI Fittings ........................................................................................... 53
APPENDIX B – QUALITY CERTIFICATIONS .............................................................................................................. 54
APPENDIX C – VONROLL DI PIPE ‘C’ CLASS AND ‘K’ CLASS ................................................................................. 59
APPENDIX D – UNRESTRAINED AND RESTRAINED JOINTS FOR VONROLL DI PIPES AND ECOFIT DI
FITTINGS ....................................................................................................................................................... 60
APPENDIX E - WSAA PRODUCT SPECIFICATION .................................................................................................... 61
APPENDIX F - SUPPLIER CONTACTS ....................................................................................................................... 64
APPENDIX G – MPA NRW AUDIT OUTCOME AT VONROLL’S MANUFACTURING PLANT .................................... 65
APPENDIX H – SITE PHOTOGRAPHS ....................................................................................................................... 66
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EXECUTI VE SUM M ARY
Reece Australia Ltd (Reece) has been appointed as the Australian Agent and Distributor for
a range of vonRoll hydro ductile iron pipes and fittings, for use in water supply (drinking and
recycled) and sewerage (gravity and pressure) applications.
vonRoll hydro (Suisse) ltd is one of a number of independent business units of the vonRoll
Infratec Group. The vonRoll Group is primarily based in Switzerland with offices and
agencies in Europe, America, Asia and the Middle East. The vonRoll name has been
associated with the manufacturing industry in Switzerland and Europe for approximately 190
years.
The vonRoll hydro DUCPUR ®, ECOPUR® and GEOPUR ® range of ductile iron pipes and
ECOFIT ductile iron fittings are manufactured to EN 545:2010 and EN 598:2007 respectively
and also meet the requirements of ISO 2531:2009. Pipe outside diameters conform to ISO
dimensions and compatible fittings also incorporate flanges to ISO dimensions .
The DUCPUR ®, ECOPUR ® and GEOPUR ® ductile iron pipes are manufactured using modern
fully automated centrifugal casting equipment at vonRoll production Choindez, in
Switzerland. The vonRoll manufacturing facility at Choindez has an accredited Quality
Management System to ISO 9001 and DUCPUR ®, ECOPUR® and GEOPUR ® ductile iron
pipes are included on the product certification licences issued by MPA NRW for EN 545 and
EN 598.
vonRoll hydro (Suisse) ltd holds ISO 9001:2008 certification for the manufacturer, system
vendor and provider of products and services for water and gas utilities, including piping and
fittings as well as manhole covers and drains for the road construction industry. The ISO
9001 Certificate of Registration No. 20430 was issued by Swiss Association for Quality and
Management System (SQS).
The manufacturing facility at Choindez produces up to 25,000 tons of ductile cast iron pipes
a year in diameters of DN 80 to DN 700 with a length of 6 metres.
DN 80 to DN 700 pipes are available in pressure classes PN 25 up to PN 100 depends on
the DN. The standard thickness class is K9 for DN 80 up to DN 700. The comparison of ‘wall
thickness class K’ and ‘pressure class C’ is detailed in Appendix C.
Scope of appraisal also includes Flanged pipe offered by vonRoll hydro as detailed in
Appendix A (Refer to A1).
A compatible range of ductile iron fittings is available in sizes DN 80 to DN 700 with various
combinations of socket and flange ends. Flanges comply with EN1092-2 PN 10, PN 16, PN
25, PN 40, PN 63 or PN 100. The available range of fittings is detailed in Appendix A (Refer
to A2).
The vonRoll range of DUCPUR ® and ECOPUR® ductile iron pipes is suitable for the transport
of drinking water, soft and aggressive water as well as media with pH values between 1 and
14. The vonRoll range of GEOPUR ® ductile iron pipes is suitable for the transport of sewage
or aggressive waters with pH values of 1 to 14.
The vonRoll ductile iron pipes are available in nominal diameters from DN 80 to DN 700 and
manufactured as:
•
DUCPUR ® pipes with either spigot and socket flexible joints or screwed on flanges and
coated externally with zinc rich paint coating having a minimum mass of 220 g/m², and a
finishing layer of black colored bituminous paint and internally lined with polyurethane
(PUR).
•
ECOPUR ® pipes with either spigot and socket flexible joints or screwed on flanges and
supplied with internally lined and externally coated with polyurethane (PUR).
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•
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GEOPUR ® pipes with spigot and socket flexible joints and supplied with polyurethane
(PUR) internal lining, outer side zinc rich paint coating having a minimum mass of 150
g/m², and a finishing layer of red brown colored bituminous paint
The pipe sizes ≤ DN 500 have a double chamber socket. The double chamber socket has
two grooves; one for the insertion of the TYTON ® elastomeric seal which enables a flexible
joint and the other for a thrust resisting ring (if required).
The pipe sizes > DN 500 (i.e. DN 600 and DN 700) have a single chamber socket, supplied
with a TYTON® seal.
The vonRoll ECOFIT fittings are manufactured by Keulahütte GmbH in Krauschwitz,
Germany and are coated internally and externally with a thick film of Resicoat R4 Fusion
Bonded Epoxy to EN 14901 and GSK (Gemeinschaft für Schweren Korrosionsschutz)
standards in a powder coating plant.
Keulahütte GmbH manufacturing facility in Krauschwitz Germany has an accredited Quality
Management System to ISO 9001:2008 for the development, manufacture and sales of
fittings, hydrants, valves and castings for mechanical engineering and vehicle construction .
The ISO 9001 Certificate of Registration No. 01 100 4186 was issued by TÜV Reheinland
Cert GmbH in Germany.
The ECOFIT ductile iron fittings for water supply (drinking and recycled) and sewerage
(gravity and pressure) applications are included in the Product Certification Licence DV7705BM0164 issued by DVGW CERT – DakkS Germany in compliance with EN 545 and EN
598.
Reece intends to supply AS/NZS 2280 DI Socketed fittings, with special EPDM TYTON®
transition elastomeric seals, with delivery of DUCPUR ®, ECOPUR® and GEOPUR® DI pipes
in sizes DN 100 to 300. Gulf Rubber supplies the special transition elastomeric seals to AS
1646.
AS/NZS 2280 allows fittings to be used with pressure pipe of alternative outside diameter by
the adoption of a compatible socket or utilisation of a transition elastomeric seals, provided
the joint meets the performance requirements of this Standard.
Tests have been carried out on the vonRoll hydro ductile iron pipe and Derwent Industries
DI socketed fittings (PA 1003 Issue 2) manufactured to AS/NZS 2280, using a transition
elastomeric seal to demonstrate compliance with the performance tests in AS/NZS 2280.
Such tests include pressure tests, vacuum tests and tests with deflection and applied shear
loading. According to the results of the performance testing the Allowable Operating
pressure (AOP) for the different diameter DN and transition elastomeric seal are as follows:
a) DN 100 - 250 Gulf Rubber TYTON® transition elastomeric seal with TYTON joint and
vonRoll hydro ductile iron pipe is 1600 kPa.
b) DN 300 Gulf Rubber TYTON ® transition elastomeric seal with TYTON joint and
The product range as described by this appraisal report meets the requirements of
a) WSA PS-202- Ductile Iron Pipes and Fittings (ISO Sized) for Pressure Applications Water Supply.
b) WSA PS-202S - Ductile Iron Pipes and Fittings (ISO Sized) for Pressure and NonPressure Applications – Sewerage.
1.1 Recommendation
It is recommended that WSAA members and associates, subject to any specific requirements
of the member or associate, accept or authorise the
(a) vonRoll ECOPUR®, DUCPUR ® and GEOPUR ® range of ductile iron pipes and
associated ECOFIT ductile iron fittings
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(b) vonRoll ECOPUR ®, DUCPUR® and GEOPUR® range of ductile iron pipes, specified
AS/NZS 2280 complaint ductile iron socketed fittings, with special EPDM TYTON ®
transition elastomeric seals.
as detailed in this report for use in the water supply (drinking and recycled) and sewerage
(gravity and pressure) applications provided design, installation, acceptance testing and
commissioning are in accordance with applicable WSAA Codes and the manufacturer’s
requirements, where specified.
2
THE DI STRIBUTOR AND M ANU F AC TURERS
2.1 The Distributor
Reece Australia Ltd (Reece) has been appointed as the Australian Agent and Distributor for
a range of vonRoll ductile iron pipes and fittings, for use in water supply (drinking and
recycled water) and sewerage (gravity and pressure) applications.
The above range of products was originally distributed by Wang Industries, before they were
acquired by Tyco Water (then Pentair and now Viadux) in 2001. Tyco Water continued to
import and distributes the vonRoll ductile iron products between 2001 and 2008. From 2008
to 2014, Promains Pty Ltd was importing, distributing and providing a full range of support
services for the vonRoll DUCPUR® and ECOPUR ® ductile iron pipes for the Australian urban
water industry.
Since February 2014, Reece has been acting as the exclusive distributor of vonRoll DI pipes
and fittings in Australia.
2.2 The Ductile Iron Pipe Manufacturer
vonRoll hydro (Suisse) ltd is one of a number of independent business units of the vonRoll
Infratec Group. The vonRoll Group is primarily based in Switzerland with offices and
agencies in Europe, America, Asia and the Middle East. The vonRoll name has been
associated with the manufacturing industry in Switzerland and Europe for approximately 190
years.
vonRoll hydro is the first Swiss supplier of products and services for water and gas supply.
vonRoll hydro deliver ductile cast iron pipes and valves systems, hydrants, road manhole
covers and systems for the water leak detection and water quality supervision.
The vonRoll ductile cast-iron pipe is manufactured at the Choindez facility in Switzerland
using fully automated centrifugal casting equipment. The manufacturing facility at Choindez
produces up to 25,000 tons of ductile cast iron pipes a year in diameters of DN 80 to DN 700
with a length of 6 metres. The ductile iron fittings are manufactured in Germany and are
coated with a thick film of epoxy resin to GSK (Gemeinschaft für Schweren
Korrosionsschutz) standards in a powder-coating plant.
vonRoll hydro has another manufacturing facility in Oensingen, Switzerland where up to
31,000 valves and 6000 hydrants are produced every year. The fittings are coated with a
thick film of epoxy resin to GSK (Gemeinschaft für Schweren Korrosionsschutz) standards
in a powder coating plant.
2.3 The Ductile Iron Fitting Manufacturer
2.3.1 ECOFIT ductile iron fittings
The ECOFIT ductile iron fittings are produced by Keulahütte in Krauschwitz, Germany.
Keulahütte is an iron foundry with production facilities for mechanical and hand-moulded
castings in the mass spectrum of 5 kg to 4500 kg. Much of the annual ductile and grey iron
production is used to run the integrated machining and epoxy powder coating process as
hydrants, valves and pressure pipe fittings. High quality industrial castings according to
customer specifications and architectural castings complete the production program.
For more information look at Keulahütte GmbH website as below:
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http://www.keulahuettekrauschwitz.de/de/produktefertigung/formstuecke/druckrohrformstue
cke/
2.3.2 Derwent Industries ductile iron fittings
Reece intends to supply Derwent Industries AS/NZS 2280 DI Socketed fittings, with special
EPDM TYTON® transition elastomeric seals, with delivery of DUCPUR ®, ECOPUR® and
GEOPUR ® DI pipes in sizes DN 100 to 300.
WSAA has successfully appraised the Derwent Industries range of DI fitting to AS/NZS 2280,
under WSAA Product Appraisal No 1003 Issue 2.
Additional testing has been performed by vonRoll hydro (suisse) Ltd to demonstrate that
Derwent Industries supplied DI socketed fittings with Gulf Rubber special EPDM TYTON ®
transition elastomeric seals meet the performance requirements of AS/NZS 2280 when used
DUCPUR ®, ECOPUR® and GEOPUR® DI pipes in sizes DN 100 to 300. Refer to Clause
6.2.7.2
3
THE PRODUCT
This appraisal applies to the vonRoll range of cast ductile iron pipes and ECOFIT ductile iron
fittings.
The vonRoll DUCPUR ®, ECOPUR ® and GEOPUR ® range of centrifugally cast ductile iron
pipes produced in a manufacturing facility owned by vonRoll in Choindez, Switzerland.
FIGURE 1: VONROLL ECOPUR ®, DUCPUR® AND GEOPUR ® DUCTILE IRON PIPE
Among the three types of connection system shown in Figure 2, this appraisal applies only
for the following two types:
 Push-in socket joint
 Flange joint.
FIGURE 2: CONNECTION TYPES IN THE VONROLL DI PIPE SYSTEM
vonRoll range of valves and hydrants that are produced in a manufacturing facility owned by
vonRoll in Oensingen, Switzerland are not included in this appraisal.
The vonRoll DUCPUR®, ECOPUR® and GEOPUR ® range of ductile iron pipes and ECOFIT
DI fittings are manufactured to:

EN 545 Ductile iron pipes, fittings, accessories and their joints for water pipelines Requirements and test methods;
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
EN 598 Ductile iron pipes, fittings, accessories and their joints for sewerage applications
- Requirements and test methods; and

ISO 2531 Ductile iron pipes, fittings, accessories and their joints for water applications.
The product range submitted for appraisal consists of ductile iron pipe with ISO outside
diameters in sizes DN 80 to DN 700, with spigot and socket pipes as detailed in Tables 1 to
3, and flanged pipes in sizes DN 80 to DN 600 as detailed in Appendix A (vonRoll catalogue
pages from 4/1.1 to 4/1.12).
ECOFIT DI fittings include configurations with socket and/or flanged ends. Product Data
Sheets are provided in Appendix A (vonRoll catalogue pages from 2/3.1 to 2/7.3).
DUCPUR ® and GEOPUR ® ductile iron pipes are internally lined with polyurethane (PUR) and
coated externally with at least 220 g/m 2 for DUCPUR ® and at least 150 g/m 2 for GEOPUR®
of zinc rich paint and a finishing layer of bituminous paint, at least 70 μm thick, applied in
accordance with ISO 8179. The socket is coated with bitumen for DUCPUR® and
polyurethane for GEOPUR ®.
ECOPUR ® ductile iron pipes are internally lined and externally coated with a Polyurethane
(PUR) coating. The polyurethane lining and coating are applied to all surfaces of the pipe
including the sockets to provide corrosion protection to the entire pipe. Refer to Table 4.
ECOPUR ® and DUCPUR ® ductile iron pipe and fittings are suitable for drinking water,
recycled water supply applications.
The GEOPUR® ductile iron pipes and fittings are suitable for most aggressive non-drinking
water supply and sewerage applications with pH values of 1 to 14.
For identification purposes GEOPUR ® ductile iron pipes are supplied with a red brown
bituminous paint. A finishing layer of black bituminous paint is applied to the DUCPUR ®
ductile iron pipes.
DUCPUR ® and GEOPUR ® ductile iron pipes may also be sleeved with blue, lilac or cream
polyethylene sleeve during installation of mains for potable water, recycled water and
pressure sewer applications respectively.
The new standard EN 545:2010 does not specify anymore the wall thickness “class K” but
the “pressure class C”.
ECOPUR ®, DUCPUR® and GEOPUR® ductile iron pipes are available in C100 (PN 100), C64
(PN 64), C50 (PN 50), C40 (PN 40), C30 (PN 30), C25 (PN 25) pressure classes, depending
on size.
vonRoll hydro still produce K9 DI pipes as standard for size DN 80 up to DN 700.
In EN 545:2006 (previous standard) and ISO 2531:2009 Class “K9” is the standard
classification for water supply pipelines. Class “K12” has a thicker wall and is specified for
flanged (screwed) pipe or where additional structure strength is required.
The new standard EN 545:2010 does not specify pressure class for the vonRoll DI fittings.
Only the minimum wall thickness is mentioned which relates to the wall thickness class K12
for all fittings; i.e. socketed and flanged.
Standardised lengths of DI pipe are permitted in EN 545 / EN 598 and are a function of pipe
size and joint type. Reece are offering to supply standard DI pipe lengths of 6 m length for
spigot / socket pipes and maximum 5.9 m length for flanged pipes.
Reece only intend to import a small quantity of the Class K12 pipe (PN 16 rated) for
manufacture of flanged pipe (screwed on and bonded).
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FIGURE 3: DUCPUR® PRESSURE PIPE WITH PUSH-IN JOINT– FIGURES 2817 and
2815
TABLE 1: DUCPUR® PRESSURE PIPE WITH PUSH-IN JOINT - FIGURE 3
Nominal
Dia DN
(mm)
Pipe
Class
Pressure
Class
PN
(bar)
Allowable
Operating
Pressure
MPa
801,2
C100
100
1001,2
C100
1251,2
C64
1501,2
2001,2
2501,2
Length
(m)
DE
Outside
Dia (mm)
eG
ePUR 1
DM
T
Weight
Kg/m
10
6.0
98
6
1.3
167
119
14.2
100
10
6.0
118
6
1.3
188
120
17.1
64
6.4
6.0
144
6
1.3
215
123
21.1
C64
64
6.4
6.0
170
6
1.3
242
126
25.2
C64
64
6.4
6.0
222
6.3
1.5
295
131
33.3
C50
50
5.0
6.0
274
6.8
1.5
352
131
46.3
3001,2
C50
50
5.0
6.0
326
7.2
1.5
410
130
58.3
3501,2
C40
40
4.0
6.0
378
7.7
1.5
464
110
71.9
4001,2
C40
40
4.0
6.0
429
8.1
1.5
518
115
86.1
5001,2
K9 / C30
30
3.0
6.0
532
9
1.5
636
115
118.6
6003
K9 / C30
30
3
6.0
635
9.9
1.5
750
120
156.1
7003
K9 / C30
30
3
6.0
738
1.08
1.5
863
150
198.9
NOTES:
NOTE 1: DN 80 up to DN 500 with double-chamber; refer Figure 3 – figure 2817
NOTE 2: The double-chamber pipe can be fitted with internal thrust-resisting ring or external thrust-resisting ring.
NOTE 3: DN 600 and DN 700 with single-chamber refer Figure 3 – figure 2815
FIGURE 4: ECOPUR® PRESSURE PIPE WITH PUSH-IN JOINT– FIGURES 2817 and
2815
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TABLE 2: ECOPUR® PRESSURE PIPE WITH PUSH-IN JOINT - FIGURE 4
Nominal
Dia DN
(mm)
Pipe
Class
Pressure
Class
PN
(bar)
Allowable
Operating
Pressure
MPa
801,2
C100
100
1001,2
C100
1251,2
1501,2
2001,2
2501,2
Length
(m)
DE
Outside
Dia (mm)
eG
ePUR 1
ePUR 2
DM
T
Weight
Kg/m
10
6.0
98
6
1.3
0.9
167
119
14.6
100
10
6.0
118
6
1.3
0.9
188
120
17.6
C64
64
6.4
6.0
144
6
1.3
0.9
215
123
21.7
C64
64
6.4
6.0
170
6
1.3
0.9
242
126
25.9
C64
64
6.4
6.0
222
6.3
1.5
0.9
295
131
34.3
C50
50
5.0
6.0
274
6.8
1.5
0.9
352
131
47.4
3001,2
C50
50
5.0
6.0
326
7.2
1.5
0.9
410
130
60.5
3501,2
C40
40
4.0
6.0
378
7.7
1.5
0.9
464
135
73.4
4001,2
C40
40
4.0
6.0
429
8.1
1.5
0.9
518
145
87.9
5001,2
K9 / C30
30
3.0
6.0
532
9
1.5
0.9
636
145
120.7
6003
K9 / C30
30
3
6.0
635
9.9
1.5
0.9
750
120
152.0
7003
K9 / C30
30
3
6.0
738
1.08
1.5
0.9
863
150
194.0
NOTES:
NOTE 1: DN 80 up to DN 500 with double-chamber refer Figure 4 – figure 2817
NOTE 3: DN 600 and DN 700 with single-chamber refer Figure 4 – figure 2815
DN 100-500
FIGURE 5: GEOPUR® PRESSURE PIPE WITH PUSH-IN JOINT– FIGURES 1817 and
1815
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TABLE 3: GEOPUR® PRESSURE PIPE WITH PUSH-IN JONT – FIGURE 5
Nominal
Dia DN (mm)
Length
(m)
DE
Outside Dia (mm)
eG
ePUR 1
DM
T
Weight
Kg/m
Item No.
1001,2
6.0
118
4.8
1.3
188
120
14.2
260800
1251,2
6.0
144
4.8
1.3
215
123
17.5
260801
1501,2
6.0
170
4.8
1.3
242
126
20.9
260802
2001,2
6.0
222
4.9
1.5
295
131
27.8
260803
2501,2
6.0
274
5.3
1.5
352
131
37.6
260804
3001,2
6.0
326
5.6
1.5
410
130
47.2
260805
3501,2
6.0
378
6.0
1.5
464
135
58.1
260806
4001,2
6.0
429
6.3
1.5
518
145
69.5
260807
5001,2
6.0
532
7.0
1.5
630
145
95.7
260808
6003
6.0
635
7.7
1.5
750
120
125.9
260809
7003
6.0
738
9.6
1.5
863
150
179.6
260810
NOTES:
NOTE 1: DN 100 up to DN 500 with double-chamber, Refer to Figure 5, figure 1817.
NOTE 3: DN 600 and DN 700 with single-chamber, Refer to Figure 5, figure 1815.
3.1 Polyurethane Internal Lining and External Coating
3.1.1 Polyurethane Internal Lining
The vonRoll DUCPUR ®, ECOPUR® and GEOPUR ® range of ductile iron pipes are internally
lined with polyurethane in accordance with EN 15655. The thickness of the polyurethane is
shown in Table 4.
TABLE 4: POLYURETHANE LINING THICKNESS
DN (mm)
Thickness (mm)
Mean Value
Minimum Value
80 - 150
1.3
0.8
200 - 700
1.5
0.8
3.1.2 Polyurethane External Coating
The vonRoll ECOPUR® range of ductile iron pipes are externally protected with polyurethane
in accordance with EN 15189. The thickness of the polyurethane is a nominal 900 micron
with a minimum of 700 microns. The entire barrel including the spigot en d is coated with
polyurethane.
The internal surface of the socket end is lined with polyurethane. The mean thickness is 150
microns and the minimum thickness is 100 microns.
3.2 Types of Joints and interconnection
vonRoll DI pipe sizes ≤ DN 500 have a double chamber socket. The double chamber socket
has two grooves; one for the insertion of the HYDROTIGHT seal which enables a flexible
joint and the other for an internal thrust-resisting ring (if required).
vonRoll DI pipe sizes > DN 500 (DN 600 and DN 700) have a single chamber socket, supplied
with a HYDROTIGHT seal, but without thrust-resisting ring.
The ‘Push-in socket joint’ includes the following jointing system:
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a) Pipe with double chamber socket (DN 80–500) unrestrained HYDROTIGHT seal
{TYTON® elastomeric seal manufactured from EPDM (water) Figure 2810 or NBR
(sewerage) Figure 2811 by Hultec Europe}. Refer to Figure 6.
b) Pipe with single chamber socket (DN 600 and 700) unrestrained HYDROTIGHT seal
{TYTON ® elastomeric seal, manufactured from EPDM (water) Figure 2810 or NBR
(sewerage) Figure 2811 by Hultec Europe}. Refer to Figure 7.
c) Pipe with double chamber socket (DN 80–500) unrestrained HYDROTIGHT seal
{TYTON ® elastomeric seal manufactured from EPDM (water) Figure 2810 or NBR
(sewerage) Figure 2811 by Hultec Europe}, with an additional:
i)
HYDROTIGHT internal thrust-resisting ring Figure 2807B1 for DN 80 to DN 300.
Refer to Figures 8 & 9 or
ii) HYDROTIGHT internal thrust-resisting ring Figure 2807A2 for DN 80 to DN 500.
Refer to Figures 8 & 9 or
iii) External restrained joint Figure 2806 for DN 80 - 500. Refer to Figures 10 & 11
d) Pipe with double chamber socket (DN 80–500) fitted with Internal restrained joint
combined gasket with steel teeth TYTON ®-SIT ® Figure 2504 (DN 80 - 400) or TYTON ®
SIT PLUS® Figure 2504-S (DN 80 – 500) exist. Refer to Figure 12.
NOTE: There is no unrestrained HYDROTIGHT TYTON® elastomeric seal (Fig. 2810 or 2811)
e) Pipe with single chamber socket (DN 600 and 700) fitted with:
i)
External restrained joint Fig. 2805, DN 600 - 700 with welded bead as shown in
Figure 13; or
ii) Internal restrained joint combined gasket with steel teeth TYTON® SIT PLUS®
Figure 2504-S, DN 600 as shown in Figure 14.
For permissible pressure for the different thrust-resisting rings (both internal and external)
refer to Table 5.
Refer to Appendix D for unrestrained and restrained joints for vonRoll DI pipes of size range
DN 80 to DN 700.
Figure 6 shows an unrestrained joint for pipe with double chamber DN 80 – 500.
1
Hydrotight thrust-resisting ring (internal) for double chamber DN 80-300 (DN 80-200 is 25 bar; DN 250-300 is 16
bar), standard Fig. 2807B
2 Hydrotight thrust-resisting ring (internal) for double chamber DN 80-500 (for higher pressure: DN 80-200 is 40 bar;
DN 250-300 is 25 bar), and pipes with DN 350-500 (16 bar). Fig. 2807A
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FIGURE 6: DOUBLE CHAMBER PIPE DN 80 – 500 WITH UNRESTRAINED JOINT
Figure 7 shows an unrestrained joint for single chamber DI fittings DN 80 – 700 and pipe
with double chamber DN 600 – 700.
FIGURE 7: SINGLE CHAMBER ECOFIT DI FITTING DN 80 – 700 AND SINGLE CHAMBER
PIPE DN 600 – 700 WITH UNRESTRAINED JOINT
NOTE: “ Unrestrained automatic joint” is the name for the completed assembly; “HYDROTIGHT TYTON®
elastomeric seal” is one element of the automatic joint.
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Figure 8 shows an internal restrained joint with double chambers for DN 80 to 500.
FIGURE 8: FIG 2807 - DOUBLE CHAMBER PIPE FITTED WITH INTERNAL RESTRAINED
JOINT SYSTEMS - HYDROTIGHT THRUST RESISTING RING SHOWN
Figure 9 shows a cutaway section of an internal restrained joint for pipes with double
chamber of size DN 80 to 500.
Rubberring with steel teeth
Fig. 2807B or Fig. 2807A
HYROTIGHT seal TYTON
EPDM (water) Fig. 2810 or NBR
(sewer) Fig. 2811
FIGURE 9: FIG 2807 - CUTAWAY SECTION OF INTERNAL RESTRAINED JOINT WITH
DOUBLE CHAMBERS FOR DN 80 TO 500
The Rubberring with steel teeth (Fig. 2807A and Fig. 2807B) is a vonRoll product, which is
manufactured and supplied by Rex Articoli in Switzerland. Their function is only to restrain,
not tightness.
The Rubberring with steel teeth (Fig. 2807A and Fig. 2807B) is different to TYTON ®-SIT ®
and TYTON ® SIT PLUS®, which are products of Hultec and have both functions in one ring,
i.e. tightness and restraint.
The Rubberring with steel teeth (Fig. 2807A or 2807B) internal restrained joint cannot be
used by the ECOFIT DI fittings supplied by Keulahütte as they have only single chamber.
The groove of the single chamber is used for unrestrained HYDROTIGHT seal TYTON ®
EPDM (water) Fig. 2810 NBR (sewer) Fig. 2811.
The single chamber ECOFIT DI fittings will be restrained in three ways (one internally and
two externally) as detailed in Section 3.4.2.
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Figure 10 shows the exploded view of the combined internal and external restrained joint
system without welded bead (Fig. 2806) with double chambers for DN 80 to DN 500.
FIGURE 10: FIG 2806 - DOUBLE CHAMBER PIPE FITTED WITH INTERNAL AND
EXTERNAL RESTRAINED JOINT SYSTEMS
Figure 11 shows the Cutaway section of a combined internal and external restrained joint
system without welded bead (Fig. 2806) with double chambers for DN 80 to DN 500.
The rubberring with steel teeth (without welded bead) belongs to the complete external
restrained joint Fig. 2806 which comprises the following:

Ductile Iron gland (Fig. 2806-1) – manufactured and supplied by Keulahütte, Germany;

The rubberring with steel teeth (Fig. 2806-2) – manufactured and supplied by Rex Articoli,
Switzerland; and

M20 Bolts and nuts galvanized or stainless steel 316 (Fig. 2806-3) – purchased by
vonRoll from third party
The whole external restraint joint (Fig. 2806) has a Product Certification in compliance with
EN 545. Individual EN 545 certificate for each component of the restraint assembly,
separately is not feasible, because only the function of the whole external restraint joint can
be tested as per the Standard.
Ductile iron gland
Fig.2806-1
Bolts and nuts
M20 Fig. 2806-3
HYROTIGHT seal TYTON®
EPDM (water) Fig. 2810 or
NBR (sewer) Fig. 2811
Rubberring with steel
Teeth Fig. 2806-2
FIGURE 11: CUTAWAY SECTION OF A COMBINED INTERNAL AND EXTERNAL
RESTRAINED JOINT SYSTEM WITHOUT WELDED BEAD WITH DOUBLE CHAMBERS FOR
DN 80 TO DN 500
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Figure 12 shows Internal Restrained Joint combined gasket with steel teeth TYTON ®-SIT®
Figure 2504 (DN 80 - 400) or TYTON ® SIT PLUS ® Figure 2504S (DN 80 - 600).
FIGURE 12: RUBBERRING RESTRAINT TYTON® SIT® FIG. 2504 (DN 80-400) OR TYTON®
SIT PLUS® FIG. 2504S (DN 80-500) FOR DOUBLE CHAMBER PIPES FIG. 2817
Figure 13 (Fig. 2805) external restrained joint with WELDED BEAD (DN 600-700) comprises
of the following:
a) DI gland (Fig. 2805-1) is made of ductile iron according to EN 545 - supplier is vonRoll
(produced in the foundry of the vonRoll group);
b) DI lock ring (Fig. 2805-2) is made of ductile iron according to EN 545 - supplier is vonRoll
(produced in the foundry of the vonRoll group);
c) M27 Bolts and Nuts (galvanised or stainless steel 316) are supplied by the same factory
as for the M20 bolts and nuts of Fig. 2806; and
d) Welded bead: The bead will be welded on the spigot end of the DI pipe after the
centrifugation and annealing. The material used is a special electrode of Fe/Ni for ductile
iron. The bead has the function to avoid the slipping of the lock ring.
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Ductile iron gland
M27 Bolts and nuts
Ductile iron lock
ring
Welded bead
HYROTIGHT seal TYTON® EPDM (water)
Fig. 2810 or NBR (sewer) Fig. 2811
FIGURE 13: EXTERNAL RESTRAINED JOINT FIG. 2805 DN 600 - 700 WITH WELDED BEAD
Figure 14 shows internal restrained joint combined gasket with steel teeth TYTON ®-SIT
PLUS ® Fig. 2504-S DN 600.
FIGURE 14: RUBBERRING RESTRAINT TYTON® SIT PLUS® FIG. 2504S FOR SINGLE
CHAMBER PIPES FIG. 2815 (DN 600)
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3.3 Elastomeric and Thrust-Resisting Joint Sealing Rings
The vonRoll hydro DUCPUR ®, ECOPUR ® and GEOPUR ® range of DI pipes are supplied with
various accessories such as elastomeric seals, rubberring with steel teeth, thrust-resisting
rings, DI components and nuts and bolts to form an unrestrained or restrained joints.
3.3.1. Unrestrained Joint
a) Double Chamber DN 80-500 - HYDROTIGHT standard elastomeric seal {TYTON ® EPDM
(water) Fig. 2810 or NBR (sewerage) Fig. 2811} – supplied by Hultec
b) Single Chamber DN 600-700 - HYDROTIGHT standard elastomeric seal {TYTON ® EPDM
(water) Fig. 2810 or NBR (sewerage) Fig. 2811} – supplied by Hultec
3.3.2 Restrained Joint
Pipe with double chamber socket (DN 80-500) fitted with unrestrained HYDROTIGHT seal
as mentioned in Item 3.3.1.1(a) above, with an additional:
a) Hydrotight internal thrust-resisting rings Fig. 2807B (DN 80-300) and Figure 2807A (DN
80-500) – vonRoll products supplied by Rex Articoli (Swiss)
b) Internal restrained joint combined gasket with steel teeth TYTON®-SIT ® Fig. 2504 (DN
80-400) or TYTON ®-SIT PLUS® Fig. 2504-S (DN 80-600) – supplied by Hultec
c) HYDROTIGHT external thrust-resisting ring without a welded bead Figure 2806 (DN 80500) – suppliers are:
i)
Rubberring with steel teeth – vonRoll product supplied by Rex Articoli (Swiss)
ii) DI gland – Keulahütte (Germany)
iii) M20 bolts & nuts galvanised / Stainless Steel 316 - purchased by vonRoll hydro
from third party
Pipe with single chamber socket (DN 600-700) fitted with:
a) Internal restrained joint combined gasket with steel teeth TYTON®-SIT PLUS ® Fig. 2504S (DN 600) – supplied by Hultec
b) Unrestrained HYDROTIGHT standard elastomeric sea as mentioned in Item 3.3.1(b)
above, with an additional HYDROTIGHT external thrust-resisting ring with welded bead
Figure 2805 (DN 600-700) – suppliers:
i)
unrestrained HYDROTIGHT seal TYTON ® – Hultec
ii) DI gland & DI locking ring – Keulahütte (Germany)
iii) M27 nuts & bolts – purchased by vonRoll hydro from third party
vonRoll hydro has submitted copies of type tests and audit reports recognised by MPA NRW
to demonstrate that the elastomeric and thrust-resisting joint sealing rings used with vonRoll
DI pipes and ECOFIT DI fittings comply with the performance requirements specified in EN
545 and EN 598.
The above documents have been sighted by WSAA and saved in the folder.
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TABLE 5: PERMISSIBLE PRESSURES FOR THRUST RESISTING RINGS
Allowable working pressure PFA (bar)
DN
Pressure
class (C)
Internal restrained
External restrained
External restrained
Fig. 2807 A / B1
TYTON-SIT / TYTON-SIT PLUS
Fig. 2806
Fig. 2805
80
K9 / C100
40 / 25
10 / 16
40
100
K9 / C100
40 / 25
10 / 16
40
125
K9 / C64
40 / 25
10 / 16
40
150
K9 / C64
40 / 25
10 / 16
40
200
K9 / C50
40 / 25
10 / 16
16/402
250
K9 / C50
25 / 16
10 / 16
16/402
300
K9 / C40
25 / 16
10 / 16
16/402
350
K9 / C40
16
10 / 16
16/252
400
K9 / C40
16
10 / 16
25
500
K9 / C30
16
- / 10
16
600
K9 / C30
-
- / 10
-
25
700
K9 / C30
-
-
-
25
NOTE 1: Internal restrained joint with all teeth execution Fig. 2807 A or the half of the teeth execution Fig. 2807 B
NOTE 2: PFA with all bolts and nuts
3.4 vonRoll ISO sized ECOFIT DI fittings
FIGURE 15: VONROLL ECOFIT DI FITTINGS (BLACK OR BLUE - WATER SUPPLY;
RED BROWN OR BLACK - SEWERAGE)
Ductile iron fittings are sand cast in accordance with ISO 2531 and with EN 545 / EN 598.
All the fittings are in the class K12 and the thickness of the fittings is in accordance with the
European Standard EN 545 / 598. The fittings are subjected to a leak-tightness test carried
out with water in accordance with ISO 2531 and with EN 545 / EN 598.
The DI fittings are provided with an integral Resicoat R4 epoxy powder coating (internal and
external) at least 250 μm thick according to EN 14901 and GSK, perfectly suited to all types
of soil. GSK is a trade association (Gütezeichen) that has been registered in Germany for
over 20 years which acts as the global network for companies that coat val ves and fittings
with an epoxy powder coating. For more information refer to http://www.gskonline.de/en/gsk.html
The coating made from epoxy resin powder (black epoxy pulver coating) provides proven
and pore-free corrosion protection for fittings used in water and gas supplies and for
wastewater disposal. The extremely smooth and pore-free epoxy internal coating offers
comprehensive protection for drinking water and meets all legal requirements on hygiene in
full. It prevents deposits from building up and is abrasion resistant. The epoxy coating is an
organic protective coating and its use has minimal environmental impact.
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3.4.1 Types of Joints and Interconnections
ECOFIT DI pipe fittings of size range DN 80 to DN 700 have a single chamber socket with a
single groove. The DI fittings are supplied with unrestrained HYDROTIGHT TYTON®
elastomeric seal which enables a flexible joint or with an internal thrust-resisting ring to form
a restrained joint system.
The material used for elastomeric seal is EPDM for water (Fig. 2810) and NBR for sewer
(Fig. 2811) in accordance with the European Standard EN 681-1. The International Standard
ISO 2230 provides a guide to the most suitable conditions for the storage of vulcanized
rubber.
The single chamber ‘Push-in socket’ includes the following jointing system:
a) Unrestrained - DI fittings with single chamber socket (DN 80 and 700) unrestrained
HYDROTIGHT seal {TYTON® elastomeric seal, manufactured from EPDM (water) Figure
2810 or NBR (sewerage) Figure 2811 by Hultec Europe}. Refer to Figure 7.
b) Restrained
i)
Internal restrained joint combined gasket with steel teeth TYTON ®-SIT ® Fig. 2504
(DN 80-400) or TYTON ® -Sit PLUS ® Fig. 2504S (DN 80-600). Refer to Figure 16.
ii) External restrained joint without welded bead Fig. 2806 (DN 80 – 500). Refer to
Figure 17.
iii) External restrained joint Fig. 2805 (DN 600 – 700) with welded bead. Refer to Figure
18.
For permissible pressure for the different thrust-resisting rings (both internal and external)
refer to Table 5.
Refer to Appendix D for unrestrained and restrained joints for ECOFIT DI fittings of size
range DN 80 to DN 700.
3.4.2 Restrained Joints for DI Fitting
3.4.2.1 Internal Restrained Joint Single Chamber DN 80 – 700
Internal restrained joint combined gasket with steel teeth TYTON ®-SIT ® Fig. 2504 (DN 80400) or TYTON ®-SIT PLUS® Fig. 2504S (DN 80-600)
Marking ring
Fig. 2504-2 / Fig. 2504S-2
Rubbering restraint
TYTON®-SIT Fig. 2504-1
or
TYTON®-SIT PLUS® Fig. 2504S-1
FIGURE 16: RUBBERRING RESTRAINT TYTON® SIT® FIG. 2504 (DN 80-400) OR TYTON®
SIT PLUS® FIG. 2504S (DN 80-600) FOR SINGLE CHAMBER DI FITTING
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3.4.2.2 External Restrained Joint Single Chamber DN 80 – 700
External restrained joint without welded bead Fig. 2806 (DN 80 – 500)
Ductile iron gland
Rubberring with
steel teeth
Gasket TYTON®
Fig. 2810 / Fig. 2811
Bolts and nuts
M20
FIGURE 17: EXTERNAL RESTRAINED JOINT FIG. 2806 (DN 80-500) WITHOUT WELDED
BEAD
External restrained joint Fig. 2805 (DN 600 – 700) with welded bead
Ductile iron gland
Bolts and nuts
M27
Ductile iron lock
ring
Welded bead
Gasket TYTON® Fig. 2810 EPDM water and
Fig. 2811 SBR sewer
FIGURE 18: EXTERNAL RESTRAINED JOINT FIG. 2805 (DN 600-700 WITH WELDED BEAD
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Refer to vonRoll technical brochure for details for thrust-resisting rings and other information
about vonRoll DI Pipes and Fittings, by clicking the below link.
vonRoll DI Pipes and Fittings
3.5 DI Fittings ISO sized – Configurations, Size and Class
The vonRoll ECOFIT ductile iron fittings range DN 80 to DN 700 consists of variety of fittings
complying with the requirements of EN 545 (Water) and EN 598 (Sewer). All fittings are lined
and coated with fusion bonded epoxy (FBE) resin.
3.6 Elastomeric and Thrust-Resisting Joint Sealing Rings ISO sized
The ECOFIT range of DI fittings with single chamber of size DN 80-700, is supplied with the
following elastomeric and thrust-resisting joint sealing rings:
3.6.1 Unrestrained Joint
Fittings with single chamber of size DN 80-700 - HYDROTIGHT standard elastomeric seal
{TYTON ® EPDM (water) Fig. 2810 or NBR (sewerage) Fig. 2811} - supplied by Hultec
3.6.2 Restrained Joint
Fittings with single chamber of size DN 80-700 have one internal and two external restrained
joints as follows:
(a)
Internal restrained joint combined gasket with steel teeth TYTON®-SIT® Fig. 2504 (DN
80-400) or TYTON ®-SIT PLUS® Fig. 2504-S (DN 80-600) – supplied by Hultec
(b)
HYDROTIGHT external thrust-resisting ring without a welded bead Figure 2806 (DN
80-500) - suppliers:
i)
Rubberring with steel teeth – vonRoll product supplied by Rex Articoli (Swiss)
ii) DI gland – Keulahütte (Germany)
iii) M20 bolts & nuts galvanised / Stainless Steel 316 - purchased by vonRoll hydro
from third party
(c)
HYDROTIGHT external thrust-resisting ring with welded bead Figure 2805 (DN 600700) - suppliers:
i)
Unrestrained TYTON ® seal – Hultec
ii) DI gland & DI locking ring – Keulahütte (Germany)
iii) M27 nuts & bolts – purchased by vonRoll hydro from third party
3.7 DI Socketed Fittings to AS/NZS 2280
WSAA has appraised the Derwent Industries range of DI fitting to AS/NZS 2280, under
WSAA Product Appraisal No 1003 Issue 2. A copy of this report can be downloaded from
the WSAA website.
Gulf Rubber supplies the special transition EPDM TYTON® elastomeric seals in compliance
with AS 1646:2007 ‐ Elastomeric seals for waterworks purposes.
Additional testing has been performed by vonRoll hydro (suisse) Ltd to demonstrate that
Derwent Industries supplied DI socketed fittings with Gulf Rubber special EPDM TYTON ®
transition elastomeric seals meets the performance requirements of AS/NZS 2280 when
used with DUCPUR ®, ECOPUR® and GEOPUR® DI pipes in sizes DN 100 to 300. (Refer to
Clause 6.2.7.2)
4
SCOPE OF THE APPR AI S AL
The scope of this product appraisal application applies to:
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a) vonRoll DUCPUR ®, ECOPUR® and GEOPUR ® range of ductile iron pipes of two
connection types (push-in socket and flanged) with unrestrained and restrained joints as
specified in Section 3 and listed in Tables 1, 2, 3 and 5 for water supply (potable and
recycled) and sewerage (gravity, pressure and vacuum);
b) vonRoll ECOFIT ductile iron ISO sized fittings for use with vonRoll DI pipes as specified
in Section 3; and
c) Use of ductile iron socketed fittings manufactured to AS/NZS 2280 with vonRoll DI pipes
as specified in Section 3.
5
APPR AI S AL CRI TERI A
5.1 Quality Assurance Requirements
The WSAA product appraisal network accepts ductile iron pipes and fittings manufactured
under third party accredited quality assurance programs complying with AS/NZS ISO 9001
Quality Management System – Requirements and product certification by a Certification
Body at the manufacturing site of strategic products to appropriate Australian or
internationally recognised standards. The Certification Body shall have relevant
accreditation by the Joint Accreditation System of Australia and New Zealand (JAS-ANZ) or
by an equivalent international accreditation system recognised by JAS -ANZ.
5.2 Performance Requirements
5.2.1 Product Manufacturing Standards
The WSAA product appraisal network accepts ductile iron pipes and fittings ma nufactured
under cover of a third party certified management system complying with AS/NZS ISO 9001
and having ISO Type 5 product certification by a JAS-ANZ accredited Conformity
Assessment Body (CAB) or by a CAB accredited by international accreditation system
recognised by JAS-ANZ. The relevant product standards are:
EN 545: 2010 Ductile iron pipes, fittings, accessories and their joints for water pipelines Requirements and test methods and
EN 598: 2007 Ductile iron pipes, fittings, accessories and their joints for sewerage
applications - Requirements and test methods
The polyurethane internal lining and external coating has been assessed against the
following European Standards:

BS EN 15189:2006 - Ductile iron pipes, fittings, accessories – External polyurethane
coating for pipes– Requirements and test methods

BS EN 15655:2009 - Ductile iron pipes, fittings, accessories – Internal polyurethane lining
for pipes and fittings – Requirements and test methods
The following WSAA Product Specifications are also relevant to this application:

WSA PS 202 - Ductile Iron Pipes and Fittings (ISO Sized) for Pressure Applications –
Water Supply

WSA PS 202S - Ductile Iron Pipes and Fittings (ISO Sized) for Pressure and NonPressure Applications – Sewerage

WSA PS – 312 Flange Gaskets and O-Rings

WSA PS – 320 Sleeving, Polyethylene (PE) for Ductile Iron Pipes and Fittings - Water
Supply and Sewerage
Refer to Appendix E for copies of the above specifications.
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COMPLI ANCE WI TH APPR AI S AL CRI TERI A
6.1 Compliance with Quality Assurance Requirements
6.1.1 Distributor
While Reece does not have a formal certified Quality Management System ISO 9001, they
have, over the past 95 years, been developing a significant management system, the Reece
Business Management System (RBMS) which underpins the delivery of Customer Projects
and consists of:

Reece R10 The Reece Way (Business Management Policy)

Reece Branch Procedures Manuals (includes Branch Audit reports)

Reece OH&S Management Systems Manual (includes OH&S Policy)

Reece Environmental Management Systems Manual

Reece Support Centre & Compliance Procedures Manual

Reece CIP Procedure Manual - (Continuous Improvement Program)

Reece After Sales & Customer Care
In addition to the above, Reece are the only Plumbing wholesaler in Australia to have its
own Test Laboratory and Aftersales Facility for their branches and customers.
The facility is a fully operational laboratory with piping and pump facility to test flows and
pressures, a spectrometer to analyse and report on material make up of metals such as
brass, copper and steel, load testing cell and gauges to check thread engagement.
The quality team at the Reece Test Facility carry out regular inspection and checks of
products delivered to their National and Regional Distribution Centres to ensure quality and
standards criteria are met. Reece test and review current and potential products to ensure
they meet the relevant Australian and International Standards.
Refer to Appendix B for a copy of the above statement in Reece letterhead.
6.1.2 Manufacturers
Quality Management System ISO 9001 and Product Certification to relevant Standards for
the manufacturers of DI pipes, DI fittings and associated components are as follows.
6.1.2.1 vonRoll DI pipes
The DUCPUR ®, ECOPUR ® and GEOPUR ® range of ductile iron pipes are produced in
vonRoll manufacturing facilities located in Choindez, Switzerland. The manufacturing
facilities are owned by the vonRoll Infratec Group. vonRoll is a quality endorsed Company
and holds ISO 9001:2008 and ISO 14001:2004 certification for the development, production
and distribution of products and systems for the public water supply and sewage disposal.
The ISO 9001 and ISO 14001 Certificate of Registration No CH-20430 were issued by Swiss
Association for Quality and Management Systems (SQS).
SQS is a member of the International Certification Network (IQNet) which entitles SQS to
use IQNet logo and Certification Certificate. IQNet certificates are accepted globally
throughout 40 different Certification Accreditation Bodies (CAB) based on multilateral
recognition arrangement (MLA).
The SQS is a Certification Body (CB), accredited by the Swiss Accreditation Services (SAS)
which is a signatory to the Multilateral Recognition Arrangement (MLA) of the Internat ional
Accreditation Forum (IAF) which is recognised and accepted by JAS-ANZ.
vonRoll manufacturing facilities in Choindez, Switzerland have been issued with Certificates
of Conformity Nos. 11 7416 – 1/6 & 2/6 to EN 545 (water supply) and Certificates of
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Conformity Nos. 11 7417 - 1/7 & 2/7 to EN 598 (sewerage) by Materialprufungsamt
Nordrhein-Westfallen (MPA NRW) for their range of ductile iron pipes.
MPA NRW possesses accreditation and recognition from the German Accreditation system
audit GmbH (DAP). Refer to Appendix A for additional information on German Accreditation
system.
The MPA NRW Certificate of Conformity carries the Deutscher Akkreditierungs Rat (DAR)
logo and DAR registration and the International Accreditation Forum, Inc. (IAF) logo. Only
accredited bodies being signatories to the Multilateral Recognition Arrangement (MLA) of
the IAF and can use the IAF logo in connection with their own accreditation mark and the
registration number. The IAF logo is recognised and accepted by JAS-ANZ.
The MPA NRW has confirmed through their letter dated 04/09/2009 that the Certificates of
Conformity (Ref. no. No. 11 7416-1/2 and No. 11 7416-2/2 dated 27/04/2007 – previously
issued certificates) issued by the MPA NRW complies with the certification procedure whic h
corresponds to the product certification described in ISO/IEC Guide 67:2004 . This is
sufficient to demonstrate compliance with ISO Type 5 product certification as specified in
WSA PS 202 - Ductile Iron Pipes and Fittings (ISO Sized) for Pressure Applicat ions - Water
Supply and WSA PS 202S - Ductile Iron Pipes and Fittings (ISO Sized) for Pressure and
Non-Pressure Applications – Sewerage
6.1.2.2 ECOFIT DI fittings and DI components for external restrained joints
ECOFIT DI Fitting manufacturer Keulahütte GmbH manufacturing facility in Krauschwitz
Germany has an accredited Quality Management System to ISO 9001:2008 for the
development, manufacture and sales of fittings, hydrants, valves and castings for
mechanical engineering and vehicle construction. The ISO 9001 Certificate of Registration
No. 01 100 4186 was issued by TÜV Reheinland Cert GmbH is valid until 3 October 2015.
TUV Rheinland Group through its Australian subsidiary TUV Rheinland Australia Pty Ltd is
affiliated with JAS-ANZ.
Keulahütte GmbH’s facility in Krauschwitz, Germany has been issued with DVGW
Certificates of Registration No DV-7705BM0164 by Deutsche Akkreditierungsstelle GmbH
(DAkkS) for their range of ductile iron fittings from DN 80 to DN 700 manufactured to EN 545
and EN 598 valid till 22 March 2016. This certification also includes potable water compliance
to DVGW W 270 - Testing and assessment of enhancement of microbial growth on nonmetallic materials in contact with drinking water.
DAkkS is Germany's government appointed National Accreditation Body to provide
accreditation of conformity to assessment bodies like DVGW Cert. DAkkS is a member of
EA (European Accreditation) and IAF (member of multilateral recognition arrangement).
IQNet certificates are accepted globally throughout 40 different Certification Accreditation
Bodies (CAB) based on multilateral recognition arrangement (MLA).
DAkkS is accredited by the Multilateral Recognition Arrangement (MLA) of the International
Accreditation Forum (IAF) which is recognised and accepted by JAS-ANZ.
6.1.2.3 TYTON ® elastomeric seals
HYDROTIGHT TYTON ® Elastomeric seals for the vonRoll DI pipes and ECOFIT DI fittings
are supplied by Hultec Europe. Hultec’s Production Plant in Vietnam (trading as Thai Duong
Joint Stock Company) is a quality endorsed Company and holds ISO 9001:2008 for
manufacture of Technical Rubber Products. TUV Rheinland Cert GmbH in Germany issued
the ISO 9001 certificate valid until 17 May 2016. TUV Rheinland Group through its Australian
subsidiary TUV Rheinland Australia Pty Ltd is affiliated with JAS-ANZ.
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A Certificate of Conformity issued by Hultec Europe (France) has been submitted to confirm
that the elastomeric compounds comply with EN 681.1. A copy of DVGW examination
Certificate DW-5114BN0161 has also been submitted to demonstrate compliance in contact
with potable water DVGW W 270.
NOTE 1: The Hultec Production Plant in Vietnam has the ISO 9001 certificate, not the Hultec Europe in France which
is a small company (office). Hultec produce the HYDROTIGHT TYTON® elastomeric seals in its Vietnam Production
Plant, not in France.
NOTE 2: Hultec Europe office in France has the lead and lodge the required applications to the relevant bodies such
as DVGW, BGA KTW (Federal Environmental Agency in Germany on the hygienic assessment of plastic materials in
contact with drinking water) and WRAS-UK (Water Regulations and Advisory Scheme) to obtain Product Certification
to EN 681.1 and drinking water compliance certificate to DVGW Code of Practice W 270 (The growth of
microorganisms on materials intended for use in drinking water systems - examination and assessment).
6.1.2.4 Internal Restrained thrust-resisting rings
The Internal Restrained thrust-resisting ring manufacturer Rex Articoli’s manufacturing
facility in Mendrisio, Switzerland has an accredited Quality Management System to ISO
9001:2008 for the project, production and marketing of technical products from rubber,
rubber metal and thermoplastic. The ISO 9001 Certificate of Registration No. 10516 valid up
to 2 nd August 2016 was issued by SQS / IQNet.
Rex Articoli and vonRoll hydro have been issued with a Product Certification for
manufacturing of internal restrained thrust-resisting joint system in compliance with EN
545:2007 (Licence 1130-700197 15-01 valid up to 11 May 2018) by MPA NRW – DakkS,
Germany.
6.1.2.5 Jointing lubricant for vonRoll DI pipes and ECOFIT DI fittings
vonRoll hydro supplies the lubricant Fig. 240 with vonRoll DI pipes and ECOFIT DI fittings.
The Lubricant manufacturer van Baerle AG (Swiss), is an ISO 9001:2008 quality endorsed
company with Certificate Registration No. 10727 (available in German) for manufacture and
supply of Specialty Chemicals, issued by SQS / IQNet valid up to 27 August 2018.
The lubricant has the hygienic compliance certification to SVGW W-UK7 / Liquid soap TN2
for use in contact with drinking water issued by the Swiss, German and French Accredited
Institutes for Water Quality; i.e. SVGW (Switzerland) / TZW (Germany) / CARSO (France)
The Certificate No. is 1205-6040 / KA 0086/12 / 12 CLP LY 003 which is available only in
German.
6.1.2.6 Bolts and Nuts for use with external restrained joints
vonRoll hydro purchases M20 and M27 Bolts and Nuts (galvanised or stainless steel 316)
manufactured to relevant standards from third party, which are used with external restrained
joints Fig. 2806 and Fig. 2805 respectively.
Refer to Appendix B for copies of the above letters and certificates related to Quality
Management Certification and Product Certification. Certificates that are not attached in
Appendix B have been sighted by WSAA and saved in the folder as they are considered as
‘Commercial-in-Confidence’ documents.
6.1.2.7 Elastomeric joint seals Gulf Rubber supplies Reece with the EPDM TYTON transition elastomeric seals.
The special EPDM TYTON transition elastomeric seals are manufactured by Gulf Rubber
and comply with the requirements of AS 681.1:2008 (EN 681-1:1996).
Gulf Rubber holds a joint certification with Thong Nhat Rubber Company for StandardsMark
product certification (Licence SMK 20133) for the manufacturer transition elastomeric seals
in compliance with AS 1646:2007 and AS 681.1:2008 (EN 681-1:1996).
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6.2 Compliance to the Appraisal Requirements
6.2.1 Material properties
6.2.1.1 Ductile iron tensile and hardness properties
EN 545 and EN 598 both require that DI pipe and fittings material conform to a minimum
tensile strength of 420 MPa. The minimum required elongation is 10% for pipe sizes DN 100
- 700 and 5% for fittings. The maximum hardness is specified as 230 HB for pipes and 250
HB for fittings.
TABLE 6: MATERIAL PROPERTIES OF CENTRIFUGALLY CAST PIPES AND FITTINGS
Mechanical properties
Symbol
Unit
Pipes
Fittings
Minimum tensile strength
Rm
MPa
420
420
Yield strength
Rp 0.2
MPa
270
270
Minimum elongation at break DN 100-700
A
%
10
5
Minimum transverse compressive strength
MPa
550
550
Bursting strength
MPa
300
300
Longitudinal flexural strength
MPa
420
420
7.05
7.05
Density
ρ
kg/dm3
Elastic modulus
E
MPa
1.7 x 105
1.7 x 105
Thermal expansion coefficient
α
1/K
10 x 10-6
10 x 10-6
HB
< 230
< 250
Hardness
The compliance to these material test requirements is checked by:

vonRoll quality assurance department, daily; and

each audit of the independent body MPA NRW.
6.2.2 Wall thickness
The minimum wall thickness of the DUCPUR ®, ECOPUR ® and GEOPUR ® range of C25 up
to C100 DI pipes and fittings comply with the minimum requirements specified in EN 545 and
EN 598.
6.2.3 Performance test requirements to EN 545 and EN 598
EN 545:2010 and EN 598:2009 incorporates a range of performance tests and acceptance
criteria aimed at setting minimum production performance levels as summarised below:
Quality control
Type performance tests
a) dimensional checks
a) leaktightness of flexible joints to positive
internal pressure under
b) tensile property determinations
• shear loading
c) hydrostatic pressure tests
• angular deflection
d) zinc coating mass determinations
e) paint coating thickness checks
b) leaktightness of flexible joints to positive
external pressure shear loading
f) polyurethane lining and coating
thickness checks
c) leaktightness of flexible joints to dynamic
internal pressure (water supply only)
g) polyurethane lining and coating
adherence checks
d) mechanical strength and leaktightness of
flange-to-pipe attachment (for screwed-on
or welded-on flanges; water pipes only)
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The manufacturing standards EN 545 and EN 598 used for the vonRoll DI pipes have similar
performance requirements to the DI pipe manufactured to AS/NZS 2280 where testing of
dimensions, mechanical properties, joint performance and pressure testing are all performed
on the pipes during manufacture. The ductile iron has equivalent mechanical properties to
AS/NZS 2280 i.e. minimum tensile strength of 420 MPa and minimum elongation of 10%.
As part of agreement no. 117455 dated 12.05.2011 between the client vonRoll hydro
(Suisse) ltd and the MPA NRW (Third party certification body) audits are conducted yearly
at their factory in line with Technical test specifications; DVGW GW 337-81, DIN EN
545:2010 and DIN EN 598:2007.
vonRoll has submitted an English translation of MPA NRW annual audit report no. 11 7455
14-01 for DUCPUR® and ECOPUR® to EN 545 conducted on 16 th and 17 th of April 2014.
In addition, vonRoll has submitted MPA NRW’s 2015 annual audit report no. 11 7455 15-01
for DUCPUR® and ECOPUR ® to EN 545 and report no. 11 7417 15-01 for GEOPUR ® to EN
598, in German. The audits were conducted on 15 th and 16 th of April 2015 and reports were
issued on 28 th April 2015 in German language. By the annual visit, MPA NRW looks at three
different executions of the pipes and associated fittings, simultaneously.
The certification from MPV NRW is accepted as sufficient conformance requirements for the
DI pipes and fittings. In addition an onsite review of the manufacturers testing data and the
process control also provide sufficient information to demonstrate compliance with both
standards EN 545 and EN 598.
WSAA has sighted the above MPA NRW annual audit reports and saved in the folder.
6.2.3.1 Type tests and audit reports for vonRoll DI pipes
vonRoll have a number of audit reports on DUCPUR ®, ECOPUR® and GEOPUR® but the
content is almost the same. By the annual audit, MPA NRW checks the routine tests in the
production as wall thickness, lining, coating, mechanical characteristics of the material,
dimensions, etc. The type tests do not fall under the scrutiny of the annual audit because
they should be renewed only in case of a new development (i.e. new connection system,
change in material or design etc.). vonRoll did a comprehensive type tests in accordance
with EN 545 and EN 598 few years ago and the results are still valid.
The type tests for GEOPUR ® DI pipe to EN 598 is similar to those of DUCPUR® and
ECOPUR ® DI pipes to EN 545.
vonRoll has submitted full report on type tests conducted for GEOPUR ® DI pipe which was
recognized by the MPA NRW for issuing the third party product certification to EN 598.
vonRoll has also submitted MPA NRW audit report for GEOPUR ® DI pipe to EN 598 but it is
in German.
The type tests and audit reports associated with EN 598 have been sighted by WSAA and
saved in folder. As these documents are treated as “Commercial-in-Confidence”, anyone
need access should obtain the consent of the supplier Reece.
Complies with Performance type test requirements
6.2.4 Pressure ratings
The pressure rating of ductile iron pipes and fittings in EN 545 depends on:
a) Nominal size
b) Class designation (pipes) - see Section 6.2.2.1 below
c) Joint type
d) casting type (pipe / fittings)
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6.2.5 Pipe class designation
The previous standard EN 545:2006 defined the classification of pipe and fittings, not related
to pressure rating but instead to coefficient “K" which when substituted in the following
formula specifies the minimum wall thickness for various nominal diameters with an absolute
minimum thickness of 6 mm for pipes and 7 mm for fittings.
e = K (0.5 + 0.001DN)
Where e is the nominal wall thickness, in millimetres:
DN is the coefficient used for the determination of the thickness. It is selected from a se ries
of whole numbers 8, 9, 10, 11, 12.
The latest standard EN 545:2010 against which vonRoll DI pipes (DUCPUR ® and ECOPUR®)
for water supply applications are manufactured, defined the pipe classification in Clause 3.21
as follows:
The pressure class of a component is defined by a combination of its structural performance
and the performance of its non-restrained flexible joint. Restrained joints may reduce the
PFA; in this case the PFA shall be declared by the manufacturer.
Pressure class (C) - alphanumerical designation of a family of components, including their
joints, relating to their operating pressures as verified by all the performance tests described
in this standard, which includes the letter C followed by a dimensionless number equal to
the maximum PFA in bars of the family of components.
As per Annex A of EN 545:2010, the maximum values of PFA, PMA and PEA are calculated
as follows:
a) PFA = (20 x emin x Rm) / (D x SF)
Where
 Emin is the minimum pipe wall thickness, in millimetres
 D is the mean pipe diameter (DE – emin), in millimetres
 DE is the nominal pipe external diameter, in millimetres
 Rm is the minimum tensile strength of ductile iron, in MPa (Rm = 420 MPA)
 SF is a safety factor of 3
The maximum PFA of a pipe is equal to its class number, e.g. PFA 40 for a class 40
pipe.
b) PMA: as PFA, but with SF = 2.5; therefore:
PMA = 1.2 x PFA
c) PEA = PMA + 5 bar
6.2.5.1 Pipe Classes for Water Supply Application
Pipe classes for water supplies is in accordance with EN 545:2010 and ISO 2531:2009
standards
a) Pipes with push-in sockets: Pressure Class C / Thickness Class K9
b) Pipes with flanges: K12 standard
The pressure performance capability of DI pipes and fittings for water supply to EN 545:2010
is shown in Table 2.
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TABLE 7: MAXIMUM VALUES OF PFA, PMA AND PEA FOR VARIOUS PIPE CLASS
PUSH-IN JOINT PIPES AND ADAPTOR FITTINGS
Nominal Diameter
DN (mm)
Pipe Class
80
Pressure in Bar
PFA
PMA
PEA
C100
100
120
125
100
C100
100
120
125
125
C64
64
76.8
81.8
150
C64
64
76.8
81.8
200
C64
64
76.8
81.8
250
C50
50
60
65
300
C50
50
60
65
350
C40
40
48
53
400
C40
40
48
53
* 500
K9 / C30
38.4
46.1
51.1
* 600
K9 / C30
35.7
42.9
47.9
* 700
K9 / C30
33.8
40.6
45.6
* NOTE: vonRoll decided to put only the K9 thickness class for the DN 500 up to DN 700 in their catalogue but the
marking on the pipes is as follows:
DN 500 K9 / C30
DN 600 K9 / C30
DN 700 K9 / C30
PFA: Allowable Operating Pressure
Maximum hydrostatic pressure that a component is capable of withstanding continuously in service
PMA: Allowable Maximum Operating Pressure
Maximum pressure occurring from time to time, including surge that a component is capable of
withstanding in service
PEA: Allowable Test Pressure
Maximum hydrostatic pressure that a newly installed component is capable of withstanding for a relatively
short duration, in order to insure the integrity and tightness of the pipeline
The allowable operating pressure for pipe classes C100, C64, C50, C40 and C30 of DI pipe (i.e.
10 MPa for 80-100; 6.4 MPa for 125-200; 5 MPa for 250-300; 4 MPa for 350-400; more than 3.38
MPa for 500-700) far exceeds the pressure needs of water supply systems which is usually 1.6
MPa.
Allowable operating pressures for DI pipelines will be dependent upon the rating of elastomeric
seals, flanges and appurtenances.
NOTE:
Applicable limits, which may not permit the full use of the pressure ranges as stated in Table 6 in an
installed pipe, must be taken into consideration.
For example:
- Operation at the PFA and PMA values given in Table 6 for socket pipes can be limited by the lower
pressure range of other pipeline components, e.g. flange pieces (Table 8), certain types of Y-fittings and
certain types of moveable connections.
- The water pressure test in pits with the high PEA values given in Table 6 can be limited due to the type
and structure of the anchoring system of the pipe and/or the moveable connections.
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6.2.5.2 Pipe Classes for Sewerage Application
vonRoll GEOPUR® DI pipe can be used for pressure (vacuum or pumping) and non-pressure
(gravity) applications.
Pipe class for pressure pipes for wastewater disposal is in accordance with the EN 598
standard as detailed in Table 8.
TABLE 8: MAXIMUM VALUES OF PFA, PMA AND PEA FOR PRESSURE PIPE CLASS
PUSH-IN-JOINT PIPES AND ADAPTOR FITTINGS USED FOR SEWERAGE TO EN 598
Pressure in Bar
Nominal Diameter
DN (mm)
PFA
PMA
PEA
80
40
48
53
100
40
48
53
125
40
48
53
150
40
48
53
200
40
48
53
250
38
46
51
300
35
42
47
350
32
39
44
400
30
36
41
500
28
33
38
600
26
31
36
700
29
35
40
6.2.5.3 Flanged pipes for water supply and sewerage application
TABLE 9: FLANGED PIPES AND FITTINGS FOR FLANGE JOINTS – HIGHEST PFA,
PMA AND PEA VALUES
DN
PN 10
PFA
PMA
PN 16
PEA
PN 25
PFA
PMA
PEA
PFA
PMA
PN 40
PEA
See PN 40
PFA
PMA
PEA
40
48
53
80
See PN 16
16
20
25
100 - 150
See PN 16
16
20
25
25
30
35
40
48
53
40
48
53
200 – 600
10
12
17
16
20
25
25
30
35
700
10
12
17
16
20
25
25
30
35
Result Complies
6.2.6 Joints
In accordance with EN 545 and EN 598, various types of joints and interconnections
(unrestrained and restrained) of:
a) vonRoll DI pipes (DUCPUR ®, ECOPUR ® and GEOPUR ®) of size DN 80 to DN 700 as
detailed in Section 3.2, are performance tested and complied with the specified
requirements in the standard; and
b) ECOFIT DI fittings of size DN 80 to DN 700 as detailed in Sections 3.4.1 are performance
tested and complied with the specified requirements in the standard.
Unrestrained push-in socket joints for vonRoll DI pipes and ECOFIT DI fittings are formed
with the use HYDROTIGHT TYTON ® elastomeric seal EPDM (water) and NBR (sewer).
Internal and External Restrained joints for vonRoll DI pipes and ECOFIT DI fittings are
formed by combining an additional HYDROTIGHT thrust-resisting rings (internal or external)
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or an internal restrained joint combined gasket with steel teeth, as detailed in Appendix D.
The allowable working pressure for thrust-rings is shown in Table 10.
The HYDROTIGHT thrust-resisting ring reliably absorbs shear, tensile and pressure forces,
which can act on the pipe axially. It can be used with pipes, elbows, y-fittings or reducers
and is a space-saving, quick-to-fit, removable and mechanical connection.
vonRoll has submitted Product Certifications to EN 545 and EN 598 to demonstrate that
various types of joints and interconnections of vonRoll DI pipes and ECOF IT DI fittings
comply with relevant standards. Refer to Appendix B for copies of the certificates.
TABLE 10: ALLOWABLE WORKING PRESSURES (PFA) FOR THRUST-RESISTING
RINGS
Allowable working pressure PFA (bar)
DN
1)
2)
Thickness Class (K)
Pressure Class (C)
Internal restrained
TYTON® SIT® / TYTON® SIT
Fig. 2807 A / B 1)
PLUS® Fig. 2504
External restrained
Fig. 2806
Fig. 2805
80
K9 / C100
40 / 25
10 / 16
40
100
K9 / C100
40 / 25
10 / 16
40
125
K9 / C64
40 / 25
10 / 16
40
150
K9 / C64
40 / 25
10 / 16
40
200
K9 / C50
40 / 25
10 / 16
16 / 40 2)
250
K9 / C50
25 / 16
10 / 16
16 / 40 2)
300
K9 / C40
25 /16
10 / 16
16 / 40 2)
350
K9 / C40
16
10 / 16
16 / 25 2)
400
K9 / C40
16
10 / 16
25
500
K9 / C30
16
- / 10
16
600
K9 / C30
-
- / 10
-
25
700
K9 / C30
-
-
-
25
Internal restrained joint with all teeth execution A or the half of the teeth execution B
PFA with all bolts and nuts
Result Complies
6.2.7 Elastomeric Seals for push-in socket joint connections
6.2.7.1 Elastomeric seals for use on vonRoll hydro DI pipes and ECOFIT DI fittings
vonRoll hydro DUCPUR ®, ECOPUR ® and GEOPUR® range of DI pipes and ECOFIT DI
fittings are supplied with unrestrained HYDROTIGHT TYTON® elastomeric seal which is
manufactured from EPDM (water) or NBR (sewerage) by Hultec Europe.
vonRoll hydro Standard” elastomeric joint (unrestrained) consists of a pipe socket profile
with a locking chamber, sealing chamber and spigot end chamber. The elastomeric seal
consists of a locking heel and a sealing body. The locking heel locates in the locking chamber
of the socket to restrain the seal from being dislodged during jointing. Sealing is achieved
by compression of the seal body between the socket sealing chamber and pipe spigot.
vonRoll hydro also supplies HYDROTIGHT thrust-resisting rings for internal or external
restraint joints of vonRoll DI pipes and ECOFIT DI fittings.
Manufacturer of the restraint joint components are:
a) Rex Articoli in Switzerland supplies Rubberring with steel teeth for internal restraint
system (Fig. 2807A and 2807B) and Rubberring with steel teeth for external restraint
system (Fig. 2806).
b) Keulahütte in Germany supplies the DI gland and DI locking ring for external restrained
system (Fig. 2805 and 2806).
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c) vonRoll hydro buys M20 and M27 nuts and bolts (galvanised or stainless steel 316) from
third party, which are required to form the external restrained joints (Fig. 280 6 and 2805
respectively).
Refer to Section 3.3 for details of elastomeric seals used to form various types of joints in
vonRoll DI pipes, and Section 3.6 for details of the same for ECOFIT DI fittings.
Copies of type test and audit reports recognised by MPA NRW have been submitted to
demonstrate that the elastomeric joints used with vonRoll DI pipes and ECOFIT DI fittings
comply with the performance requirements specified in EN 545 and EN 598.
Refer to Appendix B for copy of Hultec Europe’s DVGW Type Examination Product
Certificate DW-5114BN0161 confirming the elastomeric compounds comply with EN 681.1
Elastomer Seals - Requirements on materials for piping seals for applications in water supply
and wastewater.
As the above Certificate has expired on 16/02/2015, vonRoll has submitted Hultec Europe
(France)’s letter dated 31/03/2015 confirming that they have already started the renewal
process. Submission of the updated Certificate has been mentioned as “Future Work” item
in Section 20.
Result Complies
6.2.7.2 Transition elastomeric seals – for use on DI pipe manufactured to EN 545 / EN
598 and AS/NZS 2280 manufactured Socketed DI fittings
Reece intends to supply AS/NZS 2280 DI Socketed fittings, with special EPDM TYTON
transition elastomeric seals, with delivery of DUCPUR ®, ECOPUR® and GEOPUR® DI pipes
in sizes DN 100 to 300.
AS/NZS 2280 allows fittings to be used with pressure pipe of alternative outside diameter by
the adoption of a compatible socket or utilisation of a transition elastomeric seals, provided
the joint meets the performance requirements of this Standard.
Tests have been carried out on the vonRoll hydro ductile iron pipe and Derwent Industries
DI socketed fittings (PA 1003 Issue 2) manufactured to AS/NZS 2280, using a transition
elastomeric seal to demonstrate compliance with the performance tests in AS/NZS 2280.
Such tests include pressure tests, vacuum tests and tests with deflection and applied shear
loading. According to the results of the performance testing the Allowable Operating
pressure (AOP) for the different diameter DN and transition elastomeric seal are as follows:
a) DN 100 - 250 Gulf Rubber TYTON® transition elastomeric seal with TYTON joint and
b) DN 300 Gulf Rubber TYTON® transition elastomeric seal with TYTON joint and
Gulf Rubber holds a joint certification with Thong Nhat Rubber Company for StandardsMark
product certification (Licence SMK 20133) for the manufacturer elastomeric seals in
compliance with AS 1646:2007 ‐ Elastomeric seals for waterworks purposes. The special
EPDM TYTON adaptor rubber jointing seal is manufactured by Gulf Rubber and complies
with the requirements of AS 1646.
Table 11 shows compatibility of vonRoll DI pipes with AS/NZS 2280 manufactured DI pipes
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TABLE 11: COMPATIBILITY OF VONROLL DI PIPES WITH AS/NZS 2280
MANUFACTURED DI PIPES
External Diameter (mm) *
Nominal
Diameter DN
(mm)
vonRoll pipe to EN 545 and EN 598
DI pipe to AS/NZS 2280
Nominal
Limit deviations
Nominal
Limit deviations
80
98
+1/-2.7
96
100
118
+1/-2.8
122
+1,-2
125
144
+1/-2.8
-
-
150
170
+1/-2.9
177
+1,-2
200
222
+1/-3.0
232
+1,-2
225
-
-
259
+1,-2
250
274
+1/-3.1
286
+1,-2
300
326
+1/-3.3
345
+1,-2
Length
6m
DI – 5.5 m; PVC – 6 m
* Excluding tolerances
vonRoll has submitted Performance Test Results for the ‘Leak-tightness of flexible joints’ to
demonstrate Socketed DI fittings manufactured to AS/NZS 2280 could be joined with DI pipe
manufactured to EN 545 / EN 598, using Gulf Rubber’s special adaptor elastomeric seals.
Two tests were conducted at vonRoll facility in Switzerland:
a) On 20/12/2012 for the size range 80, 100, 150, 200, 250 and 300mm as per Clause 7.2
of BS EN 545; and
b) On 18/06/2015 for the size range 250 and 300mm as per Clause 7.2 of BS EN 545 and
Clause 4.2.1 of AS/NZS 2280, Appendix F (Paragraph F2).
Conclusion of both tests is as follows:
a) Socketed DI fittings manufactured to AS/NZS 2280 could be joined with DI pipes
manufactured to EN 545 / EN 598 at 16 Bar for sizes 100, 150, 200 and 250 and at 10
Bar for size 300 mm.
b) The test results are valid for all three vonRoll DI pipes DUCPUR ®, ECOPUR® and
GEOPUR ® and the Australian made ductile iron socketed fittings.
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TABLE 12: TYPE TEST RESULTS FOR ISO SIZED VONROLL DI PIPES AND AS/NZS
2280 MANUFACTURED SOCKETED DI FITTINGS
Test Result
Certificate of
Conformity (8
pages) for test
conducted on
20/12/2012
Leak tightness of
flexible joints
Clause 7.2 of BS
EN 545
(using special Gulf
Rubber adaptor
seal)
Sample used
Outcome of the test
Double socketed collar to
AS/NZS 2280 supplied by
Derwent and ECOPUR® DI
pipe.
Two tests were done:
Two samples were used:
 150mm sample to
represent 80 - 200mm size
group; and
 DN 100, 150 and 200 passed the test
at 16 Bar (test pressure 29 Bar = 1.5 x
16 plus 5).
 DN 250 and 300 passed the test at 10
Bar (test pressure 20 Bar = 1.5 x 10
plus 5)
 300mm sample to
represent 250 - 300mm
size group
Certificate of
Conformity (9
pages) for test
conducted on
18/06/2015
Clause 7.2 of BS
EN 545;
And
Clause 4.2.1 of
AS/NZS 2280,
Appendix F
(Paragraph F2)
Double socketed collar to
AS/NZS 2280 supplied by
Derwent and ECOPUR® DI
pipe.
Two samples were used:
250 and 300 mm to represent
250 - 300mm size group
(using special Gulf
Rubber adaptor
seal)
Three tests were done:
 DN 250 passed the test at 16 Bar (test
pressure 29 Bar as per BS EN 545)
 DN 250 has also passed the test at 16
Bar (test pressure 20.8 Bar as per
AS/NZS 2280;. 20.8 = 1.3 x 16)
 DN 300 passed the test at 10 Bar (test
pressure 13 Bar as per AS/NZS 2280;
13 = 1.3 x 10)
Note: DN 300 was not tested as per BS
EN 545 at 10 Bar because similar test
was conducted on 20/12/2012
WSAA has sighted the type test results and saved in the folder. Anyone need access to
these documents should obtain the consent of Reece as they are considered as
“Commercial-in-Confidence”,
TABLE 13: RANGE OF ADAPTOR SEALS FOR ECOPUR ®, DUCPUR® AND GEOPUR®
DI PIPES AND AS/NZS 2280 MANUFACTURED SOCKETED DI FITTINGS
Model
Identification
Model
Name
Brand
Name
Product
Description
Type
Nominal
Size
Elastomeric
Type
Nominal
Elastomeric
Hardness
4000.2
Gasket
ISO2531E
Gulf
Rubber
Gasket
ISO2531E
Elastomeric
seals
100
EPDM
55/85
4001.2
Gasket
ISO2531E
Gulf
Rubber
Gasket
ISO2531E
Elastomeric
seals
150
EPDM
55/85
4002.2
Gasket
ISO2531E
Gulf
Rubber
Gasket
ISO2531E
Elastomeric
seals
200
EPDM
55/85
4003.2
Gasket
ISO2531E
Gulf
Rubber
Gasket
ISO2531E
Elastomeric
seals
250
EPDM
55/85
4004.2
Gasket
ISO2531E
Gulf
Rubber
Gasket
ISO2531E
Elastomeric
seals
300
EPDM
55/85
A copy of the Gulf Rubber / Thong Nhat Rubber Company StandardsMark Product Certification to
AS 1646 can be found in Appendix B.
Result Complies
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Alternatively jointing between ISO sized vonRoll DI pipe (i.e. DUCPUR ® / ECOPUR® /
GEOPUR ®) and AS/NZS 2280 manufactured DI pipes at 16 Bar pressure rating is possible
with the use of DI Socket-Flange adaptors where flanges comply with AS/NZS 4087 Figure
B5, PN16. This system can be applied to 250 mm and 300 mm sizes only as shown in figure
19.
FIGURE 19: JOINTING ISO SIZED VONROLL DI PIPE TO AS/NZS 2280 MANUFACTURED
DI PIPE USING SOCKET-FLANGE ADAPTOR
6.2.8 Restrained joints
All vonRoll’s internal and external restrained joints for DI pipes and fittings conform to EN
545 as they passed all relevant type tests according to EN 545. The type tests were carried
out at vonRoll’s Choindez facility under the supervision of an Independent body MPA
Dortmund.
vonRoll hydro has submitted certificates and reports (in Germany) as evidence which have
been sighted and saved in WSAA folder.
6.2.9 Linings for DI pipes
The internal lining of ECOPUR®, DUCPUR® and GEOPUR ® pipes is a hard Polyurethane
formulation developed by vonRoll in 1972 and now incorporated into EN 15655 DI pipes,
fittings – Internal Polyurethane lining - requirements and test methods. This lining is applied
in the vonRoll factory.
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External coating
Socket end
Internal lining
FIGURE 20: INTERNAL LINING OF ECOPUR ®, DUCPUR® AND GEOPUR® PIPES
The polyurethane is composed of a two component resin. It’s three-dimensionally linked
molecular structure gives its mechanical stability. Polyurethane is a thermosetting plastic
with no solvents. Specific details of the polyurethane characteristics are shown in the vonRoll
Catalogue.
Each pipe is being grit, blasted twice and pre-heated before lining in order to obtain perfect
adhesion and curing. The smooth surface and the equal distribution of the polyurethane are
achieved by keeping the pipe in rotation during lining and coating.
The interior of the socket is fully protected with polyurethane for ECOPUR® and GEOPUR ®
and with bitumen for DUCPUR ®. The socket of the DUCPUR ® pipes can be also lined by
polyurethane.
The thickness of the polyurethane lining shall be as follows:
TABLE 14: POLYURETHANE LINING THICKNESS
DN
Thickness (mm)
Mean value
Minimum value
80 - 150
1.3
0.8
200 - 700
1.5
0.8
Socket End: The internal surface of the socket end is lined with polyurethane. The mean
thickness is 150 microns and the minimum thickness 100 microns.
The polyurethane lining applied to vonRoll ductile iron pipe has been tested by the Australian
Water Quality Centre and they have certified it complies with AS/NZS 4020 - Testing of
products for use in contact with drinking water for:
•
Taste of Water Extract, Appendix C
•
Appearance of Water Extract, Appendix D
•
Growth of Aquatic Micro-organisms, Appendix E
•
Cytotoxic Activity of Water Extract, Appendix F
•
Mutagenic Activity of Water Extract, Appendix C
•
Extraction of Metals, Appendix H
vonRoll has submitted Test Report No. 55651 dated 15/07/2009 (AWQC Ref 141020-2008CSR-2: Prod Test: Polyurethane Internal Coating) from the Australian Water Quality Centre
for DN 80 ECOPUR® pipe manufactured by VonRoll Hydro to demonstrate compliance with
AS/NZS 4020:2005.
The test results have demonstrated compliance of ECOPUR® and DUCPUR ® to AS/NZS
4020 when tested at the 'in-the-product' exposure (50,000 mm 2 per Litre). Product range –
DN 80 to DN 700 pipes.
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Based on the completion and evaluation of all test results Australian Water Quality Centre
has confirmed the products fully comply with the test requirements of AS/NZS 4020:2005.
Result Complies
6.2.10 External Coatings
6.2.10.1 Polyurethane coating for ECOPUR ® ductile iron pipes
The coating of the pipes consists of a factory applied polyurethane coating. Each pipe i s
being blasted and pre-heated before coating in order to obtain perfect adhesion and curing
in accordance with EN 15189 DI pipes – External Polyurethane coating – requirements and
test methods.
The thickness of the polyurethane is nominal 900 microns with a minimum of 700 microns.
The entire barrel included of the spigot end is coated with polyurethane. Minor coating
damage (during delivery etc.) can be repaired with an easy to use dual pack cartridge which
ensures the exact dosage of resin/hardener components. See vonRoll Products Manual.
6.2.10.2 Zinc and finishing layer for DUCPUR® and GEOPUR ® DI pipes
The DUCPUR® and GEOPUR® DI pipes are internally lined with a Polyurethane (PUR) but
are externally protected with zinc coating in accordance with ISO 8179-2 Ductile iron pipes
- External zinc-based coating - Part 2 : Rich zinc paint with finishing layer. vonRoll hydro
applies the coating at a minimum of 220 g/m 2 zinc layer as prescribed in EN 545 for
DUCPUR® and at a minimum of 150 g/m 2 as prescribed in EN 598 for GEOPUR®. The zinc
coating is applied to the substrate of the ductile iron pipe by spraying of paint reach of zinc
(min. 90%).
DUCPUR® ductile iron pipes have a black bituminous paint applied as a finishing layer to a
minimum thickness of 70 μm.
GEOPUR® ductile iron pipes have a red brown bituminous paint applied as a finishing layer
to a minimum thickness of 70 μm.
The polyurethane lining is applied only in the pipe barrel for the DUCPUR®. The socket is
lined with bitumen. The socket of the GEOPUR® is lined with polyurethane.
The application of zinc coating enhances the external corrosion protection of the pipe and
fittings in buried applications. Zinc coating has not historically been widely utilised on ductile
iron pipes in Australia, however zinc based corrosion protection systems have been used in
Europe for more than 60 years. The application of this additional corrosion protection is
considered to be acceptable and beneficial to the performance of the pipe. In many soil
conditions it is possible to install zinc-coated pipes without polyethylene sleeving.
6.2.11 Polyethylene sleeving
Most Australian Water agencies specify polyethylene sleeving of ductile iron pipes as a
means of corrosion protection. Polyethylene sleeving provides corrosion protection in
aggressive soils by creating a passive uniform environment around the pipe and limiting
oxygen exposure.
Loose PE sleeving is installed on site on ductile iron pipelines in the form of a tubular film.
Cut lengths are slipped over the pipe, overlapped and wrapped up tight before securing in
place with bands and plastic adhesive tape. Polyethylene sleeving should be installed in
accordance with AS 3681:2008 - Guidelines for the application of polyethylene sleeving to
ductile iron pipeline. As the sleeving is the primary corrosion barrier, care needs to be
exercised during installation to prevent damage. Only accredited pipe layers trained in the
application of sleeving should be employed.
ECOPUR ® DI pipe does not need the sleeving because of its polyurethane external coating
and DUCPUR® and GEOPUR® DI pipes with its zinc/bitumen coating only requires sleeving
where the soil conditions are known to be corrosive to ductile iron.
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6.2.12 Contact with drinking water
6.2.12.1 EPDM Elastomeric Seals
vonRoll has submitted a copy of the DVGW Type examination Product Certificate No. DW5114BN0161 confirming the Hultec EPDM rubber is suitable for use in contact with drinking
water as per DVGW W270 - Testing and assessment of enhancement of microbial growth
on non-metallic materials in contact with drinking water.
vonRoll has also submitted WRAS (Water Regulations Advisory Scheme) UK letter ref.
RW/M5433 dated 22/04/2008 confirming Hultec EPDM black coloured rubber (HT5557 -4)
has met the requirements of BS 6920 – Suitability of non-metallic products for use in contact
with water intended for human consumption with regard to their effect on the quality of the
water. WRAS Directory Reference No. 0406528.
Result Complies
6.2.12.2 Special Adaptor Elastomeric Seals
Gulf Rubber’s special adaptor elastomeric seals as listed in Table 13 are StandardsMark product
certified to AS 1646, which also includes compliance with AS/NZS 4020.
Result Complies
6.2.12.3 Jointing Lubricant
vonRoll hydro has submitted copies of Certificates to confirm that the lubricant Fig. 240
which is manufactured by van Baerle AG (Swiss) has the hygienic compliance for use in
contact with drinking water from the Swiss, French and German Water Quality Institutes.
The hygienic certificates have been sighted by WSAA and saved in the folder.
Result Complies
6.2.12.4 Internal coating of ECOFIT DI fittings
vonRoll has submitted WRAS letter HL/M110333 dated 30/01/2014 confirming Resicoat R4 epoxy
powder coating applied to the ECOFIT DI fittings internally and externally meet the requirements
of BS 6920. WRAS approval Number to the coating manufacturer Akzo Nobel Coating GmbH is
112500.
6.2.13 Flanged joints and flanged pipe
Flanged pipe and fittings will be drilled to suit AS/NZS 4087:2011 - Flanges for water works
purposes prior to leaving Switzerland. On the limited occasions that lengths of flanged pipes
are required, they will be manufactured to the required length in Australia using K12 pipe
and pre-drilled screwed flanges supplied by vonRoll which will be transported to Australia
for the purpose. Other flange drillings configurations can be provided on request.
6.2.14 Angular joint deflection of pipes and fittings
The maximum allowable joint deflection for ECOPUR ®, DUCPUR ® and GEOPUR ® spigot and
socket flexible push-in-joints is as follows:
TABLE 15: ELASTOMERIC SEAL JOINT DEFLECTION
DN
Maximum
Deflection
Max Deflection With
Restraining Ring
80 - 300
5°
3°
350 - 400
4°
3°
500 - 700
3°
3°
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43
FITTI NG INSTRUCTIONS , TR AI NING AND I NSTALL ATIO N
7.1 Installation Instructions
Installation methods for DI pipes are generally in accordance with AS/NZS 2566 Buried
flexible pipelines Part 2: ‘Installation’. The standard specifies the requirements for the
installation, field testing and commissioning of buried flexible pipelines with structural design
in accordance with AS/NZS 2566.1.
Installation, repair and maintenance of vonRoll DI pipe is the same as for all DI pipe systems
and should cause no problems for installers or maintenance personnel. When an ECOPUR ®
pipe is cut, the exposed end can be coated with polyurethane which is supplied in a dual
cartridge applicator which ensures the components are mixed in the correct ratio. The same
cartridge applicators are used for minor repairs to the Polyurethane coating.
The vonRoll Product Catalogue show detailed installation instructions and full details on
carrying out minor repairs to the coating using the cartridge applicator. However, a range of
restrained and unrestrained mechanical couplings and flange adaptors are available to
enable end connections between CIOD to ISO pipe sizes, in order to maintain pipeline
systems.
7.2 Ductile iron fittings
A complete range of ECOFIT branded ISO sized ductile iron bends, tees, tapers and
connectors of size DN 80 to DN 700 are available from Keulahütte GmbH in Germany. Reece
also supplies AS/NZS 2280 manufactured socketed DI fittings for use with vonRoll DI pipes
using Gulf Rubber’s special adaptor seal for size DN 100, DN 150, DN 200, DN 250 and DN
300.
7.3 Tapped connections
ECOPUR ® and DUCPUR ® ductile iron pipes may be direct tapped with or without a suitable
tapping saddle. However it is suggested the practice of drilling holes in the pipe be minimised
where possible and that the use of Pre-Tap Connectors be utilised in new installations.
vonRoll DI pipes, ECOPUR ® and DUCPUR® can be tapped for customer service connections
with or without tapping saddle using a ferrule or ball valve. For more information on direct
tapping of DI pipe refer to vonRoll hydro.
If the polyurethane coating or lining is damaged during this process please refer to 7.1 repair
lining and coating.
8
M AINTEN ANCE
A range of Mechanical Flexible Couplings and Flange Adaptors up to DN 700 and Stainless
Steel Repair Clamps up to DN 700 is available for use with vonRoll DI pipes.
9 PIPE L AYING TRAI NING AND DEVELOPMENT OF TECHNIC AL
LITER ATURE
Reece do not intend to conduct training courses for the installation of vonRoll DI pipe, as
there is already Registered Training Organisations (RTO) conducting the training. Reece
will provide local advice and supervision for the first time users if required.
vonRoll have a comprehensive product brochure which lists all product range and has
comprehensive installation instructions, maintenance instructions, repair instructions and
design guidance.
10
PRODUCT M AR KING
10.1 vonRoll DI pipes for water supply and sewerage
vonRoll DI pipes and fittings are branded with markings which clearly identify the
manufacturer’s mark, nominal size, classification, traceability using batch number and codes
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for manufacturing facility locations, and manufacturing standard. Additional markings have
been added to identify pipe class, internal linings and external coatings.
For example pipes are permanently and legibly labelled with the following markings
conforming to EN 545, EN 598 and ISO 2531 and proposed additions:

Manufacturer’s name - vonRoll

Year of manufacture – xx e.g. 14 cast into socket for 2014

Identification as ductile iron - cast into socket

Nominal size – DN xxxx cast into socket

The PN rating of the flange (when applicable) – PN 16 or PN 35

Reference to Standard – EN 545 or EN 598

Classification – Thickness class K9 and pressure class (C25, C30, C40, C64, C100)

Insertion marking line at spigot
FIGURE 21: EXAMPLES OF PIPE MARKING ON ECOPUR ®
FIGURE 22: WITNESS MARKS ON ECOPUR ®
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FIGURE 23: STORAGE OF ECOPUR ® DI PIPE WITH CAPS
10.2 ECOFIT DI fittings
ECOFIT ductile iron fittings are marked in accordance with EN 545 and EN 598. All fittings
are permanently and legibly labelled with the following:
•
Manufacturers name or mark
•
Year of manufacturer
•
The identification as ductile iron
•
The DN
•
The PN rating of the flange (when applicable)
•
The reference to this standard
FIGURE 24: ECOFIT DUCTILE IRON FITTINGS
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10.3 Polyethylene sleeving
The Polyethylene sleeving supplied by Reece for use with DUCPUR ® and GEOPUR ® ductile
iron pipes is marked as follows and is in accordance with AS 3680 Polyethylene sleeving for
ductile iron pipelines:
•
Manufacturer’s name.
•
Date of manufacture.
•
Width of sleeving and corresponding nominal pipe size.
•
Nominal film thickness.
10.4 Elastomeric joint seals
10.4.1 Elastomeric seals – supplied by Hultec for use on vonRoll DI pipe and
ECOFIT DI fittings
These elastomeric joint seals are marked with the following
•
Nominal Size
•
The quarter and year of Manufacture
•
Manufacturer’s identification
•
The abbreviation for the rubber, e.g. EPDM or NBR
•
The reference to standard with type of application and hardness category as suffix; e.g.
EN 681-1/WB/50
Tyton DN200 DIN EN U M037 C1 EN681-1 EPDM WAL/50 HT-TD
WAL refers to the designation of elastomeric joint seals by type. Type WAL refers to cold
potable water supply application. In the above example 50 refer to the hardness category.
10.4.2 Special Transition Elastomeric seals – for use on vonRoll DI pipe and AS/NZS
2280 manufactured socketed fittings
The TYTON® Special transition elastomeric seals are slightly thicker than the Australian
Standard TYTON elastomeric seal. Gulf Rubber supplies these special transition seals.
FIGURE 25: GULF RUBBER TYTON ® SPECIAL ADAPTOR ELASTOMERIC SEAL
These elastomeric seals are marked with:
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•
The DN
•
Year of manufacturer
•
Manufacturer’s code
•
Name of seal
•
The reference to Standard
•
Orange Spot
11
TR ACE ABI LI TY
47
All vonRoll ductile iron pipes and ECOFIT ductile iron fittings are provided with identification
batch marking and recording on inspection and test reports.
12
P ACK AGI NG AND TR ANSP ORTATI ON
vonRoll pipes transported from Switzerland to Australia will be in the standard bundle (pack)
configuration stacked inside transport container units. Pipes bundles have wooden supports
and spacers and are restrained with plastic strapping (See Figures 26, 27 & 28).
FIGURE 26: PLASTIC
STRAPPING
FIGURE 27: WOODEN
SUPPORTS
FIGURE 28: SPACERS
The normal method of transporting vonRoll ductile iron pipes is as follows:
•
DN 80 to DN 300 Socket / Spigot DI pipes are delivered in bundles (packs).
•
Pipes larger than DN 300 are delivered as single pipes.
vonRoll DI pipe bundles are covered with UV protective film. This covering should only be
opened when necessary and should be closed again afterwards. Each pipe is sealed on
socket and spigot end with caps. Experience to date shows there has been very little damage
to the pipe coating during transport from Switzerland.
Only wide synthetic lifting belt should be used when loading and unloading the pipes to
prevent damage to the polyurethane coating.
Piping components made of elastomers, e.g. EPDM jointing rings, can be affected by heat,
light, ozone, dampness, solvents and storage under tension. For this reason particular care
must be taken with the storage and handling of these items. Precautions include:
•
Max temperature 25°C and Minimum -10°C
•
Keep away from UV light
•
Relative Humidity under 65%
•
No ozone exposure e.g. keep away from electric motors
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48
Stored without tension e.g. not hung on any part of their circumference
FIGURE 29: PIPE BUNDLES
TABLE 16: PIPE BUNDLES / PERMISSIBLE STAKING HEIGHT
80
Pipe
Length
m
6
Pipes
per
Bundle
14
Bundle
Height
cm
30
Bundle
Width
cm
74
Bundle
Length LB
m
6.3
Weight per
Bundle
kg
1200
Max. No. of
Bundles
Stackable
15
100
6
12
35
78
6.3
1250
13
125
6
10
40
78
6.3
1260
12
150
6
8
45
77
6.3
1280
11
200
6
6
58
73
6.3
1315
9
250
6
4
67
62
6.35
1040
8
300
6
4
80
75
6.35
1360
7
DN
13
PRODUCT W AR R ANTY
The standard warranty according to vonRoll hydro (suisse) ltd sales conditions is 12 months.
However vonRoll can provide additional warranty as per Customer request.
14 WATER AGENCY EXPERIE NCE WITH THE PRODUCT O R FIELD TESTI NG
REPO RT
Examples of long and short-term use by the water industry were sought. The longer-term
information focused on the polyurethane coating performance and was obtained overseas.
The shorter-term experiences of local water Agencies were obtained to gauge installation
practices.
14.1 Long Term
The polyurethane lined pipe and more recently the lined and coated pipe has been used
widely by Zürich Water in Switzerland since the product was first developed in 1972. Some
problems were encountered with the first generation internal lining that resulted in a change
of coating formulation. The original polyurethane was of the flexible type and when this
showed signs of blistering, further research was carried out which led to the development of
a rigid polyurethane version. This later generation of coating has much higher adhesion
strength to the ductile iron that provides superior performance. The change to rigid
polyurethane was made in 1978.
A section of first generation pipe was inspected which had 20 years’ service and while this
showed considerable blistering, minimal rusting of the substrate was apparent. It was
reported that similar aged rigid polyurethane pipe performed very well without any blistering
or deterioration. Zürich Water have also carried out controlled tests since 1990 to monitor
the performance of the ECOPUR ® and DUCPUR® pipes in different soil types and at the end
of 1998 they are satisfied with the results.
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14.2 Short Term
Locally, City West Water in Melbourne has been using both ECOPUR ® and DUCPUR ® pipes
for approximately 16 years. Feedback from the construction crews has been positive and no
major problems have been encountered. It was reported that it was easier to lay the pipe as
the jointing pressures being quite low. The pipe was also easier to handle and there did not
seem to be a major problem in external coating damage to the ECOPUR ® during normal
handling.
On a precautionary note, a greater input into the supply logistics is required to ensure that
the correct fittings and adaptor rings are available and supplied. The repair coating used to
make good cut ends of the pipe also took considerable time to cure but this was usually
avoided by better planning.
Refer to Appendix H for site photographs of vonRoll ECOPUR ® ductile iron pipes used at
City West Water in Melbourne
15
AV AI L ABILI TY OF PROD UCTS
Reece is a national supplier of pipes, fittings and ancillary items for the water industry around
Australia. Reece have large stock holdings of vonRoll products in their local warehouses and
a major central warehouse with overnight deliveries to all states. The office locations with
contact details are shown in Appendix F as follows:
Head Office is located in Victoria at: Reece Australia Limited, 118 Burwood Highway,
Burwood VIC 3125; Tel: 03 9274 0132; Website: www.reece.com.au
16
REP AIRS TO POLYURETH ANE COATI NG
Users should be mindful to watch for external damage to the polyurethane coating of
ECOPUR ® DI pipe as it may be difficult to detect damage in a black coating on a black pipe.
One product is available for the repair of the polyurethane coating and lining. Repairs are
recommended when ECOPUR® pipes are cut or damaged. The repair material is an epoxy
repair kit. The epoxy repair kit is used for repairs of smaller surfaces, e.g. cut ends up to DN
300 and repairs with area up to approximately 100 Sqcm. Either repair kit can be used on
the interior green lining or exterior black coating. Similarly where cut or drilled holes are
made in the pipe, repairs should be made or if that procedure is carried out under pressure,
an anti-tuberculation insert should be provided to prevent blockage of the outlet. As stated
in Section 7.3, where possible the Pre-Tap Connectors be utilised in providing new services
instead of drilling holes on the pipe to provide services using ball valves / ferrules and tapping
bands.
Zürich Water is one the long term users of vonRoll DI pipes. Feedback from Zurich Water
indicated that they no longer repair cut ends as the level of corrosion is minimal and is
unlikely to constitute a future failure point in pressure mains.
17
DISCUSSION
vonRoll has pioneered polyurethane materials for use as a pipe lining and coating over the
last 42 years. During this time the product has been used extensively in some European,
African and Middle East markets. The direct information from one of the larger and longest
users, Zürich Water, has been positive with excellent performance reported.
The polyurethane coatings are now being adopted by some pipe manufacturers in the USA
and several recent technical papers have provided testing data of various pipe linings. While
the data does not provide any details of long-term performance the information does provide
data which demonstrates superior physical properties of polyurethane coatings compared to
other more conventional linings. This information from users and current trends in other parts
of the world give confidence that the vonRoll product will provide a long life pipe system.
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One of the advantages of this pipe is the relative inertness of the lining that has no adve rse
effect on the water quality. Additional corrosion protection is not required with the ECOPUR®
pipe.
The literature claims that the ECOPUR® pipe can be directly backfilled and buried with the
original trench excavation material. The polyurethane coating has high levels of adhesion
and is reported to have high resistance to damage and undercutting. If the external coating
is damaged, corrosion will occur and depending on the extent of damage a perforation may
occur in the longer term. While in some cases the use of trench excavation material could
be used, a number of risks emerge if this practice is adopted.
Increases the risk to damage if stony or rocky material is used up to 60 mm size.
Some trench excavation material, bigger than 100 mm, would be very difficult if not
impossible to compact which would be a problem under a carriageway.
In general it is felt that for maximum protection, selected bedding and backfills should be
utilised to minimise damage to the external coating. It is recommended to use bedding
material as sand or gravel up to 32 mm size.
In a similar context the DUCPUR ® pipe with a combined external coating of zinc and bitumen
is claimed to overcome the need to use loose fit polyethylene sleeving in low corrosivity
soils. The use of the zinc/bitumen external coating is widely used in some parts of the world
without sleeving and specific criteria has been set down where sleeving is and isn’t required.
Similar criteria can be used for ductile iron with a bitumen coating but the majority of
Australian Water agencies have adopted the policy of full sleeving of all ductile iron pipe with
zinc/bitumen coating. It is well documented that the application of a zinc coating will not
detract from the performance and in some environments there are definite improvements to
the performance of the pipe. Unless the environment is known to be low corrosivity, the use
of the sleeving in conjunction with the DUCPUR ® pipe is recommended.
Like all pipes, it is better to avoid the cutting of holes which can act as points of corrosion or
stress failures so it is felt that the use of pre tapped connector fittings for the connection of
services should be adopted in the first instance to minimise this effect. Where holes have to
be cut the use of plastic inserts is recommended to prevent the growth of rust tubercles that
can reduce flow in the longer term.
For the tapping of the vonRoll ECOPUR® and DUCPUR ® DI pipes, there will be no damage
to the coating and lining if the right equipment/device is used. Tapping wit h saddle under
pressure is always possible for the vonRoll DI pipes up to and including DN 400.
If copper services are used in conjunction with these pipes it is essential to use insulated
fittings to prevent galvanic attack of the ductile iron.
18
OUTCOMES OF EXPERT P ANEL PRODUCT REVIEW
<Enter text here>
19
LIFE EXPECTANCY
Operational experience with cast iron pipe in Australia has shown a life expectancy of over
100 years. The new generation of ductile iron pipes with the specialist coatings can only be
expected to extend this life even further. On this basis an operational pipe life of well over
100 years can be expected.
The manufacturing standards used for the pipe have similar performance requirements to
AS/NZS 2280 in that testing of dimensions, mechanical properties, joint performance and
pressure testing are all performed on the pipes during manufacture. The ductile iron has
equivalent mechanical properties to AS/NZS 2280 i.e. Minimum tensile strength of 420 MPa
and Minimum elongation of 10%. The certification from MPA NRW confirms conformity to
the relevant EN standards; i.e. EN 545 and EN 598.
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vonRoll have been manufacturing centrifugally cast iron pipes since 1925. In 1965 the pipe
material changed from grey cast iron to ductile iron and in the early 1970’s the internal
coating was changed to polyurethane.
vonRoll have supplied approximately 60-70% of all pipe in Switzerland, most of which has
been lined with polyurethane since its introduction. Zürich Water has been a major user and
was involved in the initial development of the polyurethane lining and they have been
monitoring the pipe’s performance since that time. They have exhumed some early
polyurethane coated installations and the coating was reported as being as good as when it
was installed.
20
FUTURE WORKS
Within six months of publication of this appraisal report, vonRoll hydro has to provide the
following document:
a) Hultec Europe (France)’s DVGW Cert GmbH’s Product Certification for Rubber Gasket
TYTON ® EPDM for DIN EN 681-1, DVGW W270, BGA KTW and DVGW VP 545, as the
current one expired on 16 February 2015.
21
DISCL AIMER
This Product Appraisal Report (Report) is issued by the Water Services Association of
Australia Limited on the understanding that:
This Report applies to the product(s) as submitted. Any changes to the product(s) either
minor or major shall void this Report.
To maintain the recommendations of this Report any such changes shall be detailed and
notified to the Product Appraisal Manager for consideration and review of the Report and
appropriate action. Appraisals and their recommendations will be the subject of continuous
review dependent upon the satisfactory performance of products.
WSAA reserves the right to undertake random audits of product manufacture and installation.
Where products fail to maintain appraised performance requirements the appraisal and its
recommendations may be modified and reissued. Appraisal reports will be reviewed and
reissued at regular intervals not exceeding five (5) years.
The following information explains a number of very important limits on your ability to rely on
the information in this Report. Please read it carefully and take it into account when
considering the contents of this Report.
Any enquiries regarding this report should be directed to the Program Manager Asset
Creation, Carl Radford, Phone: (03) 8605 7601 email: [email protected].
21.1 Issue of Report
This Report has been published and/or prepared by the Water Services Association of
Australia Limited and nominated Project Manager and peer group of technical specialists
(the Publishers).
The Report has been prepared for use within Australia only by technical specialists that have
expertise in the function of products such as those appraised in the Report (the Recipients).
By accepting this Report, the Recipient acknowledges and represents to the Publisher(s)
and each person involved in the preparation of the Report that the Recipient has understood
and accepted the terms of this Disclaimer.
21.2 Limits on Reliance on Information and Recommendations
21.2.1 Disclaimer of liability
Neither the Publisher(s) nor any person involved in the preparation of the Report accept(s)
any liability for any loss or damage suffered by any person however caused (including
negligence or the omission by any person to do anything) relating in any way to the Report
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or the product appraisal criteria underlying it. This includes (without limitation) any liability
for any recommendation or information in the Report or any errors or omissions.
21.2.2 Need for independent assessment
The information and any recommendation contained (expressly or by implication) in this
Report are provided in good faith. However, you should treat the information as indicative
only. You should not rely on that information or any such recommendation except to the
extent that you reach an agreement to the contrary with the Publisher(s).
This Report does not contain all information that a person might require for the purposes of
assessing any product discussed or appraised within it (Product). The product appraisal
criteria used in preparing this Report may not address all relevant aspects of the Product.
Recipients should seek independent evidence of any matter which is material to their
decisions in connection with an assessment of the Product and consult their own advisers
for any technical information required. Any decision to use the Product should take into
account the reliability of that independent evidence obtained by the Recipient regarding the
Product.
Recipients should also independently verify and assess the appropriateness of any
recommendation in the Report, especially given that any recommendation will not take into
account a Recipient’s particular needs or circumstances.
WSAA has not evaluated the extent of the product liability and professional indemnify
insurance that the provider of the product maintains. Recipients should ensure that they
evaluate the allocation of liability for product defects and any professional advice obtained
in relation to the product or its specification including the requirements for product liability
and professional indemnity insurance.
21.2.3 No Updating
Neither the Publisher(s) nor any person involved in the preparation of this Report [has] [have]
any obligation to notify you of any change in the information contained in this Report or of
any new information concerning the Publisher(s) or the Product or any other matter.
21.2.4 No Warranty
The Publisher(s) do[es] not, in any way, warrant that steps have been taken to verify or audit
the accuracy or completeness of the information in this Report, or the accuracy,
completeness or reasonableness of any recommendation in this Report.
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APPENDIX A – GERMAN ACCREDITATION SYSTEM
German Accreditation System for Testing (DAP) is a member of the German Accreditation
Council (DAR), the European co-operation for Accreditation (EA), the International
Laboratory Accreditation Co-operation (ILAC), the International Accreditation Forum (IAF)
and their Multilateral Agreements for Recognition (MLA and MRA), a member of the
European Federation of National Associations of Measurement, Testing and Analytical
Laboratories (EUROLAB), the European Organisation for Quality (EOQ), the German
Society for Quality (DGQ) and the German Institute for Standardization (DIN).
DAP is a legally independent accreditation bodies in the German. It is responsible for the
accreditation of testing and research laboratories, of certification bodies and of inspection
bodies in the voluntary area. DAP’s primary activity is the accreditation of material testing
and chemical analytical bodies in Germany. The European Series of Standards DIN EN
45000, the DIN EN ISO/IEC 17025 and the ISO/IEC-Guides are the basis for the
accreditation.
The equivalence of the accreditation systems of many countries in Europe is determined
through the European co-operation for Accreditation (EA) Multilateral Mutual Recognition
Agreements (MLA), which are signed for accreditation programmes of specific conformity
assessment activities, such as testing laboratories and product certification bodies.
Signatories to the EA MLAs recognise mutually each other's accreditation systems as being
equivalent to their own.
Bilateral agreements between EA and other accreditation bodies outside Europe have also
been signed, thereby facilitating the mutual recognition of these accreditation systems
outside of EA. Membership of the EA MLA is achieved by successfully undergo ing a system
of peer evaluations. DAP is a signatory to the EA MLA for testing laboratories and product
certification bodies since 1999. In addition, DAP also signed (through DAR) the Mutual
Recognition Arrangement of International Laboratory Accreditation Cooperation (ILAC) of
International Laboratory Accreditation Cooperation (ILAC) on 02.11.2000 and on 09.10.2004
the Mutual Recognition Arrangement of International Accreditation Forum (IAF). These
Agreements and the Arrangement would in general form the prerequisite for the recognition
of test reports and certificates issued by DAP conformity assessment bodies (testing
laboratories, certification bodies for products and inspection bodies) in the respective
countries of ILAC signatories.
The vonRoll Catalogue pages mentioned in the above A1 and A2 are available for
downloading from the WSAA ‘Members Only’ IPAM Portal Website.
A1 - vonRoll Flanged Pipe
Refer pages from 4/1.1 to 4/1.12 in the below vonRoll Catalogue
http://www.vonrollhydro.ch/Public/en/00.Products%20area/00.Pressurised%20piping%20and%20fittings/01.Catalogue%20Pressurised
%20piping%20and%20fittings/01$Pressurised%20piping%20and%20fittings%20(complete).en.pdf
A2 - vonRoll ECOFIT Socketed and Flanged DI Fittings
Refer pages from 2/3.1 to 2/7.3 in the below vonRoll Catalogue
http://www.vonrollhydro.ch/Public/en/00.Products%20area/00.Pressurised%20piping%20and%20fittings/01.Catalogue%20Pressurised
%20piping%20and%20fittings/01$Pressurised%20piping%20and%20fittings%20(complete).en.pdf
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APPENDIX B – QUALITY CERTIFICATIONS
Copies of the following Quality Certification Certificates are available for downloading from
the WSAA ‘Members Only’ IPAM Portal Website.
TABLE B1: REECE AUSTRALIA LTD – MANAGEMENT SYSTEMS
Head Office: 118 Burwood Highway, Burwood VIC 3125
Reece Quality Processes: Although Reece does not have a formal certified Quality Management System,
they have, over the past 95 years, been developing a significant management system, the Reece Business
Management System (RBMS) which underpins the delivery of Customer Projects. Please see the letter
issued by Reece in the following page.
TABLE B2: VONROLL HYDRO (SUISSE) AG – MANAGEMENT SYSTEMS
Head Office: 4702 Oensingen, Switzerland
Quality Systems Standard
ISO 9001:2008
Certificate of Registration
20430
Certifying agency
SQS / IQNet
Issued
01/04/2013
Expiry date of certification
31/03/2017
TABLE B3: VONROLL HYDRO (SUISSE) AG – CERTIFICATE OF CONFORMITY
Enterprise and Factory: VonRoll-Strasse 24 – CH-4702, Oensingen / Factory: vonRoll Casting (pipe
system) sa, CH-2830, Courrendlin
Product Standard
EN 545:2010 – Ductile iron pipes, fittings, accessories and their joints for
water pipelines
Licence
11 7416-1/6 (DN80-500) and 11 7416-2/6 (DN350, 500, 600 and 700)
Certifying agency
MPA NRW Assessment Report No. 11 7416 12
Original Issued Date
30/11/2012
01/12/2015
TABLE B4: VONROLL HYDRO (SUISSE) AG – CERTIFICATE OF CONFORMITY
Enterprise and Factory: VonRoll-Strasse 24 – CH-4702, Oensingen / Factory: vonRoll Casting (pipe
system) sa, CH-2830, Courrendlin
Product Standard
EN 598:2009-2010 – Ductile iron pipes, fittings, accessories and their
joints for sewerage applications
Licence
11 7417-1/7 (DN 80-500) and 11 7417-2/7 (DN 600-700)
Certifying agency
MPA NRW Assessment Report No. 11 7417 12-01
30/11/2012
01/12/2015
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TABLE B5: KEULAHÜTTE GMBH, GERMANY – MANAGEMENT SYSTEMS
Keulahütte GmbH, Geschwister-Scholl-Straße 15, 02957 Krauschwitz, Germany
ISO 9001:2008
01 100 4186
Certifying agency
TÜV Reheinland Cert GmbH
Issued
28/09/2015
14/09/2018
NOTE: vonRoll to arrange an updated certificate as mentioned in the Future Work in Section 20 as the current one will
expire on 3rd Oct 2015.
TABLE B6: KEULAHÜTTE GMBH, GERMANY – CERTIFICATE OF CONFORMITY
Keulahütte GmbH, Geschwister-Scholl-Straße 15, 02957 Krauschwitz, Germany
Product Standard
water pipelines
EN 598:2009-2010 – Ductile iron pipes, fittings, accessories and their
joints for sewerage applications
Licence
DV-7705BM0164
Certifying agency
DVGW CERT – DakkS, Germany
NA
23.03.2016
TABLE B7: REX ARTICOLI TECNICI SA – MANAGEMENT SYSTEMS
Rex Articoli Tecnici SA, 6850 Mendrisio, Suisse
ISO 9001:2008
10516
Certifying agency
SQS / IQNet
02/08/2013
Issued
13/09/2013
02/08/2016
NOTE: This Certificate is in French Language
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TABLE B8: REX ARTICOLI TECNICI SA AND VONROLL HYDRO (SUISSE) AG –
CERTIFICATE OF CONFORMITY FOR INTERNAL RESTRAINT JOINT
Rex Articoli Tecnici SA, 6850 Mendrisio, Suisse and VonRoll-Strasse 24 – CH-4702, Oensingen
Product Standard
water pipelines
Licence
1130-700197 15-01
Certifying agency
MPA NRW – DakkS, Germany
NA
Issued
11/05/2015
11/05/2018
NOTE: This Certificate is in German Language
TABLE B9: HULTEC VIETNAM – MANAGEMENT SYSTEMS
Head Office: Thai Duong Joint Stock Company (Hultec Vietnam), Lot A-6B-CN, My Phuoc 3 Industrial
Park, Ben Cat District, Binh Duong Province, Vietnam
ISO 9001:2008
01 100 106571
Certifying agency
TUV Rheinland Cert GmbH
Current Issued Date
30/06/2014
2010
17/05/2016
TABLE B10: HULTEC EUROPE (FRANCE) – PRODUCT CERTIFICATION FOR RUBBER
GASKET TYTON EPDM
Head Office: Hultec Europe, Impasse des Broderies, F-78314 Maurepas, Cedex.
DIN EN 681-1 (01-05-2003) – Elastomeric seals - Material requirements
for pipe joint seals used in water and drainage applications Part 1:
Vulcanized rubber
DVGW W 270 (01-11-2007);
BGA KTW (12-12-1985);
DVGW VP 546 (01.06.2007)
DW-5114BN0161
Certifying agency
DVGW Cert GmbH
Issued
NA
16/02/2015
NOTE: VonRoll Hydro has submitted a letter from Hultec Europe (France) dated 31/03/2015 confirming that
they have already started renewal of DVGW type examination certificate for rubber gasket Tyton EPDM. Once
the certificate is ready, VonRoll will submit it to WSAA. This item has stated as “Future Work” item.
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TABLE B11: GULF RUBBER AUSTRALIA AND THONG NHAT RUBBER COMPANY
RUTHIMEX – MANAGEMENT SYSTEMS
Business Location: 12-13 Green Street Revesby NSW 2122 Australia:
ISO 9001:2008
Certificate No.
QEC 23575
Certifying agency
SAI Global
First date of certification
26 November 1998
Current date of certification
18 May 2015
14 May 2018
TABLE B12: GULF RUBBER AUSTRALIA AND THONG NHAT RUBBER COMPANY
RUTHIMEX – PRODUCT CERTIFICATION
Business Location: 12-13 Green Street Revesby NSW 2122 Australia: Hamlet #12, Tan Thanh Dong
Village, Cu Chi District, Vietnam
Product Standard
AS 1646:2007 – Elastomeric seals for waterworks purposes
Certificate No.
SMKP20133
Certifying agency
SAI Global
10 December 2003
19 May 2014
9 December 2018
TABLE B13: VAN BAERLE AG – MANAGEMENT SYSTEMS
Manufacturing Plant: van Baerle AG, 4142 Münchenstein, Switzerland
ISO 9001:2008
Certificate No.
10727
Certifying agency
SQS, Bernstrasse 103, 3052 Zollikofen, Switzerland
28 August 2003
28 August 2015
27 August 2018
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TABLE B14: VAN BAERLE AG – PRODUCT CERTIFICATION
Manufacturing Plant: van Baerle AG, 4142 Münchenstein, Switzerland
Product Standard
SVGW W-UK7 / Liquid soap TN2
Certificate No.
1205-6040 / KA 0086/12 / 12 CLP LY 003
Certifying agency
SVGW (Switzerland) / TZW (Germany) / CARSO (France)
5 January 2012
2. March 2013
30 April 2018
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APPENDIX C – VONROLL DI PIPE ‘C’ CLASS AND ‘K’ CLASS
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APPENDIX D – UNRESTRAINED AND RESTRAINED JOINTS FOR VONROLL DI PIPES AND ECOFIT DI FITTINGS
D1: VONROLL DI PIPES DN 80 – 700 – UNRESTRAINED AND RESTRAINED JOINTS
Unrestrained
Restrained
Double
Chamber
DN 80 - 500
Single
Chamber
DN 600 - 700
HYDROTIGHT
seal TYTON®
- EPDM (water)
Fig 2810
- NBR (sewer)
Fig. 2811
HYDROTIGHT
seal TYTON®
- EPDM (water)
Fig. 2810
- NBR (sewer)
Fig 2811
Pipe with double chamber socket (DN 80 - 500) fitted with unrestrained
HYDROTIGHT seal TYTON® EPDM (water), NBR (sewer)
with an additional:
External
Restrained
DN 80 - 500
Internal
Restrained
DN 600
External
restrained joint
Fig. 2806 (DN
80 – 500)
Internal restrained
joint combined
gasket with steel
teeth TYTON®SIT PLUS® Fig.
2504S (DN 600)
Internal Restrained DN 80 – 500
HYDROTIGHT
internal thrustresisting ring
Fig. 2807B for
DN 80 to DN
300
HYDROTIGHT
internal thrustresisting ring
Fig. 2807A for
DN 80 to DN
500
Internal restrained joint
combined gasket with
steel teeth TYTON®SIT® Fig. 2504 (DN 80400) or TYTON®-SIT
PLUS® Fig. 2504S (DN
80 – 500)
Pipe with single chamber socket
(DN 600 - 700) fitted with
unrestrained HYDROTIGHT seal
TYTON® EPDM (water), NBR (sewer),
with an additional
External
Restrained
DN 600 - 700
External
restrained joint
Fig. 2805 (DN
600 – 700) with
welded bead
NOTE: there is no
unrestrained
HYDROTIGHT seal
TYTON®
D2: ECOFIT DI FITTINGS – UNRESTRAINED AND RESTRAINED JOINTS
Unrestrained Joint Single
Chamber DN 80 - 700
Hydrotight seal TYTON®
- EPDM (water) Fig 2810
- NBR (sewer) Fig. 2811
Restrained
External Restrained Joint Single Chamber DN 80 - 700
Internal Restrained Joint Single
Chamber DN 80 - 600
Internal restrained joint combined gasket
with steel teeth TYTON®-SIT® Fig. 2504
(DN 80 – 400) or TYTON®-SIT PLUS® Fig.
2504S (DN 80 – 600)
External restrained joint Fig.
2806 (DN 80 – 500) without
welded bead
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External restrained joint Fig.
2805 (DN 600 – 700) with
welded bead
61
APPENDIX E - WSAA PRODUCT SPECIFICATION
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APPENDIX F - SUPPLIER CONTACTS
Although Reece have over 480 branch locations throughout Australia, they have provided a
reduced list as shown in the below that are specialist Civil locations who are being trained
on VonRoll products and have the facilities onsite to distribute.
Reece believe by having more than one location in every state they can provide a greater
service level to their customers.
The Customers have to contact their
closest
visiting www.reece.com.au/civil or phone 1800 032 566
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Reece
Civil
Branch
by
65
APPENDIX G – MPA NRW AUDIT OUTCOME AT VONROLL’S
MANUFACTURING PLANT
a) Manufacturing plants: vonRoll casting sa, Choindez, CH-2830 Courrendlin, Switzerland
b) Scope of the audit: The scope of the audit is defined in line with the requirements in
DIN EN 545 and DVGW GW 337-P, and covers ductile cast iron pipes for water pipelines
designed for conducting drinking water.
c) During the audit: The production facilities were inspected, and mechanical values were
determined in the materials laboratory from reference samples. The officer examined the
microstructure on random samples under a light-optical microscope. In the selected
samples (13 embedded samples from between 14.04.2014, 9:40 and 15.04.2014, 11:50),
the officer found a completely pearlitic microstructure with nodular graphite. The officer
also took measurements on random product samples in the finished parts store.
The audit covered the following:
•
Basic requirements for the plant production control system
•
Continuous monitoring of production
•
Recording and documentation
•
Material mechanical characteristic values from reference samples
•
Dimension check on pipes (DIN EN 545)
•
Coating thickness testing on pipe coating
External coating thickness from 10 measured values: Average coating thickness > 70 µm;
Minimum coating thickness > 50 µm
Internal lining thickness from 10 measured values: DN 80 - DN 300 > 1.3 mm; DN 350 - DN
600 > 1.5 mm; DN 700 > 1.5 mm
d) Outcome of the audit: In conclusion, it has been found that the certificate holder vonRoll
hydro (suisse) ag in Oensingen (Switzerland) has the necessary measures in place in
terms of staff, production and testing, as well as a plant production control system, in
order to ensure that ductile cast iron pipes can be manufactured in accordance with the
requirements.
e) Results of the independent audit: The vonRoll hydro (suisse) ag manufacturing plant
in Oensingen (Switzerland) and its production facility, vonRoll casting sa, in Courrendlin
(Switzerland) have the necessary measures in place in terms of staff, production and
testing, as well as a plant production control system, in order to ensure that ductile cast
iron pipes for water pipelines can be manufactured in accordance with DIN 545 and
DVGW GW 337-P.
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APPENDIX H – SITE PHOTOGRAPHS
Project Details for ECOPUR ® Ductile Iron pipe
City West Water, Melbourne

Location:
Mt Alexander Road, Moonee Ponds

Project details:
Pipe size 200 mm; length 1.1 km

Where these pipes were laid: along roadway

Project type:
Watermain renewal dated 26th June 2013

Contractor:
Scarriff Pipelines Pty Ltd
City West Water, Melbourne

Location:
A’Beckett Street in Melbourne

Project details:
Water main upgrade, 235 metres of pipe from 150 mm to 200mm

Where these pipes were laid: along roadway

Project type:
Watermain upgrade in Sept 2012

Contractor:
Downer EDI Works Pty Ltd
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Mt Alexander Road, Moonee Ponds – Site photos
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A’Beckett Street in Melbourne
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Melbourne Office
Suite 8.02 Level 8,
401 Docklands Drive
Docklands VIC 3008
Phone: (03) 8605 7601
Fax: (03) 8605 7612
Sydney Office
Level 11, 39 Martin Place
Sydney NSW 2000
GPO Box 915
Sydney NSW 2001
Phone: (02) 9221 5966
Fax: (02 9221 5977
www.wsaa.asn.au
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vonRoll hydro (suisse) Ltd - Water Services Association of Australia

Transcription

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