Eadips Manual Engl PDF

E-Book 10.
2015
E-Book – Ductile iron pipe systems I
07.2014
E-Book – Ductile iron pipe systems II
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Editor: European Association for Ductile Iron Pipe Systems · EADIPS®/ Fachgemeinschaft Guss-Rohrsysteme (FGR®) e. V. III
Ductile iron pipe systems

Pipes, fittings and valves of ductile iron pipe systems
07.2014
E-Book – Ductile iron pipe systems IV
07.2014
E-Book – Ductile iron pipe systems V
Foreword
The current edition of the Cast Iron chapter is relevant for the references to
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E-Book – Ductile iron pipe systems VI
Contents 3.5 Application of coatings and linings

3.6 Marking
3.7 Testing
3.8 References
Foreword
4 Quality management
1 Introduction
1.1 General 5 Design of pipes
1.2 Cast iron as material for pipes
1.3 Joint technology 6 Design and marking of fittings
1.4 Modern ductile iron pipe techniques
1.5 Sustainability
NEW
1.6 Summary
1.7 References 7 Valves
7.1 Valves in spheroidal graphite cast iron
2 Ductile cast iron as a material 7.2 Corrosion protection of valves in spheroidal
2.1 General graphite cast iron
2.2 Structure 7.3 Principles of hydraulics and the design of valves
2.3 Technological properties 7.4 Isolation valves
2.4 References 7.5 Tapping valves
7.6 Control valves
3 Production of pipes, fittings and valves 7.7 Air valves
3.1 Melting the iron 7.8 Hydrants
3.2 Magnesium treatment
3.3 Casting process 8 Push-in joints
3.4 Post-treatment 8.1 General
8.2 Types of joint
8.3 Fields of use
8.4 References
08.2015
E-Book – Ductile iron pipe systems VII
9 Restrained socket joints 11 Safeguarding with concrete thrust blocks

9.1 General
9.2 Types of joint 12 Durability
9.3 Bases for the design and dimensioning
of restrained socket joints 13 Gaskets
9.4 Types of restrained joint 13.1 General
9.5 Type tests 13.2 Types of gaskets
9.6 Determining the forces which occur 13.3 Properties
and the lengths of pipe to be restrained 13.4 Gaskets for drinking water pipelines
9.7 Examples of installed pipelines 13.5 Gaskets for sewage drains and pipelines
9.8 Notation in equations 13.6 References
9.9 References
14 Coatings
10 Mechanical joints – wide-tolerance couplings 14.1 General
and flange adaptors 14.2 Works-applied coatings on pipes
10.1 General 14.3 Coating of fittings and valves
10.2 Construction and operation 14.4 On-site measures
10.3 Wide-tolerance couplings 14.5 References
10.4 Wide-tolerance flange adaptors
10.5 Preloading of gasket 15 Linings
10.6 Ranges of pipe outside diameters 15.1 General
10.7 Allowable angular deflection 15.2 Linings of pipes, fittings and valves
10.8 Restraint for drinking water pipelines
10.9 References 15.3 Linings in pipelines for raw water
15.4 Linings of pipes, fittings and valves
for pipelines for wastewater and sewage
15.5 Linings in pipelines for non-drinking and
cooling water
15.6 References
10.2013
E-Book – Ductile iron pipe systems VIII
16 Structural design 21.8 Disinfection process

21.9 Disinfection agent
17 Hydraulic design 21.10 Handling and disposal
21.11 Inspection and release of the pipeline
18 Welding of ductile iron pipes 21.12 Measures for existing cast iron pipelines
21.13 Summary
21.14 Closing comments, additional information
NEW and prospects
19 Transport, storage and installation 21.15 References
19.1 General
19.2 Pipeline installation regulations 22 Use of ductile iron pipes for trenchless
19.3 Transport of ductile cast iron pipes, fittings and valves installation techniques
19.4 Installation of ductile iron pipe systems 22.1 General
19.5 Installation 22.2 Coatings of ductile iron pipes for trenchless
19.6 Pipe trenches pipe installation
19.7 Special pipeline installation cases 22.3 Joint technology
19.8 References 22.4 Trenchless installation techniques
22.5 References
20 Pressure tests
23 Some new main applications for ductile iron pipes
NEW 24 Standards, directives and technical rules

21 Commissioning of ductile iron pipelines 24.1 General
21.1 Preliminary comment 24.2 The Standards Database
21.2 Preventive measures
21.3 Cleaning measures 25 Index
22.4 Flushing with water
21.5 Flushing with water and air 26 Imprint
21.6 Impulse-flushing method
21.7 Other cleaning techniques
10.2015
E-Book – Ductile iron pipe systems Chapter 1: Introduction 1/1
1 Introduction
1.1 General
1.2 Cast iron as material for pipes
1.3 Joint technology
1.4 Modern ductile iron pipe techniques
1.5 Sustainability
1.6 Summary
1.7 References
05.2014
1 Introduction stresses. Firstly there is the internal

pressure necessary to convey the medium
being transported. And secondly there are
Around 150 years ago, urban infrastructures for supplying the townsfolk the external loads exerted on the pipe-
with drinking water were constructed almost exclusively with cast iron pipes. lines above all by the soil itself and by
A major part of the supply network in operation today still dates back to that traffic in the form of ground motion and
time. Since then the ductile iron pipe system has made enormous progress: the vibrations. In addition to these internal
manufacturing processes have adapted to the increasing requirements regarding and external loads, which usually occur
dimensional accuracy, weight reduction and efficiency. Pipe joint technology has in combination and may be both static
become both more secure and simpler. The use of spheroidal graphite cast iron and dynamic in nature, there are also
means that higher mechanical loads are possible while simultaneously reducing chemical stresses from the surrounding
weight. Protection against chemical attack both inside and outside has been soil and in some cases from the medium
perfected and, with pipes, fittings, valves and accessories, a complete system has being carried; sometimes the influence of
been produced for all tasks. Nowadays the system of ductile iron pipes, fittings, temperature fluctuations has to be taken
valves and accessories ensures the problem-free and cost-effective transport of into account as well.
predominantly liquid media (water and wastewater).
In the main, the costs of transporting
water and wastewater are determined by
the costs of the pipeline, i.e. by the costs of
the pipes, fittings and valves themselves,
1.1 General The pipelines are predominantly laid for their installation and for the operation
underground and thus are not able to and maintenance of the piping network.
be inspected and monitored on any
Essential piping networks serve for the ongoing basis. Therefore they have to If damage occurs to pipelines buried
transport of be constructed in a material with high underground, not only is it very difficult
■ water (drinking water, process and resistance levels and a long working to detect and locate this but usually it is
industrial water) and life. Their joints, too, must be durably also very expensive to remedy it. In case
■ wastewater (domestic, commercial and tight against all influences from both of damage then, in addition to the actual
industrial wastewater). inside and outside. Pipelines laid in the repair costs, the costs which have to be
soil are exposed to many and varied met for digging up and repairing modern
05.2014
urban road surfaces and for diverting traf- recognised the value of a long-lasting
fic are considerably higher. Therefore and pressure-resistant material for the
sustainable piping networks must have construction of high-pressure water pipe-
high safety margins. Ductile iron pipe lines for their castles and fortresses. And
systems are characterised by the highest thus cast iron set out on its path through
safety margins and meet all requirements the centuries as a piping material.
for sustainable piping networks.
1.2.1 Old pipelines in grey cast iron
1.2 Cast iron as material for pipes Cast iron pipes have been in use for more
than 500 years, initially as grey cast iron
pipes. Their long working life is legend- Fig. 1.1 :
There is no reliable information about ary. At the start they were used above all Cast iron pipe from the water supply
when and where the casting of iron was for the transport of drinking and indus- pipeline for Dillenburg Castle (1455)
first discovered. However it is known that trial water. By way of examples of the
the art of iron casting was practised in construction of old cast iron water pipe-
China, for example, much earlier than it lines, the following facts are known:
was in Europe.
1455 the oldest cast iron pipeline
The first iron suspension bridge was was built; this was the pipe-
constructed there in around 300 AD. The line supplying water for
first cast iron gun barrels were used in Dillenburg Castle (Fig. 1.1).
Europe in the 12th century. 1562 a water pipeline was laid
in Langensalza to supply
In the first half of the 15th century remark- the Jacobi and Rathaus
able achievements were already being fountains.
made in the casting of gun barrels. It is
probable that the first conduit pipes were Fig. 1.2:
also cast by gun founders on the orders of Flanged pipe from the park at the
local noblemen. Obviously they very soon Palace of Versailles
05.2014
1661 a water pipeline was laid For the urban supply networks (drinking
for the castle in Braunfels. water) constructed since the middle of
The cast iron pipes were the 19th century, grey cast iron was
in operation until 1875 and the available material almost without
were dug up during the exception. Later, steel came along as
course of sewer laying an additional material. The German gas
work in 1932. and water industry statistics (Bundesver-
1664 – 1668 the pipeline was laid in the band der Deutschen Gas- und Wasser-
grounds of the Palace of Ver- wirtschaft e. V. – BGW) for water indicate
sailles to feed the water foun- a proportion of cast iron pipes in the
tains there (Fig. 1.2). existing network in the Federal Republic
1710 – 1717 the construction of the Fig. 1.3: in the 20th century, up to the nineteen
cascades in the Kassel- Cast iron pipeline to supply the cascades fifties, of 85 %.
Wilhelmshöhe castle park of the Hercules monument in the Kassel-
with the Hercules monument. Wilhelmshöhe castle park with water In this area of municipal water distribu-
Cast iron pipeline to supply (UNESCO World Heritage site since June tion, the main area of application for cast
the water features with water 2013) iron pipes since about 1960 was pipes and
(Fig. 1.3). Since June 2013 fitting in ductile cast iron and valves in
the Hercules monument With the necessity of conveying ever spheroidal graphite cast iron*). The length
along with the cascades has larger volumes of water to consumers, the of cast iron pipelines worldwide is esti-
been a UNESCO World operating pressures in the supply lines mated at several 107 km, of which about
Heritage Site. increase. one third are pipes in ductile cast iron;
each year several 105 km are added to this.
Since the middle of the 19th century, as Increasingly advanced processes for The reasons for this high prevalence are,
a result of increasing industrialisation melting, casting and testing have led to among other things
and the considerable growth in popula- improvements in the material properties ■ the robustness of the pipe,
tion with constant improvements in the of cast iron and hence also in the quality ■ high safety margins, even with respect
standard of living, the consumption of of cast iron pipes. to unplanned load cases,
water has been steadily rising. ■ uncomplicated installation,
05.2014
■ hygienically safe for drinking water, and areas of application with signifi- In Germany, the centrifugal casting of iron
■ the long working life of the system as cantly higher internal pressures or other pipes has been practised since 1926. This
a whole, stresses, piping systems in ductile cast process, which is ideally suited to mecha-
■ the lowest damage rate of all piping iron have proved to be excellent. Duc- nised mass production, enabled the pipe
materials, tile iron pipe systems are all-rounders foundries to meet the constantly increas-
■ the lowest leakage rate, for everything to do with water, whether ing demand for cast iron pipes without
■ the lowest operating and maintenance we are talking about simple municipal difficulty.
costs, water supply pipelines installed in the
■ the fact that they can be used any- traditional way or the most complex of Over the course of time, cast iron has
where, from the simplest to the most pipeline constructions with a whole range also undergone further developments as
difficult ambient conditions. of special structures and particularly a material to adapt it to the increasing
sophisticated construction processes. loads placed on piping networks.
*) Note:
“spheroidal graphite cast iron” and “ductile cast iron” are synonyms 1.2.2 Improvements in the produc- For example, in around 1900 a tensile
for a type of cast iron in which the graphite is predominantly present tion process and material strength of at least 120 N/mm2 was being
in spheroidal form. The expression “ductile cast iron” is normally properties demanded for sand-cast pipes, while by
used for pipes and fittings while the official material designation the thirties the minimum tensile strength
according to standard EN 1563 [1.1] for valves reads “spheroidal In order to meet increased demands, the had already reached 200 N/mm2 for cen-
graphite cast iron“. Where pipes, fittings and valves are mentioned cast iron pipe industry has developed trifugally cast pipes.
in the same breath in the sections and chapters which follow, for the new and more efficient production pro-
sake of simplicity and for easier reading, the material designation cesses. In the early days, pipes were cast The beginning of production of pipes,
“ductile cast iron” is used. one by one in horizontal sand moulds and fittings and valves in ductile cast iron is
then, in 1885, the process changed to one to be seen as the most recent and also
These days, pipes, fittings and valves in where the pipes were cast in vertical sand the most significant stage in the devel-
ductile cast iron are the most important moulds arranged on a series of frames, opment of foundry technology. Further
elements in the construction of drinking meaning that the production process details about “ductile cast iron” can be
water and sewage pipelines across the could be continuous. However, the really found in Chapter 2 of this handbook.
world. With the more recent techno- significant innovation in cast iron pipe
logical developments such as trenchless production was the introduction of the
pipe laying and replacement processes centrifugal casting process (Chapter 3.3).
05.2014
The production of pipes, fittings and In the water supply industry, i.e. for the The introduction of spheroidal graphite
valves from ductile cast iron is described transport of drinking water and indus- cast iron has proved to be an advantage
extensively in Chapter 3. trial and process water, iron pipes and for valves. Because the tensile strength
fittings in ductile cast iron have been has been doubled, the wall thicknesses
used since the middle of the nineteen of valve bodies have been able to be
1.2.3 Piping systems in ductile sixties. In accordance with standard dramatically reduced, thus halving the
cast iron for water supply EN 545 [1.2], which applies to water pipe- weight. There are more details about the
and sewage disposal lines, the nominal sizes of pressure pipes material in Chapter 7.1.
in ductile cast iron range from DN 40 to
Ductile, or malleable, cast iron pipes have DN 2000 in pressure classes C 20 to C 100. In the sewage disposal industry, i.e.
been produced in Europe since 1951 and DIN 28603 [1.3] defines push-in joints the transport of domestic, commercial
in the Federal Republic of Germany from DN 80. and industrial wastewater, pipes and
since 1956. It is the spheroidal graphite fittings in ductile cast iron were first
formation which makes malleability and For external loads produced by the ground of all used mainly for wastewater
stretching ability possible with ductile itself and by traffic, attention has to be pressure lines in difficult terrain, e.g.
cast iron. These days the tensile strength paid to observing permissible ovalisation in areas where there is a risk of
of the material for ductile iron pipes is limits for the pipe of up to 4 %. subsidence or landslides and on
at least 420 N/mm2. In addition to this steep slopes, for water crossings
high tensile strength, which already The application ranges with respect to (culverts) and where installation
very clearly shows the improvement in permissible pressures are summarised conditions present static problems.
performance, it is above all the remark- in Table 1.1 (excerpt from Table 17 of According to standard EN 598 [1.4],
able malleability which is characteristic EN 545 [1.2]). which applies to sewers and sewage
of ductile iron pipes. pipelines, the use of piping systems
in ductile cast iron is not restricted
With the improvement in the metallurgy to the construction of buried gravity
of cast iron, the conditions are met for the pipelines.
use of ductile iron pipe systems in nearly
all areas of the urban piping infrastruc-
ture (water and sewage).
05.2014
Pressure class (C classes) = PFA [bar] Table 1.1:

DN 20 25 30 40 50 64 100 Pressure classes (C classes) and minimum
emin [mm] wall thicknesses emin for ductile iron pipes
in the area of drinking water supply in
80 3,0 3,5 4,0 4,7
accordance with EN 545 [1.2];
100 3,0 3,5 4,0 4,7 PFA [bar] is the allowable operating
125 3,0 3,5 4,0 5,0 pressure
150 3,0 3,5 4,0 5,9
200 3,1 3,9 5,0 7,7
250 3,9 4,8 6,1 9,5
300 4,6 5,7 7,3 11,2
350 4,7 5,3 6,6 8,5 13,0
400 4,8 6,0 7,5 9,6 14,8
450 5,1 6,8 8,4 10,7 16,6
500 5,6 7,5 9,3 11,9 18,3
600 6,7 8,9 11,1 14,2 21,9
They can also be used for the con-
700 6,8 7,8 10,4 13,0 16,5 struction of pressure pipelines from
800 7,5 8,9 11,9 14,8 18,8 DN 80 to DN 2000. In EN 598 [1.4]
900 8,4 10,0 13,3 16,6 certain external stresses from soil and
1000 9,3 11,1 14,8 18,4 traffic loads are taken into account.
1100 8,2 10,2 12,2 16,2 20,2 These are applicable for a permissible
1200 8,9 11,1 13,3 17,7 22,0 deformation of the pipe of up to 4 % and
1400 10,4 12,9 15,5
for covering depths from 0.3 to 8.5 m.
1500 11,1 13,9 16,6
More details on the design of pipes,
1600 11,9 14,8 17,7
fittings, valves and accessories in
1800 13,3 16,6 19,9 ductile cast iron can be found in
2000 14,8 18,4 22,1 Chapters 5 to 10 as well as 14 and 15,
Note: The figures in bold indicate the standard range and on static calculations in Chapter 16.
05.2014
1.3 Joint technology ones, but not moveable joints, and way that the bolt holes lie symmetrical
they transfer longitudinal and bending to both principal axes and their number
stresses from pipe to pipe. is divisible by four in all nominal sizes.
In addition to the further development
of cast iron and the production process, The individual advantages of push-in The joint dimensions of cast iron
in order to adapt to increasing operat- joints and flanged joints can be combined flanges (external diameter, bolt hole
ing pressures in the piping networks by installing flanged sockets and flanged circle diameter, raised face diameter,
improvements have also been made to spigots on the flanges of fittings. number and diameter of bolts, bolt
the joint technology. Essentially, two types hole diameter) are determined in
of joints are used for cast iron piping We shall look at the different types of EN 1092-2 [1.5]. Additional construc-
systems: joints in greater detail below, according tion dimensions for PN 10 to PN 40
■ push-in joints, to the chronological sequence of their flanges are also given in this EN
■ flanged joints. development or their introduction onto standard. A flanged joint consists of
the market. two flanges, a sealing element and a
Push-in joints are generally used for certain number of hexagon head
underground cast iron pipelines (pipes, bolts with nuts and washers. The
fittings, valves). These are flexible, 1.3.1 Flanged joints material of the sealing element
rubber-sealed joints which offer both depends on the purpose of use in
technical and economic advantages for One of the oldest types of joints for cast each case. The flanges of ductile iron
installation. iron pipes is the flanged joint (Fig. 1.2). pipes, fittings and valves are provided
These were standardised for the first time with raised sealing faces. Fig. 1.4
Flanged joints tend to be favoured for in 1882, in the so-called “Standard com- shows a flanged joint of this kind
pipelines above ground, as are used for ponents of the year 1882” produced by (nuts to EN ISO 4034 [1.6] and hexagon
example in pumping houses, waterworks the German Association of specialists in head bolts to EN ISO 4016 [1.7]).
or elevated tanks. As regards shut-off gas and water (DVGW) together with the
valves in urban water supply networks, Association of German Engineers (VDI).
for decades the flanged joint was also Notwithstanding these first standards and
commonly used in underground pipe- regardless of the material being used, by
lines for reasons of maintenance and 1926 the arrangement of the bolt holes
repair. Flanged joints are restrained had already been determined in such a
05.2014
Fig. 1.6:
Cut section of a packed socket joint from an
approximately 300 year old cast iron pipe –
water supply pipeline for the cascades at
Fig. 1.4: Fig. 1.5: the Kassel-Wilhelmhöhe castle park with
Flanged joint Packed socket joint the Hercules monument; UNESCO World
Heritage site since June 2013
Source: mhk, Museumslandschaft Hessen Kassel
1.3.2 Packed socket joint The pipe joint is of immense importance and compression forces in the pipe run
for the reliability of a pipeline. In the without any adverse effects on tightness
Until the introduction of rubber-sealed area of cast iron pipes, the advantages at the connection points.
socket joints (around 1930) pipes and fit- of rubber-sealed socket joints were
tings in grey cast iron were mainly joined recognized very early on. After all, the Chapter 13 contains more details about
by means of packed sockets. These were rubber seal gives the pipeline flexibility the different types of sealing elements.
not restrained joints. The packed socket which allows it to adapt to the stresses
joint (Figs. 1.5 and 1.6) is rigid and is not produced by traffic vibrations and
tight in case of movement. ground movements as well as strain
05.2014
1.3.3 Screwed socket joints
The screwed socket joint has been used

in Germany since 1931. Structural design
and dimensioning are determined in
detail in DIN 28601 [1.8]. Fig. 1.7 shows
the joint in cross-section.
The inside of the socket and the outside

of the screw ring are buttress-threaded
according to the direction of load. A Fig. 1.7: Fig. 1.8:
screw ring axially compresses the elastic Screwed socket joint Bolted gland joint
sealing element, which has hard rubber
protective edges at the front and back,
into its seating via a sliding ring. This 1.3.4 Bolted gland joints allows deflections of up to 3° from
produces the seal between the socket straightness – are only produced after
and the spigot end. The protective edges The bolted gland joint has been in the joint has been assembled. These
prevent the soft rubber part under use in Germany since 1936. Its dimen- days the bolted gland joint is only used
compression in the middle from being sional construction is covered in in combination with certain types of
forced out into the sealing gap. DIN 28602 [1.9]; Fig. 1.8 shows a cross- fittings in the range from DN 500 to
section. DN 1000.
The necessary angular deflections – the
joint allows deflections of up to 3° from Here it is the gland which applies
straightness – are only produced during pressure via T-head bolts onto the
installation after tightening the screw wedge-shaped sealing element, which
ring. These days the screwed socket has a hard rubber protective edge on
joint is only used for fittings in the range the front. The sealing principle is
from DN 40 to DN 400. A restrained joint practically the same as with the
can be produced by using additional screwed socket joint. The necessary
elements. More on this in Chapter 9. angular deflections – the joint also
05.2014
Detailed information about push-in joints 1.4 Modern ductile iron pipe
and their area of use can be found in techniques
Chapter 8.
The ductile iron pipe systems used today
1.3.6 Fields of use meet the requirements which are to be
demanded of new piping networks for
The fields of use according to pressure the transport of water and wastewater
classes (C classes) and minimum wall to a particularly high degree; there are
thicknesses emin for ductile iron pipes in additional fields of application in the field
the field of water supply are shown in of industrial pipelines, e.g. for
Fig. 1.9: Table 1.1. In the field of sewage trans- ■ turbine pipelines for power produc-
TYTON® push-in joint port, ductile sewers as per EN 598 [1.4] tion,
are standardised for gravity pipelines up ■ snow-making equipment,
to 6 bar operating pressure. For higher ■ fire extinguishing pipelines,
1.3.5 Push-in joints pressures, pipes of pressure classes ■ cooling water pipelines.
(C classes) according to EN 545 [1.2] are
Nowadays, rubber-sealed push-in to be selected. But, because of their high loading
joints according to DIN 28603 [1.3] are capacity, ductile iron pipes have also
predominantly used for ductile iron Special cases, such as the construction opened up new fields of activity in
pipelines: the TYTON® push-in joint of a culvert pipeline or where there construction technology, e.g. for
system has applications for the range is a low cover depth, higher internal ■ trenchless laying techniques,
between DN 80 and DN 1400, while the pressure loads or special linings and ■ foundation piles.
STANDARD push-in joint system is used coatings can be dealt with by
in the range from DN 80 to DN 2000. additional measures, either during Corresponding details are covered in
production or during installation. Chapters 22 and 23.
The TYTON® joint (Fig. 1.9) has been
used in Germany since 1957. The pro-
filed sealing element is produced from a
mixture of hard and soft rubber.
05.2014
Ductile iron pipe systems owe their excel- The possibility of also providing such duc- 1.5 Sustainability
lent properties above all to the following tile iron pipes, fittings and valves with
features: adequate external protection depending
■ the modern jointing technology in the on the aggressive nature of the soil takes In recent times, the term “sustainability”
form of push-in joints including the account of the practical realities during has gained increasing importance when
flexible restrained push-in joints, the installation of pipelines. assessing infrastructure investments.
■ the remarkable strength and stability In such a consideration, economic,
of the material, A comprehensive description of the environmental and technical aspects are
■ the highly developed types of corro- various types of coatings can be found examined and evaluated, and this applies
sion protection in the form of linings in Chapter 14. to the entire working life of the product.
and coatings suited to specific tasks.
All system components for the transport The key points of sustainability criteria
They offer high degrees of security of drinking water, operating and process for ductile iron pipe systems with respect
against the stresses produced by the water or sewage are basically provided to an economic, environmental and tech-
highest internal pressures. In addition, with appropriate linings in accordance nical assessment are shown in Tables 1.2,
the material means that they resist prac- with EN 545 [1.2] and/or EN 598 [1.4]. 1.3 and 1.4 [1.10].
tically all ground and traffic related loads. In particular this includes cement mor-
tar and polyurethane linings for pipes.
Quite particular emphasis should be Fittings and valves are mainly coated
placed here on their ability to resist all around with epoxy resin or enamel.
the resulting crushing and bending Chapter 15 contains details about linings.
stresses, as it is precisely these types
of stress which are considerably
reduced by the flexible, rubber-sealed
push-in joints.
05.2014
Table 1.2:
Economic sustainability criteria for ductile iron pipe systems
%CONOMICALLYSUPERIOR
– push-in joints make for highly productive X reduces labour costs

installation
– no welding needed X reduces labour costs
– installation in all weathers X reduces labour costs
– sand bedding often not required X reduces materials and logistics costs
– concrete thrust blocks not needed X reduces materials and logistics costs
when joints are restrained
– joints can be deflected angularly X saves on fittings
– wide range of fittings and valves available X reduces materials and labour costs
so no need for specials
– extremely low damage rates X reduces operating, energy, repair
and maintenance costs
– operating life of up to 100 years or more X keeps renovation budgets to a minimum
)NVESTINGINDUCTILEIRONPIPESYSTEMPAYSFORITSELFINLOWINSTALLATIONAND
OPERATINGCOSTSWITHATTHESAMETIMEANEXTREMELYLONGOPERATINGLIFEØ
© eadips.org
05.2014
Table 1.3:
Environmental sustainability criteria for ductile iron pipe systems
%NVIRONMENTALLYSUPERIOR
– impermeability to diffusion Xsafeguards drinking water in all soil and

installation conditions against environmentally
damaging hydrocarbons and the groundwater
when sewage is being transported
– linings approved to food hygiene X ensure hygienic and environmentally safe
standards transport of drinking water
– scrap as the raw material X minimises the consumption of primary and fossil
raw materials and reduces CO2 emissions
– ductile iron can be recycled X saves resources for present and future
generations
– low expenditure on maintenance and X avoids waste, minimises the consumption
repair costs over a long operating life of resources and reduces CO2 emissions
$UCTILEIRONPIPESYSTEMSCANBESHOWNTOPRODUCETRUESUSTAINABILITYØ
© eadips.org
05.2014
Table 1.4:
Technical sustainability criteria for ductile iron pipe systems
4ECHNICALLYSUPERIOR
– the material is strong X allows operating pressures up to 100 bars

– effective external protection X shields against mechanical and chemical attack
– static load-bearing capacity X allows very high stresses in the transverse and
longitudinal directions
– joints X allow operating pressures up to 100 bars;
are resistant to root penetration
– ductile iron X is non-combustible
– installation X is possible with no special equipment
– restrained joints X allow very high tractive forces and are therefore
ideal for trenchless installation
– the material has superior properties X which allow special applications in mountainous
regions and for fire-fighting pipelines, snow-making
systems and hydroelectric power stations
4HETECHNICALPERFORMANCEOFDUCTILEIRONPIPESYSTEMSENSURESTHEHIGHESTSAFETY
ANDRELIABILITYINALLAREASOFTHEWATERINDUSTRYØ
© eadips.org
05.2014
1.6 Summary 1.7 References [Ductile iron pipes and fittings –

Push-in joints –
Survey, sockets and gasket]
Ductile iron pipe systems with their [1.1] EN 1563 2002-05
highly developed technology offer many Founding –
advantages. With the push-in joint they Spheroidal graphite cast irons [1.4] EN 598
are simple, safe and fast to install and [Gießereiwesen – Ductile iron pipes, fittings,
are durably tight. They also stand up Gusseisen mit Kugelgraphit] accessories and their joints for
to diverse loads from both inside and 2011 sewerage applications –
outside. Installation, maintenance and Requirements and test methods
follow-up costs are particularly low. [1.2] EN 545 [Rohre, Formstücke, Zubehörteile
Ductile iron pipes, fittings, aus duktilem Gusseisen und ihre
Consequently the ductile iron pipe system accessories and their joints Verbindungen für die Abwasser-
has an extremely long useful life. for water pipelines – Entsorgung –
Requirements and test methods Anforderungen u. Prüfverfahren]
With a multitude of technical advantages [Rohre, Formstücke, Zubehörteile 2007+A1:2009
and practical operational properties, aus duktilem Gusseisen
ductile iron pipe systems are seen as und ihre Verbindungen für [1.5] EN 1092-2
an economic and therefore sustainable Wasserleitungen – Flanges and their joints –
solution for water supply and sewage Anforderungen u. Prüfverfahren] Circular flanges for pipes,
disposal over the long term. 2010 valves, fittings and accessories,
PN designated –
[1.3] DIN 28603 Part 2: Cast iron flanges
Rohre und Formstücke aus duk- [Flansche und ihre Verbindungen –
tilem Gusseisen – Runde Flansche für Rohre,
Steckmuffen-Verbindungen – Armaturen, Formstücke und Zube-
Zusammenstellung, Muffen hörteile, nach PN bezeichnet –
und Dichtungen Teil 2: Gusseisenflansche]
1997
05.2014
[1.6] EN ISO 4034 [1.9] DIN 28602

Hexagon regular nuts (style 1) – Rohre und Formstücke aus
Product grade C (ISO 4034:2012) duktilem Gusseisen –
[Sechskantmuttern (Typ 1) – Stopfbuchsenmuffen-
Produktklasse C (ISO 4034:2012)] Verbindungen –
2012 Zusammenstellung, Muffen,
Stopfbuchsenring, Dichtung,
[1.7] EN ISO 4016] Hammerschrauben und Muttern
Hexagon head bolts – [Ductile iron pipes and fittings –
Product grade C (ISO 4016:2011) Bolted gland joints –
[Sechskantschrauben mit Schaft – Assembly, sockets, counter ring,
Produktklasse C (ISO 4016:2011)] sealing ring, bolts and nuts]
2011 2000-05
[1.8] DIN 28601 [1.10] Sustainably superior –

Rohre und Formstücke aus ductile iron pipe systems
duktilem Gusseisen – DUCTILE IRON PIPE SYSTEMS 47
Schraubmuffen-Verbindungen – (2013), p. 8/9
Zusammenstellung, Muffen, [Nachhaltig überlegen –
Schraubringe, Dichtungen, duktile Guss-Rohrsysteme
Gleitringe GUSS-ROHRSYSTEME 47
[Ductile iron pipes and fittings – (2013), S. 10/11]
Screwed socket joints –
Assembly, sockets, screw rings,
sealing rings and slip rings]
2000-06
05.2014
05.2014
E-Book – Ductile iron pipe systems Chapter 2: Ductile cast iron as a material 2/1
2 Ductile cast iron

as a material
2.1 General
2.2 Structure
2.3 Technological properties
2.4 References
05.2014
2 Ductile cast iron as a material
In contrast to grey cast iron, where the free graphite is present in lamellar form,
the free graphite in ductile (malleable) cast iron is spherical in shape (sphe-
roidal graphite). This form of graphite favours the elasticity of the cast iron
and increases its inherent strength. It was only in the 1950’s that the industrial
production of cast iron pipes with spheroidal graphite (ductile iron pipes) began.
Fig. 2.1:
2.1 General When it is used for pipes, fittings and Cast iron with lamellar graphite
accessories, the material is referred (grey cast iron)
to as ductile cast iron. Its mechanical
Ductile cast iron is a plastically malleable, and technological properties are de-
tough iron-carbon material in which the scribed in standard EN 545 [2.1]. When
carbon fraction is predominantly present used in bodies for valves it is called
as elementary spheroidal graphite. The spheroidal graphite cast iron, as is usual
main way in which it differs from grey in mechanical engineering generally,
cast iron is in the shape of the graphite and its properties are determined in
particles. The word ductile comes from standard EN 1563 [2.2]. The two stand-
the Latin “ducere” = pliable (from ductus = ards are the work of different tech-
to lead) and means malleable. In static nical standardisation committees.
calculations, pipes in ductile cast iron are
therefore considered as having pliable With grey cast iron (Fig. 2.1), because of
properties or being flexible pipes. their notching effect the graphite lamellae
reduce the relatively high stability of the Fig. 2.2:
basic structure, whereby they cause its Cast iron with spheroidal graphite
elongation after fracture to fall below 1 %. (ductile cast iron)
05.2014
In ductile cast iron or spheroidal lamellar graphite (Fig. 2.3) the lines of So that, during the solidification phase,
graphite cast iron the graphite is tension are highly concentrated at the tips the carbon crystallises in a broadly
formed spherically (Fig. 2.2). Spheroids of the graphite lamellae, they flow around spheroidal shape, the molten iron has
(spherical mineral structures) affect the the graphite precipitated in spheroidal to be treated with magnesium. The
properties of the basic metallic struc- form almost undisturbed (Fig. 2.4). For result is a considerable increase in
ture to a considerably lesser extent this reason, ductile cast iron is able to strength and malleability as compared
than lamellae. While with cast iron with deform under load. with grey cast iron.
Fig. 2.3: Fig. 2.4: Fig. 2.5:

The flow of lines of tension in cast iron The flow of lines of tension in cast iron Scanning electron micrograph of graphite
with lamellar graphite with spheroidal graphite nodules
05.2014
Fig. 2.5 shows spheroidal graphite 2.3 Technological properties

nodules on the fracture surface of a duc-
tile cast iron specimen. The size of the
graphite nodules is in a range between 2.3.1 Material properties
0.01 mm and 0.5 mm.
According to standards EN 545 [2.1] and
EN 598 [2.3], tensile strength and elonga-
2.2 Structure tion after fracture are to be tested using
round test bars. In addition, hardness of
the material is to be determined. This
According to the applicable standards is subject to an upper limit in order to
EN 545 [2.1] and EN 598 [2.3] the carbon enable machining, e.g. for flanges. Higher
fraction present as graphite must be pre- Fig. 2.6: hardness levels are permissible in the
dominantly spheroidal in form so that the Ferritic structure area of the heat affected zone of weld
workpiece has the required properties. seams (Chapter 18).
The matrix of the pipes should be pre- The standardised values for the me-
dominantly ferritic (Fig. 2.6), as ferrite chanical properties of ductile cast iron
produces the highest elongation values at and spheroidal graphite cast iron are
the lowest hardness levels. Fittings, valve given in Tables 2.1 a and 2.1 b.
bodies and accessories are produced in
sand moulds and have a ferritic-pearlitic
structure. They do not need any additional
heat treatment (Fig. 2.7).
Fig. 2.7:
Ferritic-pearlitic structure
05.2014
Table 2.1 a:
Properties of ductile cast iron
Material Application Standard Minimum 0.2 % Minimum Hardness Notched Structure

tensile elongation elongation bar
strength Rm limit1) Rp0,2 after frac- impact
ture2) A work
[MPa] [MPa] [%] [HB] [J]
Pipes
Ductile DN 80 to 3) 3)
420 300 10 < 230
cast iron DN 1000
EN 545
Ductile [2.1]
Pipes DN >1000 420 300 7 < 230 3) 3)
cast iron
EN 598
Ductile Non-centrifuged
[2.3] 3) 3)
pipes, fittings 420 300 5 < 250
cast iron
DN 80 to DN 2000
1)
The 0.2 % elongation limit (Rp0.2) can be determined. It should not be less than:
- 270 MPa if A t 12 % for DN 80 to DN 1000 or A t 10 % for DN > 1000
- 300 MPa in other cases
2)
For centrifuged pipes from DN 80 to DN 1000 and a minimum wall thickness of t 10 mm the
elongation after fracture must be at least 7 %
3)
No requirement
05.2014
Table 2.1 b:
Properties of spheroidal graphite ductile cast iron
Material Application Standard Minimum 0.2 % Minimum Hardness Notched Structure

tensile elongation elongation bar
strength Rm limit 1) Rp0,2 after frac- impact
ture2) A work
[MPa] [MPa] [%] [HB] [J]
EN-GJS-
perlitic-
500-7 500 320 7 180 – 220 6–8
ferritic
(GGG 50) Valves and
hydrants
EN-GJS-
predomi-
400-15 400 250 15 140 – 180 8 –12
EN 1563 nantly ferritic
(GGG 40)
[2.2]
EN-GJS- Valves
for use at low purely
400-18LT 400 250 18 140 – 150 >12
tempera- ferritic
(GGG 40.3)
tures
05.2014
With centrifugally cast pipes, in addition Table 2.2:

to the standard, routine ductility tests can Mechanical and physical values of ductile cast iron and spheroidal graphite cast iron
also be carried out in-works with the help
of ring flattening specimens or ball pres-
Property Dimension Value
sure specimens.
Compression strength MPa 550
The strength properties mentioned so far, Modulus of elasticity MPa 160,000 – 170,000
which are mainly to be tested on prepared
specimens, relate to the material. Mean coefficient of linear thermal
m/m · K 10 · 10–6
expansion
A summary of additional material prop- Heat conductivity W/cm · K 0.42
erties of ductile cast iron and spheroidal Specific heat J/g · K 0.55
graphite cast iron, which in some cases
come from other standards and sources,
is given in the following Table 2.2. Table 2.3:
Component strength of ductile iron pipes
Other characteristic values which relate
to components have been determined Property Dimension Value
in the context of a DVGW study [2.4] on
Compression strength MPa 550
drinking water pipelines on the basis
of tests. Longitudinal bending strength MPa 420
Bursting strength MPa 300
Pressure pipes in ductile cast iron have
Stress range MPa 135
strength values according to Table 2.3.
Because of the high bursting pressures

which ductile iron pipes resist, they offer
high safety margins.
05.2014
2.3.2 Material testing local grinding. After that a hardened

steel ball with a defined diameter and
In order to test centrifugally cast pipes, a defined test force is pushed vertically
specimen rings are separated from the into the specimen. The precise inden-
spigot end of the pipe. With fittings, tation diameter measured is inversely
accessories and valve bodies (sand proportional to the Brinell hardness.
casting) separately cast specimens are
tested. For pipes, the flattening tests on 30 mm
wide rings supplement the determination
The material properties of mechanical properties on a specimen
■ tensile strength, bar (Fig. 2.8).
■ 0.2 % proof stress and
■ elongation after fracture
are determined on machined cylindrical
test bars exclusively according to Equa-
tion (2.1).
L0 = 5 . d0 (2.1)
L0 Length of the machined cylindrical

bar in mm
d0 Diameter of the machined cylindrical
bar in mm
Hardness is determined using the

Brinell test as per ISO 6506-1 [2.5] and
EN ISO 6506-1 [2.6] on the casting
itself or on a specimen separated from
the casting. To do this, the surface to Fig. 2.8:
be tested is prepared by means of light Ring flattening test
05.2014
2.4 References [2.3] EN 598 [2.5] ISO 6506-1

Ductile iron pipes, fittings, Metallic materials –
accessories and their joints Brinell hardness test –
[2.1] EN 545 for sewerage applications – Part 1: Test method
Ductile iron pipes, fittings, Requirements and test methods [Metallische Werkstoffe –
accessories and their joints [Rohre, Formstücke, Zubehörteile Härteprüfung nach Brinell –
for water pipelines – aus duktilem Gusseisen und ihre Teil 1: Prüfverfahren]
Requirements and test methods Verbindungen für die Abwasser- 2005
[Rohre, Formstücke, Zubehörteile Entsorgung –
aus duktilem Gusseisen Anforderungen und Prüfver- [2.6] EN ISO 6506-1
und ihre Verbindungen für fahren] Metallic materials –
Wasserleitungen – 2007+A1:2009 Brinell hardness test –
Anforderungen und Prüfver- Part 1: Test method
fahren] [2.4] Deutscher Verein des Gas- (ISO 6506-1:2005)
2010 und Wasserfaches e. V.: [Metallische Werkstoffe –
„Studie über erdverlegte Härteprüfung nach Brinell –
[2.2] EN 1563 Trinkwasserleitungen aus Teil 1: Prüfverfahren
Founding – verschiedenen Werkstoffen“, (ISO 6506-1:2005)]
Spheroidal graphite cast irons Bericht II, Eschborn 2005
[Gießereiwesen – 1971
Gusseisen mit Kugelgraphit]
2012
05.2014
05.2014
E-Book – Ductile iron pipe systems Chapter 3: Production of pipes, fittings and valves 3/1
3 Production of pipes,
fittings and valves
3.1 Melting the iron
3.2 Magnesium treatment
3.3 Casting process
3.4 Post-treatment
3.5 Application of coatings and linings
3.6 Marking
3.7 Testing
3.8 References
06.2014
3 Production of pipes, fittings and valves
The raw material for iron casting is pig iron; it is reduced from iron ore in the
blast furnace with the help of coke (iron from the first smelting). In most cases
this iron undergoes further processing in the iron foundry in solid form (pig iron
ingots). Occasionally, the molten pig iron is also directly processed to produce
pipes and fittings.
Iron foundries usually melt their iron Fittings, valve bodies and accessories are 3.1 Melting the iron
in cupola or electric furnaces from cast in sand moulds; the speed of cooling
recycled material and pig iron. Coke, oil here is low enough to mean that no
or natural gas is the fuel used here; no subsequent heat treatment is necessary. In most cases iron for the production of
reduction takes place. The crystallisation pipes, fittings, valves and accessories is
of the carbon dissolved in the liquid iron As a rule, the application of linings and produced as recycled material from steel
in the form of graphite nodules is achiev- protective coatings is part of the pro- scrap, cast iron scrap and foundry pig iron
ed by the addition of magnesium into the duction process. After casting, pipes and in the cupola furnace or in the electric
molten metal. fittings with flanges, as well as most of furnace.
the components of valves, first undergo
These days pipes are manufactured ex- mechanical processing. They are only 3.1.1 Melting in the cupola furnace
clusively by means of the centrifugal coated once this is done. Throughout
casting process, where the centrifugal the entire production process there is a The cupola furnace (Fig. 3.2) is the typi-
forces produce the pipe wall. The rapid defined system of controls and tests to cal melting plant of an iron foundry; it is
cooling applied here means that heat guarantee the specified properties of an upright shaft furnace which is charged
treatment of the pipes is necessary in the product, including marking. Fig. 3.1 from the top with the raw materials (steel
order to give them a malleable micro- shows an example of the flow through the scrap, cast iron scrap, recycled material
structure. production process. and coke as the fuel).
06.2014
Fig. 3.1:
Production of a ductile
iron pipe
Video 03.01:
Iron pipe foundry
06.2014
Fig. 3.3:
Discharge of molten iron from the mixer
Heated air is blasted in from below

causing the coke to burn. The heat thus
produced melts the metallic content of
the furnace which drops into the lower
part of the shaft as molten iron. This flows
continuously at about 1,450 °C through
a channel into a collection vessel, the
mixer, from which the iron is taken out in
batches and desulphurised (Fig. 3.3).
The cupola process has the advantage

of a very good ecological balance be-
cause the metal content can consist of
up to 100 % scrap
Fig. 3.2:
Sectional view and operation of a cupola furnace
06.2014
The cupola furnace is omnivorous – even 3.1.2 The electric furnace

bundles of vehicle scrap, rusted steel
girders or excavated grey iron pipes can An equally common melting plant in
be recycled without problem, as organic iron foundries is the electric induc-
impurities are burned off and so help the tion furnace (Fig. 3.4). Its cylindrical
energy balance. Zinc, evaporated from vessel, lined with refractory materials,
the zinc-coated panels which are more is surrounded by a coil through which
and more often used in car manufacturing an alternating current flows, thereby
these days, burns to form zinc oxide which inducing a secondary current in the core
is filtered out of the flow of exhaust gas of the metallic charge. In this way the
from the furnace along with other types metal content is heated and molten. No
of dust and is sent to recycling. other energy sources, such as coke, are
needed. Energy supply and temperature
The coke used in the cupola furnace can be controlled more easily and quickly
always contains a small proportion of than in the cupola furnace.
sulphur, which dissolves in the liquid
iron and can have a negative effect on
the mechanical properties of the iron. 3.2 Magnesium treatment
This means that a stage has to be added
after the production of the molten
iron in which the sulphur is removed. Without additional treatment, the iron
This is done by using appropriate raw molten in the cupola or electric furnace
materials, such as calcium carbide, to would have a predominantly lamellar Fig. 3.4:
which the sulphur becomes chemically graphite formation. However, what Electrical induction furnace
bound. The reaction products float on is wanted is the typical spheroidal
the iron melt as slag and can thus be graphite formation of ductile cast
separated off. iron. This is achieved mainly by the The magnesium reduces almost all
addition of magnesium. A decisive the oxides present in the melt and binds
factor here is the high affinity of the sulphur as magnesium sulphide.
magnesium to oxygen and sulphur.
06.2014
Because of their very low specific weight,

the magnesium oxides and considerable
volumes of magnesium sulphide rise to
the surface of the liquid iron from where
they are taken off as slag.
Despite extensive research, the mecha-

nism by which magnesium treatment
finally results in the formation of graphite
spheroids has still not yet been clearly
explained. The favoured model repre-
sentation is that, by removing the
sulphur to a few ppm, the interfacial
tension between the surface of the
graphite crystal seeds which are form-
ing and the liquid iron is increased,
which forces the graphite crystals into
a spheroidal growth with the smallest
boundary surface.
Various processes exist, e.g. pure or Fig. 3.5:

alloyed magnesium in ceramic bell Magnesium treatment in the converter
chambers is pressed onto the bottom
of a ladle filled with liquid iron, or, in
a so-called converter, magnesium is put Another possibility is the use of a wire With all processes, the magnesium
into a chamber and, when the cov- filled with magnesium. For the pro- evaporates in the molten iron bath, pro-
ered converter is tipped, the magnesium duction of fittings and valve bodies using duces turbulence in this and so reacts
is brought into a position underneath the sand moulding process, magnesium favourably with oxygen and sulphur so
the liquid iron (Fig. 3.5). treatment in the casting mould (in-mould that small volumes of it are dissolved into
process) has proved effective (Fig. 3.6). the iron.
06.2014
3.3 Casting process Essentially, two working methods are

used:
3.3.1 Pipe production using the 1) Centrifuging in metal moulds (mould-

centrifugal casting process spinning moulds) according to the
De Lavaud process (Fig. 3.7) and
The notion of producing pipes by centri- 2) Centrifuging in metal moulds with
fuging cast iron in metal moulds dated linings according to the wet-spray
back to a patent by an engineer called process.
Eckhardt in the year 1809. However,
because there was little need for it and With both processes, the outside contour
because of insufficient technical con- of the pipe is produced by a metal mould
ditions, this invention was not able (spinning mould). The mould is located
to be implemented. A particular difficulty in a machine housing which can move
lay in the distribution of the liquid iron longitudinally. At a number of points it
Fig. 3.6: in the casting mould rotating about its rests on rollers and is held in place by
Reaction of the liquid iron during horizontal axis. pressure rollers on the top. Water is used
magnesium treatment for cooling from the outside. Driven by an
In 1910 Otto Briede from Benrath invent- electric motor, the mould rotates around
ed the moving casting machine. His idea its longitudinal axis. The internal profile
was put into practice by the Brazilian, of the mould determines the external
de Lavaud, after whom the “De Lavaud shape of the pipe. In the widening of the
process“ for the centrifugal casting of mould on the socket side, a core formed
pipes used right across the world today according to the internal profile of the
is named. Centrifuged iron pipes were pipe socket, produced from sand and a
produced in Germany for the first time binder, is inserted. At the same time this
in 1926. core closes off the mould.
06.2014
Fig. 3.7: Fig. 3.8:

Centrifugal casting machine – pipe centrifuging process in metal moulds according Pouring trough retracted from the mould
to de Lavaud
Video 03.02: Centrifugal casting machine – animation
On the spigot-end side of the mould a constant volume of iron per unit of time barrel of the pipe as a result of centrifu-
collar is applied which corresponds flows over the pouring lip of the distri- gal force as the casting machine moves
approximately to the wall thickness of bution ladle into the pouring nozzle and longitudinally (Fig. 3.8).
the pipe. The casting machine equipped from there out into the pouring trough. At
in this way is tilted towards the socket side the beginning of casting the trough proj- Because of the interaction of movements,
and is arranged on rails so that it can be ects into the mould almost to the end of the iron is laid down on the wall of the
moved longitudinally. At the upper end the socket. Before the iron starts to flow, mould in a helix which, in the liquid
of the frame is the casting device with the mould is put into rotation. The iron state, merges into a homogenous pipe.
the distribution ladle which can take the flowing out at the tip of the pouring trough A thicker or thinner pipe wall is produced
volume of liquid iron for one or more is captured by the rotating mould, first by changing the volume of iron for the
pipes. A controlled, even speed of tilting filling the space between the socket core casting process.
means that during the casting process a and the mould and then forming the
06.2014
The speed of rotation of the mould carried away with them will, because of 3.3.2 De Lavaud process
is selected so that a centrifugal force their weight, be forced inwards and are
of 15 g to 30 g is exerted on the liquid easy to remove during later cleaning. With this process, the mould is cooled
iron. Because of the centrifugal force Because of the speed of cooling and the from outside with water. Its inside sur-
and because of the directional solidi- reduction in volume of the liquid iron face is peened to produce ball-shaped
fication of the pipe wall from the occurring on solidification, the pipe comes depressions. This cold-peening in-
mould side to the inside of the pipe, a away from the wall of the mould and can creases the strength of the surface and
particularly dense structure is produced. be pulled out mould on the socket side helps the liquid iron to be taken up with
The centrifugal force has a further effect (Fig. 3.9). the rotation movement of the mould. In
in that the oxidation products produced this way, the iron pipes spun in metal
during the casting process and any slag moulds take on the surface typical of
them. During or shortly before the
pouring process, an inoculation powder
is scattered into the mould. The process
allows for extremely short cycle times
because the pipe solidifies very quickly
and can be removed within a few seconds;
the next pipe can be cast immediately
afterwards (Fig. 3.10).
In the non-lined moulds of the de Lavaud

process, the surface of the mould is sub-
jected to considerable thermal stresses
due to temperature changes:
■ outside which, in comparison to the
inside surface, is only subject to a
Fig. 3.9: Fig. 3.10: slightly fluctuating water temperature,
Iron pipe is pulled out of the casting Solidified pipe is pulled out of the mould ■ inside, with the casting temperature
machine socket-end first of the molten iron, around 1,300 °C.
06.2014
Between two casting operations, the 3.3.4 Older pipe production methods
inside temperature can drop to 200 °C and no longer in general use
below. The stress on the mould caused by
this unabsorbed temperature change is Sand moulding is the oldest method of
accordingly high, which explains its limit- producing cast iron pipes and fittings.
ed working life. For the production of pipes, two-part
horizontal sand moulds were originally
3.3.3 Wet-spray process used. Because of the high degree of
buoyancy during casting the process
With the wet-spray process the mould resulted in a restriction of pipe length.
is given an approximately 0.5 mm thick A further development was the moulding
layer of lining. This layer (quartz powder and casting in upright, seamless sand
bonded with bentonite) is wet-sprayed moulds (Fig. 3.11).
onto the mould before each casting pro-
cess. The process comes from an English- The pattern consists of a socket and a bar-
speaking area and bears the widely used rel part. The socket pattern is inserted into
name wet-spray. the vertically standing moulding box from
underneath and fixed. The barrel pattern
The thin lining reduces the amplitudes of is inserted from above and centred in the
the temperature change in the wall of the socket pattern with a conical stud.
mould, which favours the working life of
the mould. However, the lining has to be The moulding sand is put into the cavity
renewed after each casting; this extends between pattern and moulding box and
the cycle time accordingly. compacted.
a) Lost head g) Straw rope or wood
b) Pouring funnel wool wrapping
c) Moulding box h) Socket core
d) Moulding sand i) Socket flap
Fig. 3.11:
e) Core clamping tube k) Locking ring
Principle of the vertical
f) Core
static casting of pipes
06.2014
Fig. 3.12: Fig. 3.13: Fig. 3.14:

A view inside the foundry hall with a pipe Double flanged pipe DN 150/500 with Detailed view of the shrink fit after
casting carousel integral cast-on flanges cutting open
In order to increase productivity, these 3.3.5 Production of flanged pipes 3.3.6 Production of fittings and
standing moulds were arranged in valve bodies using the sand
carousels (Fig. 3.12). Depending on the Flanged pipes (Fig. 3.13) with shorter casting process
design of the moulds and cores, straight overall lengths are mainly produced
pipes or pipes with up to two sockets in two-part horizontal moulds (dou- Using the centrifugal casting process it
or flanges could be produced. ble flanged pipe). In addition there are is only possible to produce rotationally
flanged pipes which are produced by symmetrical articles with cylindrical to
pre-welding or screwing cast iron conical external contours. Components
flanges onto spun cast iron pipes. Also with curves, branches or a number of
shrink-fitting and welding is common connections (sockets or flanges) as well
practice (Fig. 3.14). as valve bodies require a different form-
ing process.
06.2014
For this purpose, patterns in metal, plastic Figure 3.15 shows a production line for
or wood are used which completely map fittings with lost cores. Figures 3.16, 3.17
the external contour of the component. and 3.18 show examples of the prepara-
With these patterns, moulds are pro- tory work for the production of fittings
duced from pure quartz sand mixed with with lost cores.
a binder as the negative for the exter-
nal contour of the component. This sand
mould withstands the pressure and the
temperature of the liquid iron until it has
solidified. After that the sand mould is
crushed and the sand is used again in
the cycle. The mould is “lost” with each
casting. Fig. 3.16:
Pattern for the production of the sand
The internal contour of the casting is mould
also mapped in this process, whereby the
quartz sand for the “core” required here
usually gets its strength from an organic
binder. The cores must also resist the cast-
ing temperature of more than 1,300 °C.
Nevertheless they must yield to the
shrinkage pressure during solidification
so that the hollow part does not tear on
the core during shrinking. Finally, they
should also be easy to remove after the
casting has cooled. As the cast metal
solidifies, it burns the binder, the core
loses its cohesion and the loose sand can Fig. 3.15: Fig. 3.17:
be removed from the cooled casting. Production of fittings with lost cores Sand mould prepared for the insertion
of the lost core
06.2014
Also there is the vacuum moulding 3.4 Post-treatment

process. Here the strength of the mould
sand, without binder, is achieved by
negative pressure. Post-treatment refers to all processes on
pipes, fittings and valve bodies which are
Smaller series and larger castings are performed after casting.
produced in individual mould boxes,
where a so-called sand slinger is used 3.4.1 Subsequent heat treatment
for compacting the moulding sand. It
centrifuges the moulding material at Some of the production processes
high speed onto the pattern and the described for pipeline components make
sand with which it is already filled. This subsequent heat treatment necessary.
Fig. 3.18: solidifies the sand-clay mixture. The
Lost core inserted in the sand mould patterns are made of wood or plastic. The reason for this is that the solid-state
carbon dissolved in the liquid iron is
Cores for fittings and valves are mainly either separated as elementary graphite
Castings produced in high volumes produced from quartz sand with cold or or remains dissolved in the iron.
are cast using moulding machines. The hot hardening binders. They must be
patterns are made of plastic or metal. The stable enough to resist the casting The higher the speed of cooling, the
preferred mould material is clay-bonded pressure which, because of the density higher is the proportion of dissolved
quartz sand with additives, usually carbon of the iron, reaches around 1 bar even carbon in the iron (cementite). This
dust. The mould material is compacted by with a static casting height of 1.40 m. structure has a high degree of hardness
shaking, pressing or shooting. Another In general it is the case that the sand and a low elongation after fracture. A
method uses boxless moulds. In this case moulding process allows an almost subsequent annealing process breaks
a hardening sand-synthetic resin mixture unrestricted freedom of design for down the cementite into ferrite and
forms the mould material. components. graphite, whereby the form of the
graphite in ductile cast iron is spheroidal.
06.2014
With sand moulding, as a rule the speed 3.4.2 Fettling and mechanical
of cooling is so low that after solidifica- processing
tion a broadly ferritic-graphitic structure
with low proportions of pearlite is present Mould and core sand is blasted from cast
and the required mechanical values are parts using cut wire (blasting) (Fig. 3.20).
reached without annealing. Casting seams, gates and riser attach-
ments are separated and ground.
By contrast, fast cooling is characteristic
for the casting of pipes in water-cooled Fittings are checked for tightness in
moulds. Pipes produced in this way accordance with EN 545 [3.1] before
must be annealed, according to the applying the coating. Then, if necessary,
necessary level of workability and Fig. 19: the flange and spigot end are machined.
ductility. This is usually done in gas- Pipes in the continuous annealing furnace Components for valves are generally
fired continuous furnaces. At tem- subjected to machining after fettling.
peratures of around 920 °C to 950 °C, the Then they are blasted and taken to the
pipes rollthrough the furnace at a con- surface coating process directly after
trolled speed (Fig. 3.19). Carriages are this. After coating the components are
used to keep them moving which are assembled as complete valves. In the final
fixed onto a transport chain. The annea- process the valves undergo tightness
ling time and the temperature are estab- and function testing.
lished in a time-temperature diagram for
the furnace and these are automatically
controlled. Large-diameter pipes can
also be annealed standing on the socket
in batch furnaces. This enables oval-
isation of the pipes to be avoided.
Fig. 3.20:
Castings after blasting
06.2014
3.5 Application of coatings Cement mortar coating

and linings
Cement mortar coating is a multi-layer
coating for pipes with the following layer
3.5.1 Pipes structure (Fig. 3.22):
■ zinc coating,
Zinc or zinc-aluminium coating with ■ with or without primer layer
protective finishing layer (two-component synthetic resin
coating),
The zinc or zinc-aluminium coating ■ cement mortar layer.
is applied to the pipes after they have
been heat-treated. With metallic zinc The cement mortar layer is a layer of
spraying, zinc wire (minimum purity Fig. 3.21: fibrous cement mortar based on blast-
99.99 %) or zinc-aluminium wire Applying the zinc-aluminium coating furnace cement, which can be polymer-
(Zn85Al15) is molten in a flame or in modified, pigmented and wrapped with a
an electric arc. The fine metallic bandage material. The primer layer may
drops are blasted at high speed onto Straight after zinc or zinc-aluminium be omitted if a polymer-modified cement
the surface to be coated. This happens coating, the pipes are checked for dimen- mortar is used. The fibres mixed with the
in automatically operating equipment; sional accuracy and tightness tested on mortar may be glass or plastic fibres. For
for example the spray gun moves along fully automated testing and fettling lines. the application of the cement mortar
the rotating pipe. In this way the zinc or Also included in this type of protection coating, there are two processes in use.
zinc-aluminium coating is applied in a of the pipes is a finishing layer which is What the two processes have in common
helix shape (Fig. 3.21). applied to the rotating pipe. The inside is that a certain amount of fibres cut
of the socket is given separate treatment to length are mixed into the polymer-
here. modified mortar which comes out of
the compulsory mixer. The mortar is
The zinc or zinc-aluminium coating for then pumped to a circular spray nozzle
pipes in ductile cast iron is standardised (spraying process) or a flat die (extrusion
in EN 545 [3.1] and EN 598 [3.2]. process).
06.2014
With the spraying process the mortar

is sprayed onto the rotating pipe using
compressed air (Fig. 3.23). The spray
nozzle is mounted on a support and
travels slowly along the pipe. A smoothing
mechanism then reduces the cement
mortar coating to the specified layer
thickness.
With the extrusion process, the cement

mortar comes out of a stationary flat
die and winds an even layer thickness
in bands around the rotating pipe as
Fig. 3.22: it slowly travels past the nozzle. Syn-
Layer structure of a pipe with cement mortar coating and cement mortar lining chronous with the application of the
mortar, this also receives a bandage of
PE net tissue. At almost the same time
as the bandaging, a smoothing mecha-
nism which is also set up to be stationary
then smoothes the surface of the mortar.
After this stage, the PE net tissue is
completely covered with a thin layer of
mortar (Fig. 3.24).
Fig. 3.23: Fig. 3.24:

Spraying process Cement mortar coating – extrusion process
06.2014
With both processes, mortar flow rate, so that it is technically clean, free of
pipe rotation speed and speed of travel rust, loose particles of material, dirt, oil,
are to be coordinated in such a way that grease and moisture. In order to meet
the nominal coating thickness for the these requirements, the surface of the
cement mortar coating keeps to a value pipes is blasted to preparation grade
of 5 mm over the entire length of the pipe SA 2 1/2 as per EN ISO 8501-1 [3.4]. The
barrel. The end face of the socket and pipes are first heated to about 50 °C in
the spigot end of the pipe remain free of order to ensure an acceleration of the
cement mortar. These parts also have a polymerisation of the components to
zinc coating and, after the cement mortar a mechanically resilient coating. The
coating has set, they are provided with a polyurethane is then sprayed onto the
finishing layer. rotating pipe (Fig. 3.25). The pore-free
PUR coating is applied to the entire pipe
The cement mortar coating of ductile cast barrel continuously from the end face Fig. 3.25:
iron pipes is standardised in EN 15542 of the socket up to and including the Applying the black PUR coating
[3.3]. According to EN 545 [3.1] these spigot end. After the coating process the
pipes can be installed in soils of any level coating is also checked to ensure that it
of corrosiveness. is free of pores.
Polyurethane coating The PUR coating has a uniform and even

appearance in terms of colour, smooth-
The polyurethane (PUR) used is a solvent- ness and structure. Adhesive strength,
free two-component system with resin freedom from porosity, hardness and
and hardening agent. Polyurethane, coating thickness are checked daily in
mineral fillers, pigments and additives production (Fig. 3.26).
are selected in such a way that the end
product meets the functional require-
ments set and the drinking water Fig. 3.26:
regulations. Before applying the PUR Ductile iron pipe with polyurethane
coating, the surface of the pipe is cleaned coating and polyurethane lining
06.2014
The PUR coating of ductile iron pipes tional acceleration. With this acceleration
is standardised in EN 15189 [3.5]. and with additional vibration forces, the
According to EN 545 [3.1] these pipes fresh mortar undergoes compaction and
can be installed in soils of any level of smoothing (Fig. 3.27).
corrosiveness.
With centrifugal rotation, part of the
Polyethylene coating mixing water is driven out. A concen-
tration of fine grains and fine ele-
The polyethylene coating consists of ments occurs towards the surface of
LDPE (low density polyethylene). It is the cement mortar lining. The cement
applied to the pipe using a soft adhesive; mortar lining hardens in curing
up to and including DN 500 this is done chambers at a defined air humidity
using the tubular extrusion process, as and temperature. The cement mortar
from and including DN 400 using the flat lining of ductile iron pipes is stand-
die wrapping extrusion process. ardised in EN 545 [3.1] and EN 598 [3.2].
Fig. 3.27:
The PE coating of ductile iron pipes is Polyurethane lining Centrifugal rotation –
standardised in EN 14628 [3.6]. Accord- applying a cement mortar lining
ing to EN 545 [3.1] these pipes can be The polyurethane used is a solvent-free
installed in soils of any level of corrosive- two-component system with resin and requirements the inside surface of
ness. hardening agent. Mineral fillers, pig- the pipe is ground and double-blasted
ments and additives are selected in such a to preparation grade SA 2 1/2 as per
Cement mortar lining way that the end product meets the func- EN ISO 8501-1 [3.4]. The pipes are first
tional requirements set and the drinking heated to about 50 °C in order to ensure
In the centrifugal rotation process, water regulations (e.g. DVGW). Before an acceleration of the polymerisation of
after the application of the fresh mortar applying the PUR lining, the inside sur- the components. This means that short
(sand-cement-water mixture) the pipe face of the pipe is cleaned so that it is cycle times can be achieved in the coating
is brought to a sufficiently high speed technically clean, free of rust, loose process.
of rotation so that the centrifugal accel- particles of material, dirt, oil, grease
eration is at least twenty times gravita- and moisture. In order to meet these
06.2014
The polyurethane is then sprayed onto The inside of the socket is also lined with 3.5.2 Fittings and valves
the rotating pipe using a lance with a polyurethane. In combination with the
rotating nozzle (Fig. 3.28). The centri- PUR lining, an iron pipe is also provided Epoxy resin coating
fugal force produced by the rotation of with integral corrosion protection.
the pipe itself results in a very smooth As is the case with valves, the powder coat-
surface which has good hydraulic proper- After the coating process the lining ing of fittings with epoxy resin is becom-
ties. The pore-free polyurethane lining is is checked to ensure that it is free of ing increasingly important. According to
applied continuously to the whole of the pores. The PUR lining has a uniform EN 545 [3.1], fittings coated in this way are
pipe surface. and even appearance in terms of colour, suitable for soils of all classes of aggres-
smoothness and structure. Adhesive siveness. The same also applies to valves
strength, freedom from porosity, hard- coated with fusion bonded epoxy.
ness and coating thickness are checked
daily in production. To achieve this, the castings first of all
undergo surface treatment in the form
The polyurethane lining of ductile iron of blasting (preparation grade SA 2 1/2).
pipes is standardised in EN 15655 [3.7]. The castings are then heated to an object
temperature of approximately 200 °C and
dipped into a fluidised bed with epoxy
resin powder (Fig. 3.29) or coated electro-
statically using a spray gun (Fig. 3.30).
This produces pore-free coatings with

layer thicknesses of more than 250 μm.
Depending on the type of equipment
used, the coating process may be
automated. Continuous monitoring of
the coating as regards cross-linking,
Fig. 3.28: mechanical properties, disbonding and
Applying the PUR lining using a lance coating thickness ensures constant
with rotating nozzle quality.
06.2014
The epoxy powder coating of ductile iron Depending on the particular case, blast
fittings is standardised in EN 14901 [3.8] furnace cement is generally used here.
and RAL GZ 662 [3.9]. The epoxy coat- With this type of mortar application it is
ing of valve bodies is standardised not possible for excess water to be driven
in DIN 30677-1 [3.10], DIN 30677-2 [3.11], out; the preparation of the mortar using
DIN 3476 [3.12] and RAL GZ 662 [3.9]. the necessarily low water-cement ratio is
made possible by the addition of a syn-
Cement mortar lining thetic resin emulsion.
Fittings are lined with cement mortar Depending on the nominal size, the total
using the projection process in accord- coating thickness is 2.5 mm to 9 mm.
Fig. 3.29: ance with EN 545 [3.1] and EN 598 [3.2].
Epoxy powder applied by robots in the In this process a worm pump is used to As an external coating, fittings lined with
fluidised bed process pump the cement mortar through a tube cement mortar are usually provided with
and then through a rotating projection a 70 μm bitumen coating. In individual
head driven by compressed air onto the cases a two-component zinc rich paint
wall of the pipe, thereby compacting it. and a bitumen finishing layer are also
After curing at defined conditions the used.
fittings then undergo further processing.
The cement mortar lining of ductile iron
fittings is standardised in EN 545 [3.1]
and EN 598 [3.2].
Fig. 3.30:
Electrostatic application of epoxy powder
with a spray gun
06.2014
Technical enamelling The basic material consists of so- The slip is applied to the casting by
called enamel frits. These are produced dipping, pouring (Fig. 3.32) or spraying
Vitreous enamel as a coating material by smelting (at over 1,200 °C) and (Fig. 3.33) and then dried at d 110 °C.
tends to be used in places where vessels, then quenching and breaking up This is then followed by the actual firing
pipes, fittings and valves need to be natural inorganic materials including process, in a temperature range of
protected against chemical exposure and quartz, feldspar, borax, soda, potash, between 750 °C and 900 °C depending on
in some cases also extreme conditions aluminium oxide and other metal the quality of the enamel.
(Fig. 3.31). oxides. The enamel frits are milled
with additives and water to produce an
With ductile cast iron as the base material, enamel slip.
vitreous enamel produces a combination
which offers a range of significant prop-
erties, for example:
■ a smooth, anti-adhesive surface,
■ a high degree of hardness,
■ a glass-like, fully inorganic structure,
■ a high chemical resistance.
The castings are often annealed before

enamelling in order to improve con-
ditions for enamelling.
After the annealing process the surface is

blasted (EN ISO 12944-4 [3.13]; SA 2 1/2).
Blasting cleans and activates the surface
and produces a certain degree of sur-
face roughness. In addition the specific
surface is increased. This means that it Fig. 3.31: Fig. 3.32:
meets the conditions for material bonding Fitting coated outside and inside Applying enamel by pouring
in the following enamelling process. with enamel
06.2014
Fig. 3.33: Fig. 3.34:

Applying enamel by spraying Examples of the labelling of ductile fittings
The enamelling of ductile cast iron 3.6 Marking The marking of material, production date
fittings and valves is standardised in and nominal size is cast into or onto the
DIN 51178 [3.14]. A detailed description 3.6.1 Marking of pipes and fittings product.
of the enamelling technique can be found in ductile cast iron
in Chapter 7.2. The marking of the material as “ductile
The marking of pipes and fittings cast iron”, which must also be visible after
(Fig.3.34) is defined in product stand- installation, consists of three raised or
ards EN 545 [3.1] and EN 598 [3.2] recessed points arranged in a triangle or
and also in EADIPS®/FGR® - Standard three parallel, notch-shaped depressions
33 [3.15]. The marking of allowable on the end face of the socket.
operating pressures (PFA) for the
restrained flexible push-in joints of For socket pipes produced by means
pipes is covered in EADIPS®/FGR® - of the centrifugal casting process, the
Standard 75 [3.16] (Figs. 3.35 and 3.36). marking is basically applied to the
socket.
06.2014
In this case nominal size, manufacturer The following markings can also be cast,
identification and year are to be cast into applied with paint or enclosed with the
the inside of the socket where they will packaging:
not interfere with the function of the joint. ■ Reference to the relevant standard
(e.g. EN 545 [3.1]),
Coloured markings for the wall thick- ■ Indication of the certification authority
ness class and for the type of lining and (e.g. DVGW).
coating, but also additional markings, will
be applied to the end face of the socket For flanged pipes with welded, shrink-
or directly behind the socket. fit or screwed flanges the marking is
Fig. 3.35: cast into the back of the flange and for
Marking of a ductile iron pipe with Fittings will be marked as following in cast flange pipes it is applied to the pipe
restrained flexible push-in joint in accordance with product standards: barrel.
accordance with [3.16] ■ Marking of the manufacturer,
■ Marking of the year of manufacture, FGR® marking with a number (the
■ Marking for ductile cast iron, number is allocated to a manufacturer),
■ Nominal size DN, e.g. FGR® 2, indicates that this manu-
■ Nominal pressure PN for flanges, facturer is a member of the Euro-
■ The degree mark for bends. pean Association for Ductile Iron Pipe
Systems · EADIPS® / Fachgemeinschaft
The markings are cast onto the outside of Guss-Rohrsysteme (FGR®) e. V.
the body of the fitting.
Fig. 3.36:
Marking of allowable operating pressure
(PFA) in accordance with [3.16]
06.2014
3.6.2 Marking of valves in

spheroidal graphite cast iron
The marking of valves (Figures 3.37,

3.38, 3.39 and 3.40) is done according
to the specifications of EN 19 [3.17] and
EN 1074-1 [3.18].
Fig. 3.38: Fig. 3.39:

Marking of a gate valve, Marking of a plunger valve,
DN 100, GR 14 DN 800, PN 10/16
Fig. 3.37: Fig. 3.40:

Marking of a nozzle check valve Marking of a butterfly valve,
DN 800, PN 10
06.2014
3.7 Testing rial testing laboratories. These values Tightness and function tests on fittings
are to be tested on cylindrical test and valves are incorporated at an appro-
bars machined from the pipe wall. priate point in the overall course of their
3.7.1 Testing the pipe production. This also applies to all testing
The requirements for the lining and of material properties, dimensions and
After the annealing process and after the tests which need to be carried other criteria as required in the product
tightness testing, ductile iron pipes with out are defined in EN 545 [3.1] and and coating standards for process control.
or without zinc coating undergo dimen- EN 598 [3.2]. Regular testing in the con-
sional checking on combined fettling text of certification ensures consistent Depending on the agreement reached, the
and testing lines. In addition, they are quality, as in e.g. DVGW test specifi- results of the testing of pipes, fittings and
checked for any flaws outside and inside cation GW 337 [3.19] and DVGW supple- valves are recorded in a works certificate
by means of visual inspection. For ment GW 337-B1 [3.20]. or an acceptance certificate in accordance
example, wall thickness measurements are with EN 10204 [3.21].
taken with quick-test gauges. The sockets 3.7.2 Testing fittings and valves
and spigot ends are checked with limit
gauges. Hardness testing is carried out for For castings, fittings and valve bodies
a subsequent assessment of the annea- produced in sand moulds, similar testing
ling process. An evaluation of ferrite levels criteria to those for pipes apply. However,
and ductility (elongation after fracture) is unlike the procedure for pipes, with
provided by the ring flattening test (defor- fittings the specimens cannot be taken
mation of a ring cut from the pipe) on the from the casting itself without destroy-
fettling and testing line; compact-ability is ing it. Mechanical properties are tested
a reference value for ductility. on cylindrical test bars taken from
separately cast U or Y specimens; hard-
Instead of the ring flattening test, a ball ness can be measured on the casting itself.
indentation test can also be carried out. For the quick-test for ductility, sound
The precise mechanical strength values velocity measurement is carried out using
(tensile strength, 0.2 % yield point, ultrasound, either on a separately cast
elongation after fracture and Brinell test bar or on the casting itself.
hardness) are determined in mate-
06.2014
3.8 References [3.3] EN 15542 [Vorbereitung von Stahloberflächen

Ductile iron pipes, fittings and vor dem Auftragen von
accessories – Beschichtungsstoffen –
[3.1] EN 545 External cement mortar coating Visuelle Beurteilung der
Ductile iron pipes, fittings, for pipes – Oberflächenreinheit –
accessories and their joints for water Requirements and test methods Teil 1: Rostgrade und Oberflächen-
pipelines – [Rohre, Formstücke und Zubehör vorbereitungsgrade von
Requirements and test methods aus duktilem Gusseisen – unbeschichteten Stahloberflächen
[Rohre, Formstücke, Zubehörteile Zementmörtelumhüllung und Stahloberflächen nach ganz-
aus duktilem Gusseisen und ihre von Rohren – flächigem Entfernen vorhandener
Verbindungen für Wasserleitungen – Anforderungen und Prüfverfahren] Beschichtungen (ISO 8501-1:2007)]
Anforderungen und Prüfverfahren] 2008 2007
2010
[3.4] EN ISO 8501-1 [3.5] EN 15189
[3.2] EN 598 Preparation of steel substrates Ductile iron pipes, fittings and
Ductile iron pipes, fittings, before application of paints and accessories –
accessories and their joints for related products – External polyurethane coating
sewerage applications – Visual assessment of surface for pipes –
Requirements and test methods cleanliness – Requirements and test methods
[Rohre, Formstücke, Zubehörteile Part 1: Rust grades and preparation [Rohre, Formstücke und Zubehör
aus duktilem Gusseisen und ihre grades of uncoated steel substrates aus duktilem Gusseisen –
Verbindungen für die Abwasser- and of steel substrates after overall Polyurethanumhüllung von Rohren –
Entsorgung – removal of previous coatings Anforderungen und Prüfverfahren]
Anforderungen und Prüfverfahren] (ISO 8501-1:2007) 2006
2007+A1:2009
06.2014
[3.6] EN 14628 [3.8] EN 14901 [3.10] DIN 30677-1

Ductile iron pipes, fittings Ductile iron pipes, fittings and Äußerer Korrosionsschutz
and accessories – accessories – von erdverlegten Armaturen;
External polyethylene coating Epoxy coating (heavy duty) of Umhüllung (Außenbeschichtung)
for pipes – ductile iron fittings and accessories – für normale Anforderungen
Requirements and test methods Requirements and test methods [Corrosion protection of
[Rohre, Formstücke und Zubehör- [Rohre, Formstücke und Zubehör buried valves;
teile aus duktilem Gusseisen – aus duktilem Gusseisen – coating for normal requirement]
Polyethylenumhüllung von Rohren – Epoxidharzbeschichtung (für 1991
Anforderungen und Prüfverfahren] erhöhte Beanspruchung) von
2005 Formstücken und Zubehörteilen [3.11] DIN 30677-2
aus duktilem Gusseisen – Äußerer Korrosionsschutz von
[3.7] EN 15655 Anforderungen und Prüfverfahren] erdverlegten Armaturen;
Ductile iron pipes, fittings and 2006 Umhüllung aus Duroplasten
accessories – (Außenbeschichtung) für erhöhte
Internal polyurethane lining [3.9] RAL – GZ 662 Anforderungen
for pipes and fittings – Güte- und Prüfbestimmungen [External corrosion protection
Requirements and test methods Schwerer Korrosionsschutz von of buried valves;
[Rohre, Formstücke und Zubehör- Armaturen und Formstücken durch heavy-duty thermoset plastics
teile aus duktilem Gusseisen – Pulverbeschichtung coatings]
Polyurethan-Auskleidung von [Heavy duty corrosion protection 1988
Rohren und Formstücken – of valves and fittings by powder
Anforderungen und Prüfverfahren] coating –
2009 Quality aussurance]
2008
06.2014
[3.12] DIN 3476 [3.14] DIN 51178 [3.16] EADIPS®/FGR® 75

Armaturen und Formstücke für Emails und Emaillierungen – Rohre aus duktilem Gusseisen -
Roh- und Trinkwasser – Innen- und außenemaillierte Kennzeichnung des zulässigen
Korrosionsschutz durch EP-Innen- Armaturen und Druckrohr- Bauteilbetriebsdrucks (PFA)
beschichtung aus Pulverlacken (P) formstücke für die Roh- und längskraftschlüssiger beweglicher
bzw. Flüssiglacken (F) – Trinkwasserversorgung – Steckmuffen-Verbindungen von
Anforderungen und Prüfungen Qualitätsanforderungen Rohren –
[Valves and fittings for untreated und Prüfung Ergänzung zur EN 545:2010
and potable water – [Vitreous and porcelain enamels – [Ductile iron pipes -
Protection against corrosion by Inside and outside enamelled valves Marking of the allowable operating
internal epoxy coating of coating and pressure pipe fittings for un- pressure PFA of restrained flexible
powders (P) or liquid varnishes (F) – treated and potable water supply – push-in socket joints of pipes –
Requirements and tests] Quality requirements and testing] Supplement to EN 545:2010]
1996 2009-10 2013-06
[3.13] EN ISO 12944-4 [3.15] EADIPS®/FGR® 33 [3.17] EN 19

Paints and varnishes - Corrosion pro- Rohre und Formstücke aus Industrial valves –
tection of steel structures by duktilem Gusseisen – Marking of metallic valves
protective paint systems – Kennzeichnung von Rohren [Industriearmaturen –
Part 4: Types of surface and surface und Formstücken Kennzeichnung von Armaturen
preparation (ISO 12944-4:1998) [Ductile iron pipes and fittings – aus Metall]
[Beschichtungsstoffe – Korrosions- Marking of ductile iron pipes 2002
schutz von Stahlbauten durch and fittings]
Beschichtungssysteme – 2013-06
Teil 4: Arten von Oberflächen und
Oberflächenvorbereitung
(ISO 12944-4:1998)]
1998
06.2014
[3.18] EN 1074-1 [3.20] DVGW-Arbeitsblatt GW 337-B1

Valves for water supply – Beiblatt 1 zu DVGW-Prüfgrundlage
Fitness for purpose requirements GW 337 Rohre, Formstücke und
and appropriate verification tests – Zubehörteile aus duktilem Gusseisen
part 1: General requirements für die Gas- und Wasserversorgung –
[Armaturen für die Wasser- Anforderungen und Prüfungen
versorgung – [DVGW worksheet GW 337-B1
Anforderungen an die Gebrauchs- Supplement 1 to DVGW test
tauglichkeit und deren Prüfung – specification GW 337
Teil 1: Allgemeine Anforderungen] Ductile cast iron pipes, fittings and
2000 accessories for gas and water supply –
Requirements and tests]
[3.19] DVGW-Arbeitsblatt GW 337 2012-08
Rohre, Formstücke und Zubehör-
teile aus duktilem Gusseisen für die [3.21] EN 10204
Gas- und Wasserversorgung – Metallic products –
Anforderungen und Prüfungen Types of inspection documents
[DVGW worksheet GW 337 [Metallische Erzeugnisse –
Ductile cast iron pipes, fittings Arten von Prüfbescheinigungen]
and accessories for gas and 2004
water supply –
2010-09
06.2014
06.2014
E-Book – Ductile iron pipe systems Chapter 4: Quality management 4/1
10.2010
E-Book – Ductile iron pipe systems Chapter 4: Quality management 4/2
This chapter is being prepared.
10.2010
E-Book – Ductile iron pipe systems Chapter 5: Design of pipes 5/1
5 Design of pipes
10.2010
E-Book – Ductile iron pipe systems Chapter 5: Design of pipes 5/2
5 Design of pipes
10.2010
E-Book – Ductile iron pipe systems Chapter 6: Design and marking of fittings 6/1
6 Design and marking

of fittings
10.2010
E-Book – Ductile iron pipe systems Chapter 6: Design and marking of fittings 6/2
6 Design and marking of fittings

10.2010
E-Book – Ductile iron pipe systems Chapter 7: Valves 7/1
7 Valves
7.2 Corrosion protection of valves in spheroidal graphite cast iron
7.3 Principles of hydraulics and the design of valves
7.4 Isolation valves
7.5 Tapping valves
7.6 Control valves
7.7 Air valves
7.8 Hydrants
E-Book – Ductile iron pipe systems Chapter 7: Valves 7/2
7 Valves
Valves are components in piping systems which, in addition to the function of
“conducting the medium” (directing, changing the nominal width), also have the
functions of blocking or regulating the rate of flow and the pressure. Depending
on use, different materials are commonly used. The following chapter looks at
valves in which the main material is spheroidal graphite cast iron.
E-Book – Ductile iron pipe systems Chapter 7: Valves 7.1/1
7.1.1 Classification of valves

7.1.2 Spheroidal graphite cast iron as valve material
7.1.3 Materials in contact with drinking water
7.1.4 References Chapter 7.1
07.2013
7.1 Valves in spheroidal graphite 7.1.1 Classification of valves For the isolation function only the “fully
cast iron open” or “closed” valve positions are
In general, valves can be distinguished permissible. With regulating valves on
according to their the other hand, all intermediary positions
The following section contains general ■ functional features, are also admissible.
information on function, construction, ■ basic design and
connection and material. This information ■ type of connection. Table 7.1.1-02 contains a classification of
is obligatory for all valves. For valves in The functional features of valves are valves according to basic design.
the drinking water area, the requirements defined in EN 736-1 [7.1-01]. Table
for materials in contact with drinking 7.1.1-01 contains a classification of Table 7.1.1-03 gives a comparison of
water also apply. valves according to their functional designs, connection possibilities and func-
features. tional features.
Isolating valves are basically intended

for shutting off lines. Because of their
construction they are not suitable for
flow regulation, or only to a limited
extent.
07.2013
Table 7.1.1-01:
Classification of valves according to functional features
Valve design Type of action on the fluid Examples
Isolating valve Blocking or releasing the flow Shutoff valve, gate valve,
of substance butterfly valve
Regulating valve Reducing the working pressure Pressure reducing valve, throttle valve
Tapping the flow substance Sampling valve
Control device Separate or combined control of pressure, Control valve, control butterfly valve, regu-
temperature and volume lating cock, servo valve
Controlling a fluid level Level control valve
Safety valve 1) Preventing excess pressures and Outlet valve, safety valve,
subsequent shutoff safety shutoff valve
Bursting disc safety device Preventing excess pressures without Bursting disc safety device
subsequent shutoff
Return flow inhibitor Preventing a reversal of flow Non-return valve, check valve
1)
[German designation differs] in DIN EN 736-1 [7.1-02]
Source of Table 7.1.1-01 and Table 7.1.1-02:

Manual of pipeline construction, Vol. 1: planning, production, facilities
3rd edition, Günter Wossog, Vulkan Verlag, ISBN 978-3-8027-2745-0
07.2013
Table 7.1.1-02: Classification of valves according to basic design
Working mechanism of the closure device
Turning around the axis perpendicular Deformation of a

Linear to the direction of flow flexible component
Direction of flow in the connection area

Perpendicular to the move- In the direction of move- Different depending
ment of the closure device ment of the closure device Through the closure device Around the closure device on design
Designation of basic designs
Gate valve Control valve Cock Flap valve 1) Diaphragm valve
Type of connection
Wedge, plate, piston, Cup, cone, Teller, cylinder Ball, cone (tap), Disc, plate, rotary plug Diaphragm, tube
diaphragm, disc (piston), ball, needle cylinder
Design examples
Gate valve, slide valve, Shutoff valve, throttle Ball cock, cylinder cock, Butterfly valve, Diaphragm shutoff valve,
dam gate valve, safety valve, one-way stopcock check valve, eccentric diaphragm return flow
non-return valve, hydrant rotary plug valve inhibitor
1)
This also includes the eccentric rotary plug valve
07.2013
Table 7.1.1-03: A comparison of valve designs
Criterion Design
Gate valve Control valve Cock Flap valve Diaphragm valve
Flow resistance Low High Low Medium Medium
Connection possibilities Flanged, threaded, Flanged, Flanged, threaded Flanged, Flanged,

push-in socket, push-in socket, push-in socket, screwed socket
weld-on end threaded weld-on end
Piggable Yes No Yes No No
07.2013
The classification of valves according to and ageing resistance. Experience

connection type is covered in Chapter 7.9 shows it to be just as good as regards
(in preparation). corrosion protection. For centuries a
form of cast iron has been used which
contains graphite in the form of
7.1.2 Spheroidal graphite cast iron flakes (lamellar graphite cast iron).
as valve material These days spheroidal graphite cast
ironis used almost without exception
Because of their diverse functions, for the production of valve bodies in
valves are more cost-intensive and accordance with EN 1563 [7.1-03].
more complex to produce than pipes
or fittings and they consist of a number As well as the properties mentioned
of individual parts. When it comes to above, this material additionally offers
producing the complicated contours outstanding toughness, which is par-
of their body, the “casting” production ticularly important for valves with their
process is the most suitable. diverse range of load situations.
“Cast iron”, a material which was already A summary of the types of spheroidal
being used at a very early stage, not only graphite cast iron normally used today
offers a high degree of freedom in its for the production of valves and fittings
shaping but it also has great strength can be found in Table 7.1.2-01.
07.2013
Table 7.1.2-01:
A comparison of the properties of different types of spheroidal graphite cast iron for valves as per EN 1563 [7.1-03]
and ductile cast iron for fittings as per EN 545 [7.1-04]
Material Use Standard Tensile Yield Elongation Brinell- Modulus of Structure

strength strength at break Hardness elasticity
Rm [MPa] RP0,2 [MPa] A5 [%] [HB] [N/mm²]
EN-GJS-500-7 Valves and EN 1563 500 320 7 170–230 169.000 pearlitic –

(GGG 50) hydrants [7.1-03] ferritic
EN-GJS-400-15 400 250 15 135–180 170.000 pre-

(GGG 40) dominantly
ferritic
EN-GJS-400-18LT Valves 400 240 18 130–175 169.000 purely

(GGG 40.3) for use at ferritic
low tem-
peratures
EN 545 [7.1-04] Fittings EN 545 420 270 t5 < 250 170.000 pre-
[7.1-04] dominantly
ferritic
07.2013
Although spheroidal graphite cast iron The modern types of corrosion pro- 7.1.3 Materials in contact with
is a material which has been very tection for components in spheroidal drinking water
broadly perfected, further development graphite cast iron provide reliable cover
potentials can nevertheless be identified for all areas of use as regards soil type The 2nd amendment to the drinking water
for the future: and medium carried (Chapter 14 and regulation which came into effect on
Chapter 15). 13 December 2012 and in particular its
■ new moulding processes guarantee- article 17, Requirements for materials,
ing castings of the highest precision Stainless steel is used among other means that in future the German Federal
and the most complex configuration, things for drive shafts and other un- Environmental Agency will determine
■ 3D development of valves – coated parts. Bolts are produced in legally binding evaluations. These con-
construction with FEM simulation, A2 quality as a minimum (material tain test specifications, test parame-
construction of pattern equipment, no. 1.4301). Stem nuts and other com- ters and guidelines for methods. This
solidification simulation, rapid ponents subject to tribological stress also includes positive lists of basic and
prototyping, are usually in copperalloys. working materials and substances
■ development of ADI materials which come into contact with drinking
(ADI = Austempered Ductile Iron) NBR and EPDM as per EN 681-1 water. The former Federal Environ-
with tensile strength > 1,000 MPa [7.1-05] are usually used for the seals mental Agency guidelines, which had a
and acceptable elongation at break, (Chapter 13). voluntary character, will be replaced by
■ development of materials with wall these evaluation regulations.
thicknesses up to 2 mm and high
fatigue strength (3.8 % C; 2.9 % Si; Valve bodies in spheroidal graphite cast
0.04 % Mn; 0.040 % Mg) and wall thick- iron are always coated with epoxy or
ness reductions by means of micro- enamel. The drinking water has no contact
alloys, with the spheroidal graphite cast iron.
■ silicon doped ferritic cast iron with
improved mechanical properties The epoxy resins used as corrosion pro-
(up to 3.2 % Si), EN-GJS-500-12, tection meet the requirements of the
■ development of new welding filler guidelines for the hygienic assessment
materials with 58 % Ni for the reli- of organic coatings in contact with drink-
able production of a pearlitic structure. ing water of the German Federal En-
07.2013
vironmental Agency (UBA) [7.1-06]. Other functional parts such as gate valve
Annex 5 of the coating guideline wedges as well as flaps and gaskets are
[7.1-07] contains a list of approved counted as elastomer materials in con-
products. tact with drinking water. DVGW work-
sheet W 270 [7.1-08], Enhancement of
In addition, all components and all coat- microbial growth on materials in con-
ings of an organic nature which come tact with drinking water is to be ob-
into contact with drinking water are to served for this. In addition, the Federal
be tested for their potential to enhance Environment Agency elastomer guide-
microbial growth in accordance with line applies [7.1-11].
DVGW worksheetW 270 [7.1-08].
Furthermore the requirements and test
For enamelled valve bodies which come methods of the Federal Environment
into contact with drinking water, a draft Agency lubricants guideline [7.1-12]
enamel guideline is under preparation are to be observed for the lubricants
at the Federal Environment Agency. which are used on the moving functional
It is planned that the draft will be elements in valves.
published in 2013 and the evaluation
regulations will be established one year
later.
In Germany DIN 50930-6 [7.1-09] is to

be observed as regards metallic materials
coming into contact with drinking water.
This concerns components in stainless
steel and copper alloys. They are includ-
ed in the Federal Environment Agency
list “Metal materials suitable for hygienic
drinking water” [7.1-10].
07.2013
7.1.4 References Chapter 7.1 [7.1-04] EN 545 [7.1-06] Umweltbundesamt, Deutschland

Ductile iron pipes, fittings, UBA-Beschichtungsleitlinie –
[7.1-01] EN 736-1 accessories and their joints for Leitlinie zur hygienischen
Valves – Terminology – water pipelines – Beurteilung von organischen
Part 1: Definition of types Requirements and test methods Beschichtungen im Kontakt mit
of valves [Rohre, Formstücke, Zubehörteile Trinkwasser
[Armaturen - Terminologie – aus duktilem Gusseisen und ihre [UBA-Coatings Guideline –
Teil 1: Definition der Verbindungen für Wasser- Guideline for the hygienic
Grundbauarten] leitungen – assessment of organic coatings
1995 Anforderungen und in contact with drinking water]
Prüfverfahren] 2010-11
[7.1-02] DIN EN 736-1 2010
Armaturen – Terminologie – [7.1-07] Umweltbundesamt, Deutschland
Teil 1: Definition der Grund- [7.1-05] EN 681-1 Anlage 5 der Leitlinie zur
bauarten; Elastomeric seals – Material hygienischen Beurteilung von
Deutsche Fassung EN 736-1:1995 requirements for pipe joint seals organischen Beschichtungen im
[Valves – Terminology – used in water and drainage Kontakt mit Trinkwasser,
Part 1: Definition of applications – Organische Beschichtungen mit
types of valves; Part 1: Vulcanized rubber bestandener Prüfung
German version EN 736-1:1995] [Elastomer-Dichtungen – entsprechend dieser Leitlinie,
1995-04 Werkstoff-Anforderungen Beschichtungen auf Epoxidharz-
für Rohrleitungs-Dichtungen für basis
[7.1-03] EN 1563 Anwendungen in der Wasser - [Coatings Guideline –
Founding – Spheroidal graphite versorgung und Entwässerung – Annex 5 (list of products) PDF /
cast irons Teil 1: Vulkanisierter Gummi] 60 KB, in German]
[Gießereiwesen – Gusseisen mit 1996 + A1:1998 + A2:2002 + 2011-11-15
Kugelgraphit] AC:2002 + A3:2005
2011
07.2013
[7.1-08] DVGW-Arbeitsblatt W 270 Part 6: Evaluation process and [7.1-12] Umweltbundesamt, Deutschland
Vermehrung von Mikroorga- requirements regarding the UBA-Schmierstoffleitlinie –
nismen auf Werkstoffen für den hygienic suitability in contact Leitlinie zur hygienischen Beur-
Trinkwasserbereich – with drinking water] teilung von Schmierstoffen im
Prüfung und Bewertung 2013-01 Kontakt mit Trinkwasser
[DVGW worksheet W 270 (Sanitärschmierstoffe)
Enhancement of microbial [7.1-10] Umweltbundesamt, Deutschland [UBA- Lubricant Guideline –
growth on materials in contact Empfehlung – Guideline for the hygienic
with drinking water – Trinkwasserhygienisch geeig- assessment of lubricants in contact
Test methods and assessment] nete metallene Werkstoffe with drinking water
2007-11 [Recommendation – (sanitary lubricants)]
List of metallic materials suitable 2010-11
[7.1-09] DIN 50930-6 for contact with drinking water]
Korrosion der Metalle – 2012-12
Korrosion metallener Werkstoffe
im Innern von Rohrleitungen, [7.1-11] Umweltbundesamt, Deutschland
Behältern und Apparaten bei UBA-Elastomerleitlinie –
Korrosionsbelastung durch Leitlinie zur hygienischen Beur-
Wässer – teilung von Elastomermaterialien
Teil 6: Bewertungsverfahren und im Kontakt mit Trinkwasser
Anforderungen hinsichtlich der (Elastomerleitlinie)
hygienischen Eignung in Kontakt [UBA-Rubber Guideline –
mit Trinkwasser Guideline for the hygienic assess-
[Corrosion of metals – ment of elastomer materials in
Corrosion of metallic materials contact with drinking water
under corrosion load by water (Elastomer Guideline)]
inside of pipes, tanks and 2012-05
apparatus –
07.2013
07.2013
7.2 Corrosion protection of valves in spheroidal graphite cast iron
7.2.1 Epoxy coating

7.2.2 Enamel coating
07.2013
7.2 Corrosion protection of valves Epoxy powder coating guarantees a Duty Corrosion Protection of Powder
in spheroidal graphite cast seamless and homogenous all-over Coated Valves and Fittings (GSK), sets
iron coating (inside and outside). Because high requirements for epoxy pow-
corrosion primarily tends to start at the der coating. It possesses the following
transition between different types of characteristics:
7.2.1 Epoxy coating coating, a pore-free and flawless coating
is the best protection against corrosion. ■ hygienic and bacteriological safety,
The epoxy coating of valves has mean- Smooth internal surfaces ensure a high ■ chemical resistance,
while become the standard coating degree of protection against abrasion ■ smooth surface, low tendency for
method for all valves in the areas of raw and incrustation. incrustation,
water, drinking water and wastewater. ■ absence of pores both inside and
Because of its good adhesion, hardness outside (test voltage 3 kV),
Alongside the use of high-quality epoxy and dimensional stability under thermo- ■ high impact and pressure resistance,
paints, epoxy powder coating, also known setting, epoxy powder coating can also be ■ suitable for all soil classes as per
as EP coating, has become particularly used on the contact surfaces of sealing DIN 50929-3 [7.2-06], OENORM
popular for valves, being environmentally elements in valves. B 5013-1 [7.2-07] and DVGW
friendly and free of solvents. In the fusion worksheet GW 9 [7.2-08],
bonding process the coating powder melts Epoxy powder coating requires little ■ coating thickness t 250 μm,
and becomes chemically bonded to the energy for the coating process. ■ full protection (continuous),
previously blasted metallic surface. ■ high adhesive strength of at least
According to the epoxy powder coat- 12 N/mm2 after 7 days immersion
The overall, pore-free and complete pro- ing of fittings described in EN 14901 in hot water,
tection provided by epoxy powder coating [7.2-01], external and internal epoxy ■ no emissions of solvents during the
with a minimum coating thickness of coatings for valves (Figs. 7.2.1-01, coating process,
250 μm durably protects the fitting in all 7.2.1-02 and 7.2.1-03) are standard- ■ resistance to gases in accordance with
soil classes. The smooth internal surface ised in standards DIN 30677-1 [7.2-02], DVGW worksheet G 260 [7.2-09].
also prevents incrustation. DIN 30677-2 [7.2-03] and DIN 3476
[7.2-04]. In particular RAL GZ 662
[7.2-05], the standard issued by the
Quality Association for the Heavy
07.2013
Fig. 7.2.1-01: Fig. 7.2.1-03:

Butterfly valve – coated inside and outside Check valve – external and internal
with epoxy powder in accordance with coating with epoxy powder in accordance
RAL GZ 662 [7.2-05] with RAL GZ 662 [7.2-05]
Fig. 7.2.1-02:
Gate valve with flanges – epoxy powder
coating inside and outside in accordance
with RAL GZ 662 [7.2-05]
07.2013
Application is by means of electro-

static powder coating with a spray gun
(Fig. 7.2.1-04) or using the fluidised
bed technique (Figs. 7.2.1-05., 7.2.1-06
and 7.2.1-07); if the corresponding
process parameters are observed, a con-
sistently high coating quality is achieved
with both processes.
A precondition for high-quality powder

coating is the surface preparation of the
parts. To achieve this, the parts of valves Fig. 7.2.1-04: Fig. 7.2.1-05:
to be coated are blasted directly before Electrostatic application of epoxy powder Application of epoxy powder by robot
the coating process. Blasting removes dirt, with a spray gun using the fluidised bed technique
rust, grease and humidity from the parts
producing a degree of purity of SA 2½ in
accordance with EN ISO 12944-4 [7.2-10].
Constant cleaning of the blasting agent
to remove impurities from circulation, as
described in the GSK guidelines, is one
of the essential conditions for the very
good adhesion characteristics.
After that, depending on the epoxy

powder used, the valve parts are heated
in the oven to about 190 °C to 200 °C.
In the subsequent coating process the
heated parts are sprayed with epoxy Fig. 7.2.1-06: Fig. 7.2.1-07:
powder or else dipped into a fluidised Dipping a valve body into the fluidised Gate valve body coated in the fluidised
bed of powder. bed of powder bed of powder
07.2013
Because of the fast cross-linking of corrosion protection but it also gives

the resin the parts coated e.g. by the the valve a very long-lasting protection
fluidised bed process can be taken out against the light.
after only approximately 30 seconds
without the coating being damaged by 7.2.2 Enamel coating
pressure marks. After the end of the
coating process the parts are slowly As an outstanding and durable corrosion
cooled down to room temperature. protection, enamel has been established
in the area of water supply for more than
There then follows comprehensive 50 years.
quality testing which includes monitor-
ing the coating thicknesses and impact Since the end of the nineties enamel
resistance on original parts. This testing has started to be applied on top of the Fig. 7.2.2-01:
is also accompanied by inspection for external coating in order to produce an Valve with complete enamel coating
disbonding of the coating, adhesive integral, continuous coating. As regards
strength after 7 days immersion in hot the material, the production technique
water and cross-linking. and the testing technique, a proven and 7.2.2.1 Requirements and charac-
self-contained “complete enamel” coating teristics of enamel coating
For valves to be installed outdoors, for system (Fig. 7.2.2-01) has been available
example pillar hydrants, there is a need for several years and it has now found its The requirements for enamel coating
to protect the epoxy powder coating way into practical applications in the area are determined in DIN 51178 [7.2-11]
against long periods of UV exposure. To of transporting raw water, drinking water and in the DEV guideline “Quality
do this it has proved effective to apply and wastewater. and testing requirements for enamelled
an additional polyester coating, approx. cast iron valves and pressure pipe fittings
100 μm thick, to the outside surface for the raw and drinking water supply
while the epoxy film is still hot at about sector” [7.2-12]. Testing according to
170 °C. This duplex coating is then DVGW worksheet W 270 [7.2-13] is
hardened at approx. 200 °C. The in- not necessary as this is directed at the
separable composite layer which this tendency to enhance microbial growth
produces not only provides very good in organic materials. As a purely inor-
07.2013
ganic material, enamelling does not

supply any nutrients for microorgan-
isms and thus does not promote the for-
mation of biofilms.
7.2.2.2 Complete enamelling
The “complete enamel” coating system

has to meet two further requirements,
which are irrelevant for the internal area:
■ high impact resistance of the enamel

bond,
■ resistance against the corrosion
environments of soil class III
(highly aggressive soils) according
to the specifications of DIN 50929-3
[7.2-06], OENORM B 5013-1 [7.2-07]
and DVGW worksheet GW 9 [7.2-08].
The finely dispersed deposits of ex-

tremely small particles suppress the
development and proliferation of cracks
at points of excess stress, e.g. impact
or thrust stress. Fig. 7.2.2-02:
Detailed image of an enamel composite layer with spheroidal graphite cast iron;
scanning electron microscope image, Fraunhofer Institute ISC, Würzburg
07.2013
With complete enamelling of this upwards, a seam of approx. 2 μm which

standard of quality the specific material seems to be homogenously mixed can
advantages of the enamel are united as be detected. Above that there is then
follows: the actual composite layer, clearly over
10 μm thick, with different precipitations
■ integral protection (continuous), and deposits.
■ hygienic and bacteriological safety,
■ suitable for all soil types, When enamelling valves in spheroidal
■ high impact and pressure resistance, graphite cast iron,a series of essential
■ diffusion-proof, production parameters and restrictions
■ resistance to disbonding even where determines the quality of the enamelling.
there is local surface damage, The chemical composition of the cast iron Fig. 7.2.2-03:
■ ageing resistance. substrate material, its microstructure, its Gate valve body after blasting
pre-treatment and its surface condition
Enamelling is characterised by an inten- are of decisive importance.
sive physical and chemical bonding
with the substrate material (DIN 51178 A clean ferritic structure in the surface
[7.2-11]). This takes the form of a dif- layer makes the enamelling easier.
fusion process from the substrate mate- Thermal/mechanical pre-treatment is the
rial towards the enamel and vice versa second essential condition. Clean blasting
during firing. This causes a true composite material with an abrasive effect cleans the
layer to be formed with a thickness from a surface of the cast iron part, activates it
few to, depending on the material system, and increases the specific surface.
a few tens of micrometres (Fig. 7.2.2-02).
In the image, the micro-roughness of the

surface of the cast iron part (light, bottom) Fig. 7.2.2-04:
is clearly visible. The fine cracks dis- Slip application on the outside of gate
cernible in this are the indentations be- valve bodies by spraying
tween iron and enamel. Then moving
07.2013
This means that it is necessary to have a

rapid production process
■ pre-treatment (Fig. 7.2.2-03),

■ application of the enamel slip
(Fig. 7.2.2-04),
■ drying (Fig. 7.2.2-05),
enamel curing (Figs. 7.2.2-06 and
7.2.2-07).
Fig. 7.2.2-05: Fig. 7.2.2-06: Fig. 7.2.2-07:

Internally coated gate valve bodies in the A view inside the curing oven Enamelled gate valve bodies and
drying line fittings after curing
The basis for the testing and evaluation

of enamelled components is DIN 51178
[7.2-11]. It describes test methods which
simulate typical and realistic loads on the
components.
07.2013
7.2.3 References Chapter 7.2 [7.2-03] DIN 30677-2 [7.2-05] RAL – GZ 662
Äußerer Korrosionsschutz von Güte- und Prüfbestimmungen –
[7.2-01] EN 14901 erdverlegten Armaturen; Schwerer Korrosionsschutz von
Ductile iron pipes, fittings and Umhüllung aus Duroplasten Armaturen und Formstücken
accessories – (Außenbeschichtung) für erhöhte durch Pulverbeschichtung –
Epoxy coating (heavy duty) of Anforderungen Gütesicherung
ductile iron fittings and [External corrosion protection of [Quality and test provisions –
accessories – buried valves; Heavy duty corrosion protection
Requirements and test methods heavy-duty thermoset plastics of valves and fittings by powder
[Rohre, Formstücke und Zubehör coatings] coating –
aus duktilem Gusseisen – 1988-09 Quality assurance]
Epoxidharzbeschichtung 2008
(für erhöhte Beanspruchung) [7.2-04] DIN 3476
von Formstücken und Zubehör- Armaturen und Formstücke für [7.2-06] DIN 50929-3
teilen aus duktilem Gusseisen – Roh- und Trinkwasser – Korrosion der Metalle;
Anforderungen und Korrosionsschutz durch EP-Innen- Korrosionswahrscheinlichkeit
Prüfverfahren] beschichtung aus Pulverlacken (P) metallischer Werkstoffe bei
2006 bzw. Flüssiglacken (F) – äußerer Korrosionsbelastung;
Anforderungen und Prüfungen Rohrleitungen und Bauteile in
[7.2-02] DIN 30677-1 [Valves and fittings for untreated Böden und Wässern
Äußerer Korrosionsschutz von and potable water – [Corrosion of metals;
erdverlegten Armaturen; Protection against corrosion by probability of corrosion of metallic
Umhüllung (Außenbeschichtung) internal epoxy coating of coating materials when subject to
für normale Anforderungen powders (P) or liquid varnishes (F) – corrosion from the outside;
[Corrosion protection of burried Requirements and tests] buried and underwater pipelines
valves; 1996-08 and structural components]
coating for normal requirement] 1985-09
1991-02
07.2013
[7.2-07] OENORM B 5013-1 [7.2-09] DVGW-Arbeitsblatt G 260 [Vitreous and porcelain enamels-
Oberflächenschutz mit Gasbeschaffenheit Inside and outside enamelled valves
organischen Schutzmaterialien [DVGW worksheet G 260 and pressure pipe fittings for un-
im Siedlungswasserbau – Gas quality] treated and potable water supply –
Teil 1: Abschätzung der Korrosions- 2013-03 Quality requirements and testing]
wahrscheinlichkeit und Schutz von 2009-10
unlegierten und niedriglegierten [7.2-10] EN ISO 12944-4
Eisenwerkstoffen Paints and varnishes – [7.2-12] DEV-Richtlinie
[Corrosion protection by organic Corrosion protection of steel struc- Qualitätsanforderungen und
coatings for water and waste- tures by protective paint systems – Prüfvorschriften für emaillierte
water engineering in residential Part 4: Types of surface and Gussarmaturen und Druckrohr-
areas – surface preparation formstücke für die Roh- und Trink-
Part 1: Assessment of corrosion [Beschichtungsstoffe – wasserversorgung
probability and protection of Korrosionsschutz von Stahlbauten [Quality requirements and test speci-
unalloyed and low-alloyed ferrous durch Beschichtungssysteme – fications for enamelled cast iron
materials] Teil 4: Arten von Oberflächen und valves and ductile iron fittings for
2013-12-1 Oberflächenvorbereitung] untreated and potable water supply]
1998 2006-09-27
[7.2-08] DVGW-Arbeitsblatt GW 9
Beurteilung der Korrosions- [7.2-11] DIN 51178 [7.2-13] DVGW-Arbeitsblatt W 270
belastungen von erdüberdeckten Emails und Emaillierungen – Vermehrung von Mikro-
Rohrleitungen und Behältern aus Innen- und außenemaillierte organismen auf Werkstoffen für
unlegierten und niedrig legierten Armaturen und Druckrohr den Trinkwasserbereich –
Eisenwerkstoffen in Böden formstücke für die Roh- und Prüfung und Bewertung
[DVGW worksheet GW 9 Trinkwasserversorgung – [DVGW worksheet W 270
Assessment of the corrosion level Qualitätsanforderungen und Enhancement of microbial
of buried pipes and tanks in unal- Prüfung growth on materials in contact
loyed and low-alloyed ferrous with drinking water –
materials in soils] Test methods and assessment]
2011-05 2007-11
07.2013
7.3 Principles of hydraulics and the design of valves
7.3.1 Hydraulic principles

7.3.2 Valve design
08.2015
7.3 Principles of hydraulics and 7.3.1 Hydraulic principles The resistance of a component can be
the design of valves determined mathematically or by hydrau-
Physical laws influence the basic con- lic measurements. The result is the flow
Valves need to be designed for specific struction, nominal size and equipment of resistance coefficient, referred to as zeta.
applications so that they can fulfil their control valves. Therefore it is also impor- As a rule the Greek letter ȗ (zeta) is used
desired functions correctly. Below you tant to consider these laws when selecting as the symbol in formulas.
will find some explanations on the basic a control valve.
design of valves. 7.3.1.2 Pressure
7.3.1.1 Flow resistance coefficient
The terms used have been taken from Bernoulli’s equation describes the
EN 736-1 [7.3-01], EN 736-2 [7.3-02] and If solid bodies on top of each other are changes in pressure across a pipeline
EN 736-3 [7.3-03]. moved against each other, there is a through which a medium is flowing. This
resistance to be overcome. This resist- equation is also referred to as the law of
When designing valves, the difference ance is determined by the roughness conservation of energy. Bernoulli assumes
between isolation valves and control of the surfaces in contact, among other that, when a medium is flowing through
valves is an important aspect. While, as a things. The same also applies in a com- a pipeline, energy is not lost but is sim-
rule, isolation valves are selected accord- bination of a solid body and a liquid such ply converted. The energy contained in
ing to the nominal size and pressure rat- as water. The roughness of the surface a medium flowing through a pipe can be
ing of the pipeline, the choice of control of the solid body determines the level of described as follows.
valve is made on the basis of the hydrau- the resistance. The rougher the surface,
lic requirements of the control task to be the greater the resistance. However, the It contains:
performed. geometry of the solid body guiding the
flow also affects the resistance; changes ■ Pressure energy p [N/m²]
In order to assist the user in selecting the of direction increase it. Bearing this in
correct valve for his purposes, manufac- mind, components along the line of flow ■ Potential (stored) energy
turers publish specific technical data on can be considered and the resistance Epot = ݃ ‫[ ݖ כ ߩ כ‬N/m²] (7.3.1)
their valves. determined for each point. Finally the
individual resistance values can be added
together to produce an overall resistance.
08.2015
■ Kinetic energy through speed If the application is reduced to the control

ఘ
Ekin = ଶ ‫ ܿ כ‬ଶ [N/m²] (7.3.2) valve, simplifications can be achieved. So
potential energy no longer applies as the
height difference between the inlet and
■ Friction outlet of the valve has no influence worth
ఘ
wR = ଶ ‫ ܿ כ‬ଶ ‫ כ‬σ [N/m²] (7.3.3) mentioning.
Equally the kinetic energy can be ignored

Key: as the speed, with reference to the nomi-
ȡ density of the flow medium [kg/m³] nal size of the line, is and remains the
g = acceleration due to gravity same before and after the valve.
= 9.8 [m/s²]
z = height [m] Fig. 7.3.1:
c = speed of flow of the medium with Change in the energy proportions between
reference to nominal size [m/s] point 1 and point 2 of a line
= zeta value [-]
Between the inlet (point 1) and the outlet Simply the fact that that friction has to be
(point 2) these energy proportions change overcome on the way through the pipeline
(Fig. 7.3.1). results in a change in the energy propor-
tions. This means that the energy state can
be described as follows:
ఘ ఘ ఘ
‫݌‬ଵ + ߩ ‫ݖ כ ݃ כ‬ଵ + ܿଵଶ = ‫݌‬ଶ + ߩ ‫ݖ כ ݃ כ‬ଶ + ‫ܿ כ‬ଶଶ + ‫ܿ כ‬ଶଶ ‫ כ‬σ Ɍ = ܿ‫ݐݏ݊݋‬.
ଶ ଶ ଶ
[N/m²] (7.3.4)
08.2015
Thus we arrive at: The equation of continuity states that the 7.3.1.4 Kv-value
same volume of flow is present at every
ఘ
‫݌‬ଵ = ‫݌‬ଶ + ‫ ܿ כ‬ଶ ‫ כ‬σ Ɍ [N/m²] point in the pipeline, regardless of its local For the selection and dimensioning of
ଶ
(7.3.5) diameter. control valves, a characteristic value is
usually used – the Kv-value or flow coef-
or transposed It follows that: ficient.
ఘ
‫݌‬ଵ െ ‫݌‬ଶ = ο‫= ݌‬ ‫ܿ כ‬ଶ ‫ כ‬σ Ɍ [N/m²] ‫ܣ = ܿ כ ܣ‬ଵ ‫ܿ כ‬ଵ = ‫ܣ‬ଶ ‫ܿ כ‬ଶ = ܿ‫ݐݏ݊݋‬. The Kv-value is a parameter for the
ଶ
(7.3.6) achievable throughput of a medium –
[m³/s] (7.3.7) liquid or gas – through a component. The
Kv-value is expressed either as [m3/h] or
7.3.1.3 Flow velocity as [L/min]. Where water is the medium,
గ
with ‫=ܣ‬ ‫ܦ כ‬ଶ [m²] (7.3.8) the Kv-value indicates the volume of flow
ସ
Flow velocity describes the speed at which with a pressure difference of 1 bar over
a medium is transported through a pip- the length of the component. It is appli-
ing system. As a rule the nominal sizes of it then follows cable for a water temperature of between
pipelines are designed with energy-saving 5 °C and 30 °C. When a control valve is
௖
aspects in mind, meaning that different ‫ܦ‬ଶ = ට‫ܦ‬ଵଶ ‫ כ‬భ [m] (7.3.9) fully open it is referred to as the Kvs-value.
௖ మ
nominal sizes may be present in the same
pipeline system. Using the equation of The Kv-value is calculated as follows:
continuity, the optimum nominal size for Key:
ଵ ௕௔௥
the control valve can be determined. A = cross-sectional area of the ‫ܭ‬௩ = ܸሶ ‫ כ‬ට [m³/h] (7.3.10)
ο௣
nominal pipe size [m²]
c = flow velocity [m/s]
D = internal diameter of the Key:
nominal size [m] Kv flow coefficient [m³/h]
ܸሶ volume flow =
throughput volume [m³/h]
ǻS actual pressure difference
present [bar]
08.2015
7.3.1.5 Cavitation energy conversion occurs from pressure cess is not without loss, so that even
energy to kinetic energy and lost energy higher pressure losses are experienced
The deductions using the Bernoulli (Fig. 7.3.2). in addition.
equation at the end of Chapter 7.3.1.2
show that control actions change the After the water has passed through the Depending on the conditions of operat-
physical parameters of pressure and throttling point it undergoes another ing parameters this may mean that the
speed of flow. Control valves only work energy conversion. Because the flow pressure of the water in the throttling
at their best with higher speeds. This cross-section is now larger again, the point is lower than the vapour pressure
means that very high flow velocities speed of flow reduces. This means of the water. This then leads to the for-
can occur at throttling points. At the that kinetic energy is converted back mation of vapour bubbles in the flow of
throttling points only, considerable to pressure energy. However, this pro- water.
Fig. 7.3.2: Fig. 7.3.3:

Hydraulic energies in the area of the throttle gap Phase diagram of water
08.2015
The probability of this gets higher as forming a micro water jet, which shoots
the pressure after the throttling point through the vapour bubble. This process
approaches the level of atmospheric is summarised by the term “cavitation”
pressure. Depending on the pressure (Fig. 7.3.5).
and temperature of the water, it changes
its physical state. With an air pressure of Pressures of up to 10,000 bar have been Fig. 7.3.4:
1 bar and a temperature of 100 °C vapour able to be determined in micro water jets, Vapour bubble formation in a throttling
bubbles begin to form: the water boils regardless of the pressure in the pipe point
(Fig. 7.3.3). cross-section. These are the kind of ener-
gies which are used for waterjet cutting, of
The water in drinking water pipelines steel for example. A similar effect is also
usually has a temperature of between produced by cavitation in valves used for
5 °C and 20 °C in our latitudes. The asso- control purposes.
ciated vapour pressure is then at around
0.015 bar absolute, or about 0.9 bar below In order to keep the consequences of
atmospheric pressure. cavitation as slight as possible, there
are the following possibilities: Fig. 7.3.5:
Once the pressure in the throttling point ■ Directing the imploding vapour bub- Schematic diagram of cavitation
reaches vapour pressure or below, the bles to the centre of the component
formation of vapour bubbles begins. The so that they do not actually come into
intensity of the vapour bubble formation contact with it (Fig. 7.3.6).
depends on the degree to which the pres- ■ Use of a material with a higher resist-
sure is below vapour pressure (Fig. 7.3.4). ance to cavitation.
■ Selection of an appropriate valve to
After the throttling point a further energy avoid cavitation. Fig. 7.3.6:
conversion takes place. The increased Directing vapour bubbles to the centre of
pressure in the medium which this causes In order to evaluate cavitation in pipe- the pipe
then has an effect on the vapour bubbles. line systems with control valves, the
The vapour bubbles are “dented” under sigma cavitation index is applied.
the increased pressure and they implode,
08.2015
7.3.2 Valve design
7.3.2.1 Design of isolation valves
The design of isolation valves is essen-

tially limited to determining nominal
sizes and pressure ratings. As long as the
flow velocity is within the range of the
specifications in EN 1074-1 [7.3-04] and
EN 1074-2 [7.3-05], the isolation valve is
determined in much the same way as the
pipeline itself.
7.3.2.2 Design of control valves
For control valves the hydraulic proper-

ties required of the control function need
to be taken into account. This may mean
that the different design stages have to
be repeated a number of times. Fig. 7.3.2:
Cavitation assessment for an operating point
As regards nominal pressure, the design
of control valves is based on that of the
pipeline. The nominal size of the control valve is Example:
determined for the maximum volume of ■ Nominal size of pipeline DN 150,
water required. When doing this, the maxi- ■ maximum flow rate 96 m³/h (usual
mum allowable flow velocity according rate for extinguishing water in the
to the manufacturer’s specification must municipal sector),
also be taken into account. ■ maximum flow velocity according to
manufacturer’s specification, e.g. 4 m/s.
08.2015
This results in a minimum diameter of 7.3.3 References Chapter 7.3 [7.3-04] EN 1074-1
81.6 mm for the control valve. Allowing a Valves for water supply –
tolerance for the flow velocity to be less [7.3-01] EN 736-1 Fitness for purpose requirements
than specified, this suggests a nominal Valves – Terminology – and appropriate verification tests –
size of DN 80 for the control valve. Part 1: Definition of types Part 1: General requirements
of valves [Armaturen für die Wasserver-
7.3.2.3 Checking for the absence [Armaturen – Terminologie – sorgung –
of cavitation Teil 1: Definition der Grund- Anforderungen an die Gebrauchs-
bauarten] tauglichkeit und deren Prüfung –
Once the nominal size and pres- 1995 Teil 1: Allgemeine Anforderungen]
sure rating have been established, a 2000
specific valve is selected. Each valve has [7.3-02] EN 736-2
a specific characteristic for the Valves – Terminology – [7.3-05] EN 1074-2
sigma cavitation index. A valve is Part 2: Definition of components Valves for water supply –
said to be cavitation-free if its of valves Fitness for purpose requirements
cavitation lines ( and ) are [Armaturen – Terminologie – and appropriate verification tests –
below the “valve in operating situation” Teil 2: Definition der Armaturen- Part 2: Isolating valves
line ( )(Fig. 7.3.7). teile] [Armaturen für die Wasserver-
1997 sorgung –
Anforderungen an die Gebrauchs-
[7.3-03] EN 736-3 tauglichkeit und deren Prüfung –
Valves – Terminology – Teil 2: Absperrarmaturen]
Part 3: Definition of terms 2000 + A1:2004
[Armaturen – Terminologie –
Teil 3: Definition von Begriffen]
2008
08.2015
7.4 Isolation valves
7.4.1 Gate valves

7.4.2 Butterfly valves
7.4.3 Ball valves
05.2014
7.4 Isolation valves whole of the pipe cross-section is open.

This means that there are only very slight
7.4.1 Gate valves pressure losses. In addition, this makes
pigging possible. Also in wastewater
7.4.1.1 Field of application applications, the open cross-section is a
great advantage because it prevents clog-
The gate valve is the most frequently ging with floating particles and solids. The
installed valve in the water supply indus- classic construction connects the bonnet
try and can therefore be described as a to the valve body with bolts. More recent
standard valve. These days it is practically constructions have non-bolted connec-
only resilient seated gate valves (rubber tions. To date, the necessarily complex
coated valve wedges) which are used in geometry of a wedge gate valve can
drinking water applications and they are only be produced cost-effectively by the
subject to national approval regulations. casting process. In case of overhaul, its
Resilient seated and metal seated gate design allows moving parts to be replaced
valves are used in the wastewater sector. without removing the entire valve.
The flow through a gate valve can be in
both directions. Resilient seated wedge gate valves are
characterised by the fact that there is
7.4.1.2 Resilient seated wedge a vulcanised rubber coating on the Fig. 7.4.1-01:
gate valves wedge of the valve which comes into Design of a wedge gate valve:
contact with the corresponding sealing Body, bonnet, stem drive and wedge
A resilient seated wedge gate valve essen- surfaces in the valve body, thereby sealing
tially consists of the valve body, the valve the valve (Figs. 7.4.1-02, 7.4.1-03,
wedge and the bonnet with integrated 7.4.1-04, 7.4.1-05, 7.4.1-06, 7.4.1-07 present. This means that resilient seated
stem seal (Fig. 7.4.1-01). The valve wedge and 7.4.1-08). The elastic rubber coat- gate valves are also suitable for communal
is moved by the stem drive in the passage. ing of the wedge compensates for any sewage systems where there is a certain
In the open position these gate valves slight irregularities in the cast body and degree of solids content.
have a clear passage, in other words the forms an optimum seal even when dirt is
05.2014
Fig. 7.4.1-02: Fig. 7.4.1-04: Fig. 7.4.1-06:

Sectional image of a resilient seated flanged Resilient seated flanged gate valve with Resilient seated Novo SIT® push-in gate
gate valve with a non-bolted connection threadless stem mounting valve
between bonnet and body
Fig. 7.4.1-03: Fig. 7.4.1-05: Fig. 7.4.1-07:

Sectional image of a resilient seated Resilient seated TYTON® push-in gate valve Resilient seated TYTON® push-in gate valve
flanged gate valve with a bolted connec- DN 150 with spigot end and socket end, BAIO®
tion between bonnet and body system
05.2014
Smooth and homogeneous coatings, such The gate valves meet the requirements
as the epoxy resin powder coating accord- of both EN 1074-2 [7.4-04] and EN 1171
ing to GSK guidelines for heavy-duty [7.4-05]. Also to be considered are DVGW
corrosion protection RAL GZ 662 [7.4-01] Worksheets GW 336-1 “Stem extensions
or enamelling to DIN 51178 [7.4-02] and for underground installation – Part 1:
DEV guideline [7.4-03], prevent incrus- Standardisation of interfaces between
tations from forming in the valve body. buried valves and spindle extensions”
Because of the free and smooth pas- [7.4-06] and W 363 “Isolating valves, check
sage, the resilient seated gate valve has valves, air valves and control valves made
broadly replaced the metal seated valve from metal for drinking water distribu-
Fig. 7.4.1-08: as the standard gate valve. It is available tion systems – Requirements and testing”
Resilient seated wedge gate valve with in nominal pressure stages PN 10, PN 16 [7.4-07].
spigot end and socket end and PN 25.
Other standards to be considered are:
Resilient seated gate valves are not EN 558 [7.4-08], EN 736-1 [7.4-09],
suitable as flow control and regulation EN 1503-3 [7.4-10], EN 12516-2 [7.4-11]
devices – they are simple ON/OFF valves. and EN 12516-4 [7.4-12].
The reason for this lies in the geometry
of the wedge guiding. When the wedge
moves into the cross-sectional area of 7.4.1.3 Metal seated wedge
flow, high forces occur in the intermediate gate valves
positions which put stress on one side of
the opening; if it stays in this intermediary The metal seated wedge gate valve
position for long, this can cause damage. (Fig. 7.4.1-09) is characterised by a
Where the flow is restricted to a high metal shut-off device which moves into a
degree there is also the risk of cavitation so-called valve bag in the lower part of
Fig. 7.4.1-09: damage to the valve body. In addition, the the body when the valve closes.
Metal seated wedge gate valve resilient seated wedge gate valve also has
poor control characteristics.
05.2014
Table 7.4.1-01:
Field of application of resilient seated knife gate valves
Field of application Type of application (examples)

Hand-
Wastewater Digested sludge, wastewater, raw sludge, air wheel
Chemical industry Chemically contaminated wastewater

Biogas plant Sludge, waste water
Stem
mounting
The drawback with this type of construc- 7.4.1.4 Resilient seated Stem
tion lies with the sealing principle, in terms knife gate valves
of the valve bag and the high breakaway
Stem nut
torque when the valve opens. In the open Resilient seated knife gate valves are
position, flow resistances occur with a used above all in wastewater and in-
deadwater area, favouring the formation dustrial applications for the widest
Transverse
of deposits and incrustations. This can range of media. As pressures in these
seal
result in high actuating torques on open- areas of use are normally lower than
ing and closing. Metal seated gate valves with drinking water applications, it is
are normally used in the area of water and usually the simpler and cheaper
Valve plate
wastewater, in industrial applications and design of knife gate valve which is
in district heating systems up to a nominal selected. Fig. 7.4.1-10 shows the
pressure of PN 40. construction of a resilient seated knife U-frame
gate valve. They are produced in nomi-
nal sizes DN 50 to DN 1400 for operating
pressures of up to 16 bar. Table 7.4.1-01
gives some examples of the fields of use Fig. 7.4.1-10:
of resilient seated knife gate valves. Construction of a knife gate valve
05.2014
Fig. 7.4.1-11: Fig. 7.4.1-12: Fig. 7.4.1-13: Fig. 7.4.1-14:

Resilient seated knife gate Resilient seated knife gate valve Resilient seated knife gate Resilient seated knife gate valve
valve PN 10 with hand-wheel PN 10 with pneumatic drive valve with electric drive for installation underground
Resilient seated knife gate valves Resilient seated knife gate valves are used A major advantage of the gate valve
(Figs. 7.4.1-11, 7.4.1-12 and 7.4.1-13) above all in wastewater applications, but construction is the completely free pas-
essentially consist of a cast valve body, they are also used for controlling other sage when the valve is open and the valve
a stainless steel valve plate and a stem liquid media. They are not suitable for plate which is impervious to dirt. Because
drive, often with integral position display. use with drinking water. Resilient seated of the free passage through the valve
Depending on the application, various knife gate valves are primarily installed body, no solids can get stuck in the valve.
sealing materials and operating methods in shafts and structures, but constructions
are possible. are also available for installation under-
ground (Fig. 7.4.1-14).
05.2014
Knife gate valves with a fully devel- 7.4.2 Butterfly valves The designs most commonly used today
oped flange (through bolt holes and are resilient seated centric or double-
blind threaded holes) can be used both 7.4.2.1 General eccentric butterfly valves.
for installation between flanges and
for end-of-line applications without a After the gate valve, the second most Butterfly valves essentially consist of a
counter-flange. The short K1 face-to-face frequently installed type of valve for valve body, which is installed in the pipe-
length meets standard EN 558 [7.4-08]. water supply applications is the line with flanged joints, and a shut-off
butterfly valve (Figs. 7.4.2-01, 7.4.2- element, referred to as the butterfly disc.
Modular systems make other configu- 02, 7.4.2-03, 7.4.2-04, 7.4.2-05, 7.4.2- The butterfly disc is usually adjusted by
rations possible, such as: 06 and 7.4.2-07). They have a shut-off means of a gear mechanism and, in the
■ electrical display of limit positions, element located in the cross-section of open position, lies parallel to the direc-
■ scraper for cleaning the valve plate, the line which is referred to as the tion of flow (Fig. 7.4.2-03). The standard
■ triangular or pentagonal orifices for butterfly disc. Just like gate valves, range of nominal sizes goes from DN 50 to
regulation purposes, butterfly valves are purely shut-off DN 4000 and the normal pressure stages
■ numerous actuator and actuator devices (ON/OFF function). range from PN 6 to PN 40.
extension possibilities.
Depending on the medium carried,

suitable materials are available for the
valve plate and the seals.
Fig. 7.4.2-01:
Examples of butterfly valves with hand-wheel – butterfly valve coated with epoxy resin
powder (left) and fully enamelled butterfly valve (right)
05.2014
Fig. 7.4.2-02: Fig. 7.4.2-04: Fig. 7.4.2-06:

Centric butterfly valve with worm-gear and Double-eccentric butterfly valve with slider Double-eccentric butterfly valve with
hand-wheel crank mechanism and hand-wheel spindle gear and electric drive for large
nominal sizes, e.g. DN 1800
Fig. 7.4.2-03: Fig. 7.4.2-05: Fig. 7.4.2-07:

DN 250 double-eccentric butterfly valve Double-eccentric butterfly valve with loose Double-eccentric butterfly valve with
with slider crank mechanism flange hydraulic drive for very large nominal sizes,
high pressure stages and as a safety valve
05.2014
Advantages of butterfly valves as Disadvantages of butterfly valves as ■ operating pressure,

compared with gate valves: compared with gate valves: ■ operating medium,
■ installation situation,
■ Less space required – butterfly valves ■ Greater flow resistance – while gate ■ pigging possibilities.
can be made to be very compact even valves present practically no flow
for large diameters. No deadwater resistance in the fully open position For reasons of price, the gate valve is
space as the shut-off device is inte- (pressure loss coefficient ȟ = 0.1 – 0.2), generally used up to DN 300.
grated directly in the cross-section of ■ butterfly valves have relatively high
the pipeline and does not need any flow resistance values in the open 7.4.2.2 Types of butterfly valves
installation space. position, depending on the design and
■ Lighter weight – because of their com- dimensions (pressure loss coefficient With butterfly valves, a distinction is
pact construction, butterfly valves are ȟ = 0.2 – 0.9). made between the following types of
lighter in large diameters. ■ Expensive construction – as compared construction:
■ Low actuating moment – because of with gate valves, the construction is
the friction in the wedge-guide, par- somewhat more expensive and only ■ Centric mounting of the butterfly
ticularly with high nominal sizes, gate becomes worthwhile with larger nomi- disc (Fig. 7.4.2-08) – the shaft of the
valves have high actuating moments. nal sizes. butterfly disc is arranged both in the
By contrast, double eccentric butter- ■ Pigging is not possible in pipelines centre of the valve body and in the
fly valves are also easier to actuate with butterfly valves. centre of the disc. Because of its short
because of the gearing mechanisms overall length (EN 558, overall length
used. Selection criteria: K1 [7.4-08]), this construction with
■ When installed underground, because tight-closing, resilient seated elasto-
of the low overall height (the same When deciding between gate valves and mer body seating is very suitable for
as the pipeline) and especially with butterfly valves, the following examples fittings between two pipeline flanges
higher nominal sizes, no conduits are represent factors which are of particular or for flange-mounting as an end-
necessary for frost protection. importance: of-line device. Actuation is often by
means of a ratch lever (to DN 300),
■ actuation torque, electric drive or pneumatic drive.
■ weight of the valve, The arrangement of the elastomer
■ flow rates, sealing seat in the body opens up the
05.2014
possibility of producing the butter- 7.4.2.3 Types of body construction In pipelines as from DN 500, butter-
fly disc in the widest range of ma- fly valves of length R15 with integral
terials. This offers the advantage that In the construction of water supply bypasses are also used. For pipelines
the valve can be used for the widest pipelines, it is mainly butterfly valves in waterworks, and above all with
range of mediums. with flanges and face-to-face lengths in smaller nominal sizes, short sandwich-
■ Simple eccentric mounting of the accordance with EN 558 [7.4-08] series type butterfly valves in length R20 are
butterfly disc – the shaft is arranged R14 which are installed (Fig. 7.4.2-11). also used (Fig. 7.4.2-13).
on the pipe axis of the valve body Alternatively, butterfly valves with
outside the seating surface of the but- push-in joints can also be supplied
terfly disc (Fig. 7.4.2-09). With this, (Fig. 7.4.2-12).
as well as the centric mounting of
the shaft, the butterfly disc performs
a purely rotary movement.
■ Double eccentric mounting of the
butterfly disc – the shaft is arranged
both outside the pipe axis of the valve
body and outside the seating surface
of the butterfly disc (Fig. 7.4.2-10).
This means that the butterfly disc per-
forms a relative movement resulting
from a linear and rotary movement
of the butterfly disc. In this move-
ment, when it leaves the seating sur-
face, the seal applied to the butterfly
disc is completely separated from the
seating surface in the valve body after
a short rotation movement, thereby
making opening and closing easier. Fig. 7.4.2-08: Fig. 7.4.2-09: Fig. 7.4.2-10:
The double eccentric butterfly valve Centric design Simple eccentric design Double eccentric design
can react to pressure from both sides.
05.2014
Fig. 7.4.2-11: Fig. 7.4.2-13: Fig. 7.4.2-15:

Butterfly flange valve with gearing and Flange-mount butterfly valve with gearing Lug-type butterfly valve with lever
hand-wheel and hand-wheel
Fig. 7.4.2-12: Fig. 7.4.2-14: Fig. 7.4.2-16:

Butterfly valve with push-in joints Centric wafer-type butterfly valve with lever U-type design with gearing and
hand-wheel
05.2014
Fig. 7.4.2-17: Fig. 7.4.2-18: Fig. 7.4.2-19:

Sealing ring seated directly on the cast iron Sealing ring seated on the seat ring Sealing ring seated on a seating area
body produced by overlay welding
With flange-mount butterfly valves, a 7.4.2.4 Sealing principles ■ As a rule, eccentrically mounted
distinction is made between the follow- butterfly discs are designed with re-
ing designs: Depending on the type of construction, silient seating. The main seal, in the
different sealing principles and body form of a profile-ring seal, is clamp-
■ Wafer-type: designed for clamping designs are used: ed and fixed to the butterfly disc. The
(Fig. 7.4.2-14), body belonging to this type comes in
Lug-type: designed with threaded ■ With centrically mounted butterfly two different designs of seating sur-
blind holes (Fig. 7.4.2-15), discs, the valve body is designed with face. In one version the profile sealing
U-type: designed for U-form clamping a rubber sleeve. This sealing principle ring seals onto a corrosion-protected
(Fig. 7.4.2-16). also allows the use of a body in the seating surface prefabricated directly
form of a flange-mount butterfly valve. into the body (Fig. 7.4.2-17).
05.2014
In the other version the body has a 7.4.3 Ball valves ■ Firstly there are ball valves con-
stainless steel ring in the seating structed with the ball plug mount-
area of the body (Fig. 7.4.2-18) or Ball valves have robust forms of shell. ed and run directly in the valve
a seating area produced by overlay Ball valves are generally used as shut- body. The drive shaft is not used
welding (Fig. 7.4.2-19). This sealing off elements. They mainly consist of balls for mounting but only for actuation.
principle requires on the one hand a which present a through-hole in the open With this type of construction the seals
mounting of the butterfly disc which position. Figs. 7.4.3-01 and 7.4.3-02 are required for making the valve tight
is at least eccentric and on the other schematic diagrams of the functions of are housed in the body. The ball plug
hand a body in different face-to-face a ball valve. constantly presses the seal into the
lengths. body (Fig. 7.4.3-03).
Resilient seated ball valves are mostly ■ With the other construction principle,
Practical tip: used in the water industry. There are basi- the ball plug is double-eccentrically
With butterfly valves for flanged connec- cally two different construction principles mounted in the body with the use of
tions it must be borne in mind that, in the available: shafts on both sides. In a similar way
open position, the butterfly disc projects to butterfly valves, the ball plug pivots
beyond the end of the body. Particularly in its seat.
with flange-mount butterfly valves, it is
important to check that there is no danger
of collision with adjacent components.
Fig. 7.4.3-01: Bild 7.4.3-02:

Ball valve position: Ball valve position:
fully “open” fully “closed”
05.2014
With this system, the sealing element

is applied to the ball plug. It is only in
contact with the body and/or the body
seating for about the last 10° of the
rotary movement. In all other posi-
tions of the ball plug there is a gap
between body and ball plug.
In practice the construction with

double eccentrically mounted ball plug
(Fig. 7.4.3-04) has proved to be very
well suited in the field of water supply Fig. 7.4.3-03: Fig. 7.4.3-05:
but also in pressure pipelines for con- Cross-section of a ball valve – DN 1000 ball valve for a wastewater pressure
veying wastewater (Fig. 7.4.3-05) and is valve shell with ball plug pipeline
low-maintenance.
To date, ball valves have found their use 7.4.3.1 Double eccentric ball valve
above all in pipelines carrying water at
higher pressure stages of up to 100 bar The basic construction of ball valves used
and higher flow rates of up to 15 m/s. in the water supply industry is based on
The undisrupted flow at the outlet of the positive experiences with double
the ball valve also means that they are eccentric butterfly valves. With just a 3°
predestined for installation in the intake pivoting movement, the ball plug moves
before turbines and pumps. In the double free of the seating on opening. This means
eccentric construction, the ball valve can that the working life of the profile seal is
be used for control functions because of considerably increased.
the behaviour of the pressure loss coef-
ficient ȟ. Fig. 7.4.3-04:
Ball valve with slider crank mechanism and
hand-wheel
05.2014
Advantages and construction features of

a double eccentric ball valve:
■ In the open position (Figs. 7.4.3-06

and 7.4.3-07) the profile ring is
outside the area of flow. The sealing
part, which is not sensitive to deposits,
retains its sealing properties in both
directions of flow.
■ There is a clearance between the out-
side diameter of the ball plug and the
valve body which produces a very Fig. 7.4.3-06: Fig. 7.4.3-08:
smooth flow behaviour in the inter- Ball valve fully open Ball valve half open
mediary position (Fig. 7.4.3-08). This
means that oscillations and vibrations
at high flow speeds and high pres-
sures are avoided.
■ The ball plug, with equalised pres-
sure and the current flowing round it
(Fig. 7.4.3-08), can thus be used for
a flow speed of up to 15 m/s without
problem.
Fig. 7.4.3-07: Fig. 7.4.3-09:

Cross-section of a ball valve – Ball valve closed
fully open position
05.2014
With these construction features, al- 7.4.4 References Chapter 7.4 [7.4-03] DEV-Richtlinie
though the ball valve is not suitable Qualitätsanforderungen und
for flow control and regulation op- [7.4-01] RAL – GZ 662 Prüfvorschriften für emaillierte
erations, it is the ideal isolating valve Güte- und Prüfbestimmungen – Gussarmaturen und Druckrohr-
for higher pressure stages and flow rates Schwerer Korrosionsschutz von formstücke für die Roh- und
(Fig. 7.4.3-09). Armaturen und Formstücken Trinkwasserversorgung
durch Pulverbeschichtung – [Quality requirements and test
The entirely free and undisturbed pas- Gütesicherung regulations for enamelled cast
sage through the valve (Fig. 7.4.3-04) [Quality and test provisions – iron valves and pressure pipe
means that only very slight pressure loss- Heavy duty corrosion protection fittings for untreated and potable
es occur. For this reason this valve is not of valves and fittings by powder water supply]
only used for the flushing and draining coating – 2006-09-27
of main lines but it is also very often in- Quality assurance]
stalled before turbines or as a start-up 2008 [7.4-04] EN 1074-2
valve after pumps (Fig. 7.4.3-05). Valves for water supply –
[7.4-02] DIN 51178 Fitness for purpose requirements
Ball valves are either mechanically, elec- Emails und Emaillierungen – and appropriate verification tests –
trically, pneumatically or hydraulically Innen- und außenemaillierte Part 2: Isolating valves
actuated. Armaturen und Druckrohr- [Armaturen für die Wasser-
formstücke für die Roh- und versorgung –
Trinkwasserversorgung – Anforderungen an die Gebrauchs-
Qualitätsanforderungen und tauglichkeit und deren Prüfung –
Prüfung Teil 2: Absperrarmaturen]
[Vitreous and porcelain enamels – 2000 + A1:2004
Inside and outside enamelled
valves and pressure pipe fittings
for untreated and potable water
supply –
Quality requirements and testing]
2009-10
05.2014
[7.4-05] EN 1171 [7.4-07] DVGW Prüfgrundlage W 363 [7.4-09] EN 736-1

Industrial valves – Absperrarmaturen, Rückfluss- Valves – Terminology –
Cast iron gate valves verhinderer, Be-/Entlüftungs- Part 1: Definition of types of valves
[Industriearmaturen – ventile und Regelarmaturen aus [Armaturen – Terminologie –
Schieber aus Gusseisen] metallenen Werkstoffen für Trink- Teil 1: Definition der Grund-
2002 wasserversorgungsanlagen – bauarten]
Anforderungen und Prüfungen 1995
[7.4-06] DVGW-Arbeitsblatt GW 336-1 [DVGW test specification W 363
Erdeinbaugarnituren – Isolation valves, check valves, air [7.4-10] EN 1503-3
Teil 1: Standardisierung der valves and control valves made Valves – Materials for bodies,
Schnittstellen zwischen erd- from metal for drinking water bonnets and covers –
verlegten Armaturen und distribution systems – Part 3: Cast irons specified in
Einbaugarnituren requirements and testing] European standards
[DVGW worksheet GW 336-1 2010-06 [Armaturen – Werkstoffe für
Stem extensions for underground Gehäuse, Oberteile und Deckel –
installation – [7.4-08] EN 558 Teil 3: Gusseisen, das in Euro-
Part 1: Standardisation of inter- Industrial valves – päischen Normen festgelegt ist]
faces between buried valves and Face-to-face and centre-to-face 2000 + AC:2001
spindle extensions] dimensions of metal valves for use
2010-09 PN and Class designated valves [7.4-11] EN 12516-2
[Industriearmaturen – Industrial valves –
Baulängen von Armaturen aus Shell design strength –
Metall zum Einbau in Rohr- Part 2: Calculation method for
leitungen mit Flanschen – steel valve shells
Nach PN und Class bezeichnete [Industriearmaturen –
Armaturen] Gehäusefestigkeit –
2008 + A1:2011 Teil 2: Berechnungs-
verfahren für drucktragende
Gehäuse von Armaturen aus Stahl]
2004
05.2014
[7.4-12] EN 12516-4
Industrial valves –
Shell design strength –
Part 4: Calculation method for
valve shells manufactured in
metallic materials other than
steel
[Industriearmaturen –
Gehäusefestigkeit –
Teil 4: Berechnungsverfahren
für drucktragende Gehäuse
von Armaturen aus anderen
metallischen Werkstoffen
als Stahl]
2008
05.2014
7.5 Tapping valves
7.5.1 Sealing for supply lines

7.5.2 Tapping valves without operational shut-off
7.5.3 Tapping valves with operational shut-off
7.5.4 Tapping process for tapping valves
05.2014
7.5 Tapping valves In the water supply industry, tapping

valves are usually connected by means
of clamps or straps.
Tapping valves have a large field of
application in the public water supply 7.5.1 Sealing for supply lines
system. They are used as connections
and branches in pipelines as from A seal is required for tapping valves
DN 80. DIN 3543-2 [7.5-01] as well as which are not welded to the pipeline. The
DVGW worksheets GW 336-1 [7.5-02], following types of seals can be used:
GW 336-2 [7.5-03], W 332 [7.5-04], W 333
[7.5-05], W 336 [7.5-06] and W 365 [7.5-07] ■ Profile seals (these directly surround
are to be observed. the area of the tapped opening), Fig. 7.5.2-01:
■ Flat sealing mats (these are pressed Tapping valve without operational shut-off,
Tapping valves are most frequently used onto a large area between the tapping with clamp
for the connection of service pipelines valve and the line).
or branch pipelines. The major advan-
tage of tapping valves is the possibility 7.5.2 Tapping valves without
of producing a later connection with the operational shut-off
supply pipeline system without having
to take the whole system out of operation. Tapping valves without operational shut-
off (Figs. 7.5.2-01 and 7.5.2-02) are only
Additional fields of application: suitable if there is no need for a possibil-
ity of shutting off the flow directly from
■ The production of venting points, the valve.
■ The production of drainage points,
■ The production of measurement and
injection points.
Fig. 7.5.2-02:
Tapping valve without operational shut-off,
with steel strap
05.2014
Basically, tapping valves without op- The purpose of auxiliary shut-off devices
erational shut-off usually consist of the is to prevent the medium being carried
following two components: from escaping when the tapping equip-
ment is being assembled or taken down.
■ Connection piece without operational There are different designs of auxiliary
shut-off, shut-off devices:
■ Clamp (this serves to attach the
connection piece to the supply pipe- ■ as an additional shut-off integrated
line). into the tapping valve for operational
shut-off,
The connection piece may be threaded, ■ an auxiliary and operational shut-off
for example, to enable it to be connected device in one unit,
to other supply pipelines. ■ as a separate and reusable tool (is
installed during the assembly of
7.5.3 Tapping valves with the tapping valve).
operational shut-off
The different types of operational
The purpose of the operational shut-off shut-off devices (Fig. 7.5.3-01) are
device is to allow the flow of water in the covered in DIN 3543-2 [7.5-01].
branch pipeline to be interrupted and,
in case of underground piping systems,
it is usually actuated by means of a stem
extension with an operating key.
Tapping valves with operational shut-off

can be equipped with an auxiliary shut-
off device. Auxiliary shut-off devices are Fig. 7.5.3-01:
used while the pipeline is being tapped. Different types of operational shut-off
device according to DIN 3543-2 [7.5-01] –
d1 is equivalent to diameter of connection
05.2014
In addition, and depending on the field

of application and the diameter of the
pipe, there are numerous types of tapping
valves (Figs. 7.5.3-02 and 7.5.3-03)
Fig. 7.5.3-02: Fig. 7.5.3-03:

Tapping valve for cast iron pipelines Tapping valve for cast iron pipelines
with cast iron bracket with steel strap
05.2014
More tapping valves with different house

connections are shown in Figs. 7.5.3-04,
7.5.3-05, 7.5.3-06, 7.5.3-07 and 7.5.3-08.
Fig. 7.5.3-05: Fig. 7.5.3-07:

Tapping sleeve with steel strap – Tapping sleeve – house connection via push-
house connection via male thread in joint and integral auxiliary shut-off device
Fig. 7.5.3-04: Fig. 7.5.3-06: Fig. 7.5.3-08:

Tapping sleeve with steel strap – Tapping sleeve with integral shut-off device – Tapping valve with steel strap and
house connection with female thread house connection via push-in joint lateral outlet
05.2014
7.5.4 Tapping process for tapping 7.5.4.2 Tapping using separate on different, commercially available
valves tapping equipment tapping valves using an adapter are to
be preferred. Tapping can be done
There are different methods for tapping For tapping purposes, the tapping device manually or with motor-driven equip-
the main pipeline: is fixed to the tapping valve by means of a ment (e.g. compressed air or electric
■ Tapping by means of an integral threaded or flanged connection. Universal drive) (Fig.7.5.4-02).
milling tool or punch, tapping devices which can be mounted
■ Tapping using separate tapping
equipment.
The geometry and the material for drills,

milling tools and punches depend on
the material of the supply pipeline to
be tapped. For pipelines in ductile cast
iron and grey cast iron, twist drills are
used as well as bore-type cutters. When
using hole cutters it is important to make
sure that the disk of pipe wall cut out
remains in the cutter after completion.
7.5.4.1 Tapping by means of an

integral milling tool or punch
With this type of tapping valve the milling

tool or punch is directly integrated into
the tapping valve and stays there after the
tapping process (Fig. 7.5.4-01).
Fig. 7.5.4-01: Fig. 7.5.4-02:
Tapping valve with integrated Bore-type Example of tapping equipment –
cutter manual or motor-driven
05.2014
7.5.5 References Chapter 7.5 [7.5-03] DVGW-Arbeitsblatt GW 336-2 [7.5-06] DVGW-Arbeitsblatt W 336
Erdeinbaugarnituren – Wasseranbohrarmaturen;
[7.5-01] DIN 3543-2 Teil 2: Anforderungen und Anforderungen und Prüfungen
Anbohrarmaturen aus Prüfungen [DVGW worksheet W 336
metallischen Werkstoffen [DVGW worksheet GW 336-2 Tapping valves for water –
mit Betriebsabsperrung – Stem extensions – Requirements and testing]
Maße Part 2: Requirements and 2004-06
[Metallic tapping stop valves – test methods]
Dimensions] 2010-09 [7.5-07] DVGW-Arbeitsblatt W 365
1984-05 Übergabestellen
[7.5-04] DVGW-Arbeitsblatt W 332 [DVGW worksheet W 365
[7.5-02] DVGW-Arbeitsblatt GW 336-1 Auswahl, Einbau und Betrieb von Transfer points]
Erdeinbaugarnituren – metallischen Absperrarmaturen 2009-12
Teil 1: Standardisierung der in Wasserverteilungsanlagen
Schnittstellen zwischen erd- [DVGW worksheet W 332
verlegten Armaturen und Selection, installation and
Einbaugarnituren operation of metallic isolation
[DVGW worksheet GW 336-1 valves in water distribution
Stem extensions – installations]
Part 1: Standardisation of inter- 2006-11
faces between underground
valves and stem extensions] [7.5-05] DVGW-Arbeitsblatt W 333
2010-09 Anbohrarmaturen und Anbohr-
vorgang in der Wasserversorgung
[DVGW worksheet W 333
Tapping valves and tapping
process in water supply]
2009-06
05.2014
05.2014
7.6 Control valves
7.6.1 General
7.6.2 Areas of application
7.6.3 Designs
7.6.4 Operating limits
08.2015
7.6 Control valves The main areas of use of control valves Valves using an external power source
are:
■ Water pumping for reservoirs and Valves which are operated by an exter-
7.6.1 General dams, nal power source are moved to the
■ Bypass pipelines for hydropower required regulating position by drive
Control valves are special valves con- plants, mechanisms such as a hand wheel, elec-
structed specifically for performing con- ■ Long-distance pipelines, tric actuators and pneumatic or hydrau-
trol functions in the water supply industry. ■ Water treatment in waterworks, lic drives. With smaller dimensions the
In contrast to gate valves and butterfly ■ Water supply to pumping stations, usual construction is a seating sur-
valves, which are mainly used as shut- ■ Controlling the intake of elevated tanks, face arranged vertically to the pipe axis
off devices in pipeline systems, control ■ Drinking water networks, (Fig. 7.6.1). With this type of design the
valves meet the particular requirements ■ Cooling water circuits for industrial valve is referred to as a piston valve.
of controlled operations. Control valves and power station applications.
are predominantly used for applications
where volume flow rates need to be accu- Another example of use is controlling
rately metered or water pressure has to be the air supply to aeration basins in sew-
precisely regulated or reduced. To achieve age treatment plants. In this case con-
this, control valves can be operated in any trol valves are also used with air as the
position between fully open and closed. medium because their control character-
istics allow for better metering than knife
7.6.2 Areas of application gate valves or waver-type butterfly valves
(Chapter 7.6.3.5).
Control valves are suitable both for puri-
fied and drinking water and for cooling 7.6.3 Designs
water at temperatures which are custom-
arily as high as 50° C. Control valves are basically divided into
two different groups. One group requires
an external power source and the other
is by own-medium controlled. Fig. 7.6.1:
Piston valve
08.2015
A particular form of this is the plunger

valve in which the hydraulic cylinder in
the pipe axis moves towards the seating
surface (Fig. 7.6.2). Plunger valves are
used e.g. for the control of very high vol-
umes of water in the bottom outlet of res-
ervoirs (Fig. 7.6.3).
Own-medium controlled valves
Own-medium controlled valves draw

the energy for their movement from the
pressure in the pipeline. These valves Fig. 7.6.2: Fig. 7.6.4:
include both pilot-operated control Plunger valve Pilot-operated control valve
valves (Fig. 7.6.4) and direct operated
valves (Fig. 7.6.5).
7.6.3.1 Piston valves
With piston-type control valves the flow

inside the valve is diverted. The hydraulic
piston moves perpendicular to the pipe-
line. This type of construction is mainly
used in sizes up to DN 150. The valve
consists of a valve body, a mounting
flange, a top column, a protective cover
and the interior parts with valve piston, Fig. 7.6.3:
control cylinder and stem. Plunger valve DN 800, PN 10,
with aeration as a bottom outlet valve in Fig. 7.6.5:
the wall of a dam Direct operated control valve
08.2015
With the pressure-relieved valve pis- Piston valves are mainly operated by
ton the power required for operating the electric drive mechanisms (Fig. 7.6.6).
valve is largely independent of operating However hand-wheels are also used
conditions. Pressure and flow rate are (Fig. 7.6.7) as well as, for container
affected by the position of the interior inlets, levers with floats (Fig. 7.6.8).
parts and the control cylinder. The seal
on the valve seat is produced by O-rings 7.6.3.2 Plunger valves
or securely fitted profile sealing rings.
The plunger valve (Fig. 7.6.9) is a
straight form control valve with a flow
cross-section which is annular in every
position.
Fig. 7.6.7:
Piston valve with hand-wheel
Fig. 7.6.6: Fig. 7.6.8: Fig. 7.6.9:

Piston valve with electric drive Piston valve with float Plunger valve
08.2015
Inside the valve body the plunger (also Large numbers of plunger valves are Internal parts are usually entirely made
called the piston) is moved by a crank in use around the world, including of stainless steel. A major advantage of
mechanism in the direction of flow axial some valves in pressure stage PN 160 the plunger valve is the fact that the
to the seating surface of the valve. (Fig. 7.6.10). The compactly designed plunger runs through stainless longi-
body is generally produced in high-qual- tudinal guides hard-faced or screwed to
Plunger valves are regulating devices ity ductile cast iron. the valve body (Fig. 7.6.11). This pro-
which generate different pressure drops vides an optimum guide for the plunger
in piping systems by continuously con- In some particular applications plunger and thus ensures free of play sliding
stricting the flow at the valve seat accord- valves have also been produced from with extremely low actuation forces at
ing to the plunger setting. Depending on special materials such as high-grade the same time.
the application, the nominal size of the steel.
valve must be sufficiently dimensioned The shape of the outlet of the plunger
to be able to achieve the greatest rate valve is variable (Figs. 7.6.12 to 7.6.14)
of flow required with the lowest pres- and, like a kind of construction kit, it
sure difference and to relieve maximum allows the valve characteristics to be
pressure differences over the long term changed. This is a very important advan-
without damage. Additionally no damage
whatsoever must be caused by vibrations
or cavitation effects along the course of
travel to the piping system downstream
or to the structure as a whole.
In recent decades the reliable plunger

valve has been further developed for
control tasks in water supply systems.
Current plunger valves are more or less
universally available in nominal sizes
DN 150 to DN 2000 in pressure ratings
PN 10 to PN 63. Fig. 7.6.10: Fig. 7.6.11:
Plunger valve PN 160 Longitudinal guides of the plunger valve
08.2015
tion as a pressure reduction valve. These

valves have a chamber separated by a
diaphragm which forms the basis for the
hydraulic control of the valve position.
Because of the differences in surface at
the valve seat and the diaphragm, at the
same pressure a force is produced on
these surfaces which closes the valve.
This state exists if the pilot valve is com-
pletely closed (Fig. 7.6.15).
When the pilot valve is open water flows

Fig. 7.6.12: Fig. 7.6.14: through the control circuit. This causes
Slotted cylinder Special forms a pressure drop at an orifice plate, the
pressure in the diaphragm chamber and
hence the closing force decrease and the
tage of the plunger valve as it means that main valve opens (Fig. 7.6.16).
even after installation in the pipeline it
can be adapted to altered operating con- In the control mode the pilot valve opens
ditions. according to its function (e.g.: pressure
reduction valve or overflow valve). The
7.6.3.3 Pilot-operated valves main valve both opens and closes due
to pressure differences in the dia-
Pilot-operated control valves perform phragm chamber. The valve regulates
the widest variety of control functions; according to the demands of the pilot
they work in almost all applications valve. Where there is a balance of forces
without an outside energy source. The between the seat and the diaphragm,
most common type of design for pilot-op- the valve remains in its current position
Fig. 7.6.13: erated control valves are the so-called (Fig. 7.6.17).
Perforated cylinder diaphragm-operated valve in its func-
08.2015
Fig. 7.6.15: Fig. 7.6.17:

Main valve and pilot valve closed Main valve and pilot valve going into control mode
Fig. 7.6.16: Fig. 7.6.18:

Main valve and pilot valve completely open Pilot-operated plunger valve driven by its own medium
08.2015
With pilot-operated control valves there pressure (P2) (Fig. 7.6.19). The mov- the valve. By preloading the spring
are also applications in which plunger ing parts of the valve are pressure- accordingly, the desired value for the
valves are used. In this case special compensated as regards the forward back pressure can be set or changed.
drives are necessary for use in water pressure which means that this has
(Fig. 7.6.18). no effect on the control function of
7.6.3.4 Direct-operated
control valves
Direct-operated control valves (Fig. 7.6.5)

are predominantly used for pressure
reduction. They must be capable of
converting a fluctuating inlet pressure
to a lower supply pressure regardless
of flow rate. Direct-operated, spring-
loaded pressure reduction valves are
very suitable for this and offer an
economically interesting solution if
no high requirements are set for
control accuracy. In contrast to pilot-
operated pressure reduction valves,
the back pressure set falls as the flow
rate rises. With a pressure difference
of more than 3 bar between forward
pressure and back pressure the use of
these valves is no longer worth rec-
ommending because of the possibil-
ity of cavitation occurring. The valves
are equipped with adjustable com- Fig. 7.6.19:
pression springs for setting the back Construction of the valve
08.2015
If the back pressure drops below the set 7.6.4 Operating limits
value, the valve opens. When it increases
again it then closes. If there is a balance The maximum operating temperatures
between the force on the valve plate and and operating pressures specified in the
the spring force, then the valve stays in manufacturer’s technical documenta-
an intermediate position. tion should not be exceeded. The closed
valve should only be loaded up to the
7.6.3.5 Special applications maximum allowable pressure Ps,max. This
may be different from the PN. In com-
The use of valves for controlling common parlance, PN refers to the nominal
pressed air is one possible application. pressure. However the definition accord-
Special gate valves can also be used ing to EN 1333 [7.6-02] states that the
for regulating the air supply to aer- PN is merely an alphanumerical param-
ation tanks in sewage treatment plants, eter to ensure that pipeline parts can be
such as knife gate valves (Figs. 7.6.20 connected with each other.
and 7.6.21) or butterfly valves, since the
operating pressures to be governed are The maximal allowable flow velocity
very low. With operating pressures above is based on EN 1074-1 [7.6-03]. Over
0.5 bar the requirements of the pressure and above this and regardless of the
equipment directive [7.6-01] are to be Fig. 7.6.20: Fig. 7.6.21: pressure stage, control valves should
observed. Knife gate valve with Knife gate valve be operated with a flow speed of up to
perforated aperture with control 5 m/s. These are considered as reference
orifice values at full operating pressure. If the
flow speed is any higher, this can result
in turbulence in the valve and even cav-
itation. Exceptions are use as the end
valve in the bottom outlets of reservoirs
and dams.
08.2015
When it comes to selecting the correct 7.6.5 References Chapter 7.6 [7.6-03] EN 1074-1
nominal diameter (DN) there is a signifi- Valves for water supply –
cant phrase in DVGW technical infor- [7.6-01] DIRECTIVE 97/23/EC Fitness for purpose requirements
mation sheet W 335 [7.6-04]: “With all DIRECTIVE 97/23/EC OF THE and appropriate verification tests –
control valves, correct dimensioning does EUROPEAN PARLIAMENT AND Part 1: General requirements
not depend on the nominal diameter of OF THE COUNCIL of 29 May 1997 [Armaturen für die Wasserver-
the pipeline but on the flow rate and on the approximation of the laws sorgung –
the operating pressures”. of the Member States concerning Anforderungen an die Gebrauchs-
pressure equipment tauglichkeit und deren Prüfung –
For this reason it is important to have „Pressure Equipment Teil 1: Allgemeine Anforderungen]
the equipment data to hand when select- Directive (PED)“ 2000
ing a control valve so that suitability can [Richtlinie 97/23/EG
be checked against the manufacturer’s des europäischen Parlaments [7.6-04] DVGW-Merkblatt W 335
technical data. und des Rates vom 29. Mai 1997 Druck-, Durchfluss- und Niveau-
zur Angleichung der Rechts- regelung in Wassertransport und
Another important operating limit for vorschriften der Mitgliedstaaten -verteilung
control valves is cavitation. A cavitation über Druckgeräte – [DVGW technical information
study needs to be carried out for each „Druckgeräterichtlinie (DGRL)“] sheet W 335
application so that the control valve can 1997-05-29 Pressure, flow and level control
perform sustainably and without damage in water transport and water
(Chapter 7.3). [7.6-02] EN 1333 distribution]
Flanges and their joints – 2000-09
Pipework components –
Definition and selection of PN
[Flansche und ihre Verbindungen –
Rohrleitungsteile –
Definition und Auswahl von PN]
2006
08.2015
7.7 Air valves
7.7.1 General
7.7.2 Air release
7.7.3 Aeration
7.7.4 Selection of air valves
08.2015
7.7 Air valves The gas bubbles trapped in pipelines pressures and rising temperatures. This
(air, carbon dioxide etc.) reduce the free means that air bubbles (Fig. 7.7.1) tend
cross-section of flow, increase the pres- to collect at
7.7.1 General sure loss in the pipeline and in some cases ■ static high points
cause unwanted pressure surges. (L 1, L 3, L 6, L 7) and
According to DVGW technical information ■ hydraulic high points (L 2, L 4).
sheet W 334 [7.7-01] the accumulation of As a rule, air valves are installed in shafts Hydraulic high points sometimes occur
air in drinking water pipelines can lead to or buildings. They can also be installed on in certain operating situations and are
considerable dynamic pressure changes pipelines running above ground. However transitory in nature.
on account of the different density of there are also designs which are suitable
the two types of medium. It is therefore for buried installation in the form of air 7.7.3 Aeration
important that pipelines are kept as free valve sets.
of air as possible. Aeration by means of automatic air valves
7.7.2 Air release is necessary in the following cases:
Air can get into pipelines in a number of ■ the draining of sections of pipeline,
ways, for example: Air release is not necessary in normal ■ where negative pressures are pro-
■ dissolved in the water, network operation as branches in the duced, to protect the pipeline (for
■ present in empty or drained pipeline, hydrants and above all house example behind pipe burst safety
pipelines, connections automatically provide devices) (Fig. 7.7.1).
■ sucked in at high points, venting. Even with long-distance pipe-
■ sucked in from a sump pit, lines, no forced air release is required 7.7.4 Selection of air valves
■ introduced via surge vessels. if the speed of flow is sufficient to carry
the air bubbles away, even when the Most air valve designs (Fig. 7.7.2) are
To protect the pipeline against unaccep- pipeline runs along a downward gra- based on the float principle with and
table pressure fluctuations and ensure dient. In cases where disruptive accu- without lever reinforcement.
that it functions without problem, air mulations of air can form, automatically
release or air admission is necessary for operating air release valves are used.
the equipment in the pipeline depending Air is mainly to be expected in water
on operating status. pipelines in places where certain con-
ditions are present, such as decreasing
08.2015
Fig. 7.7.1: Fig. 7.7.2:

Installation locations of air valves in a pipeline Air valves
08.2015
7.7.4.1 Float principle
Large diameter float Small diameter float The air valve can be effective for both
main ventilation and operational air
The float is raised by the operating The float is raised by the operating release. This state occurs for example
medium and always stays closed under medium and closes the nozzle (Fig. 7.7.3). when starting to fill a pipeline with water.
pressure even when air accumulates It opens again if air bubbles accumulate
during operation (Figs. 7.7.3 and 7.7.4). in the body during operation (Fig. 7.7.4).
Main venting Operational venting Main venting Operational venting
Larger Smaller Larger Smaller

float float float float
Fig. 7.7.3: Fig. 7.7.4:

Air valve with large and small float in the open state The valve is tightly closed.
Both main venting and operational venting are closed because there
is no accumulation of air in the pipeline
08.2015
7.7.4.2 Valve lever function
In the normal operating state the float

is in its “up” position. The nozzle valves
are closed (Fig. 7.7.5, left). In case of
a negative pressure wave the float
drops and the nozzle valves open. Air
in the pipeline is sucked out through
the nozzles. The liquid level drops accord-
ingly (Fig. 7.7.5, centre). As soon as the
pressure wave goes back to positive pres-
sure, the central valve plate closes the
large nozzle (Fig. 7.7.5, right).
Fig. 7.7.6 shows a section through an air Fig. 7.7.5:

valve with valve lever function, which can The float mechanism and valve lever function
be used in valves for water and sewage
pipelines under pressure (Fig. 7.7.7). Left: The valve is closed. The float is positioned at the top.
7.7.4.3 Lever principle Middle: Under negative pressure the float drops down. The nozzle valves open and air is
introduced into the pipeline. The liquid level falls accordingly.
A float is attached to a lever which in
turn is mounted on an articulated joint. Right: As soon as the pressure wave goes back to positive pressure, the central valve plate
The lever performs a pivoting movement closes the large nozzle. In this process, the free-moving valve plate acts like a non-
(Fig. 7.7.8). return valve. The air that is drawn in by this action can now only escape slowly and
in a controlled way through the two small nozzles. The two columns of water are
slowed down and slowly merge with each other. An abrupt collision is avoided
along with the effects resulting from this.
08.2015
Operational venting
Valve tappet
Valve lever Valve Valve plate
Fig. 7.7.6:
Sectional view of a single chamber valve with valve lever for small and large air volumes
Lever
Float
Fig. 7.7.8:
Different lever principles for air valves –
the illustration shows the operational
venting process. The float is attached to a
lever. A valve tappet on the lever closes the
venting hole under positive pressure. Under
negative pressure the float drops and the
hole is opened. Air can escape.
Fig. 7.7.7:
Air valve with lever function for sewage pipelines under pressure
08.2015
7.7.4.4 Dynamic pressure brake
A movable gate is mounted in the flow

path of the valve body. When a certain
flow velocity is exceeded the medium
pushes the gate into the seat of the valve.
This only leaves a reduced cross-section
free. This dynamic pressure brake is used
to protect the air valve from pressure
surges (Fig. 7.7.9).
7.7.4.5 Air valve with slide gate

Spring
So that the air valve can be isolated
Dynamic
from the pipeline for overhaul work, a pressure
gate valve is often installed before the brake
air valve. This means that the air valve
can be dismantled or cleaned even while
the main pipeline remains in operation
(Fig. 7.7.10). A soft-seated gate valve Fig. 7.7.9: Fig. 7.7.10:
is best suited to this function as it Air valve with dynamic pressure brake Air valve with gate valve
allows free passage.
08.2015
7.7.4.6 Air valve 7.7.4.7 Air valve 7.7.4.8 Operating characteristics

with air-intake stop with air-release stop
If air is given off when filling pipelines
In order to prevent air inflow with small In order to prevent air outflow with small via venting valves, the speed of filling
air valves and only ensure air release air valves and only allow the admission must be kept as slow as possible. The
functions, air valves with a device to stop of air, air valves with air-release stop are dreaded pressure surge (Joukovsky
air-intake are often used (Fig. 7.7.11). often used (Fig. 7.7.12). The main appli- surge), which occurs if the float of the
The main application for these valves cation for these valves is in pressure pipe- venting valve slams the valve seat shut
is in suction pipelines for mechanically lines for drinking water or mechanically at the end of the filling process, must
purified water or in the drinking water purified water. remain below the allowable maximum
industry. operating pressure (PMA = maximum
hydrostatic pressure, including surge,
that a component can withstand from
time to time in service [7.6-02]). As a rule
the allowable pressure surge is limited
Air-intake to 3 bar for safety reasons. According
stop to DVGW technical information sheet
W 334 [7.6-01] the filling speed is limited
to 0.25 m/s.
The size and number of venting valves

is to be determined according to the
nominal size of the pipeline, the fill-
Air-release ing volume, the topography and the
stop maximum allowable air speed in the
narrowest cross-section of the venting
valve (main venting).
Fig. 7.7.11: Fig. 7.7.12:
Air valve with air-intake stop Air valve with air-release stop
08.2015
As regards aeration parameters it is gen- 7.7.4.10 Air valves for small The valve is fitted with an internal
erally assumed that the pressure in the volumes of air thread and can be mounted directly on
pipeline should not be below the abso- the pipeline (Fig. 7.7.15). Valves of this
lute pressure of 0.8 bar (0.2 bar negative Air valves are available for the admis- kind are mainly used for installation in
pressure). According to experience, the sion and release of small volumes of air. buildings.
limits are met with sufficient certainty if
the air inlet speed in the correctly dimen-
sioned aerator is no more than 80 m/s.
Also, the speed of 80 m/s should not be
exceeded for reasons of noise prevention.
7.7.4.9 Air valves for buried

installation
In general, air valves are installed in

shafts. Their construction is described
in DVGW worksheet W 358 [7.7-03].
In order to save on construction work
for the shaft, air valve sets are used
(Figs. 7.7.13 and 7.7.14). On the left
is an illustration of an air valve which
releases air underground via a surface
box. The figure on the right shows an
above ground design.
Fig. 7.7.13: Fig. 7.7.14:

Air valve for buried installation Air valve for buried installation –
above ground design
08.2015
[7.7-01] DVGW-Merkblatt W 334

Be- und Entlüften von
Trinkwasserleitungen
[DVGW technical information
sheet W 334
Aeration and air release for
drinking water pipelines]
2007-10
[7.7-02] EN 805
Water supply –
Requirements for systems and
components outside buildings
Fig. 7.7.15: [Wasserversorgung –
Air valve for small volumes of air with internal threaded connection Anforderungen an Wasserver-
sorgungssysteme und deren Bau-
teile außerhalb von Gebäuden]
2000
[7.7-03] DVGW-Arbeitsblatt W 358

Leitungsschächte und Auslauf-
bauwerke
Manholes and outlet structures
for piping systems]
2005-09
08.2015
7.8 Hydrants
7.8.1 Field of use

7.8.2 Materials
7.8.3 Pillar hydrants
7.8.4 Underground hydrants
7.8.5 Industrial hydrants
05.2014
7.8 Hydrants Possible fields of application for hydrants: More far-reaching regulations (specific
■ Taking off extinguishing water, to individual countries) can be found
■ Ventilating pipelines, in standards EN 14384 [7.8-03] and
7.8.1 Field of use ■ Flushing piping networks, particu- EN 14339 [7.8-04].
larly in end sections for reasons
A hydrant is part of the central ex- of hygiene, As it must be assumed that the users of
tinguishing water supply for towns ■ Producing temporary network hydrants will have different qualifica-
and communities. It makes firefight- connections, tions, high requirements are set for
ing possible but it also helps public ■ Emergency water take-off, construction, ease of operation, ease of
users (e.g. road maintenance and ■ Short-term water supply, e.g. for maintenance and operational safety:
urban departments) and private users construction purposes, funfairs, etc.,
(e.g. street cleaning companies and ■ Bridging for emergency supplies, 1. Low flow resistance:
open-air festival organisers) to take water ■ Drainage of pipelines, ■ A hydrodynamically efficient con-
from the public water supply network ■ Leak detection. struction of the shell and valve body,
(communal water supply). In addition, ■ Minimum flow rate at 1 bar pressure
hydrants prove to be very helpful for Depending on the position of the outlet difference (kV value):
operational measures such as the opening, a distinction needs to be drawn pillar hydrants as per Table 7.8.-01,
flushing and ventilation of piping between underground and pillar hydrants. underground hydrants to EN 14339
networks. They are the only valves Pillar hydrants are preferable for fire- [7.8-04]
which allow drinking water to be taken fighting purposes; they are easy to find, - 60 m³/h for DN 80 and
directly from the supply network. easily accessible and ready for operation - 75 m³/h for DN 100.
at all times. However, in densely built-up
DVGW worksheet W 331 [7.8-01] covers areas and in narrow streets with heavy 2. Pressurised water tightness:
the choice, installation and operation traffic, underground hydrants have to be ■ For hydrants with automatic drainage,
of hydrants and DVGW worksheet used and their location must be identified the main shut-off device must be
W 405 [7.8-02] deals with the provision with indication plates. closed before the drainage device
of extinguishing water. opens or the drainage device must
be closed before the main shut-off
device opens.
05.2014
Table 7.8.-01:
Minimum flow rate values kV for pillar hydrants as per Table 4 of EN 14384 [7.8-03]
Number and size of outlets to be tested
Hydrant 1 x 37,5 2 x 37,5 1 x 50 2 x 50 1 x 65 2 x 65 1 x 100 2 x 100 1 x 150 2 x 150

DN mm mm mm mm mm mm mm mm mm mm
80 und
30 60 40 60 80 140 160 a) – – –
100
150 – – – – 80 140 160 280 300 –
a)
Does not apply to DN 80
– Combination of DN/size of outlet not permissible
Table 7.8.-02: 3. Low residual water volume: 4. Protection from roots:

Maximum residual water volume after ■ Permissible residual water volumes ■ The drainage opening must be
draining pillar and underground hydrants for automatic drainage devices in protected against root penetration,
accordance with EN 14384 [7.8-03] e.g. with a 50 mm dry section beneath
Maximum residual water volume after and EN 14339 [7.8-04] with refer- the drainage point as per DVGW test
draining as per EN 1074-6 [7.8-05] ence to EN 1074-6 [7.8-05] as per specification VP 325 [7.8-06].
Table 7.8-02 for pillar and under-
DN Residual water max. ml
ground hydrants,
65 100
80 100
100 150
150 200
05.2014
5. Actuating the main shut-off device: 7.8.2 Materials 7.8.3 Pillar hydrants
■ In accordance with EN 1074-6
[7.8-05] the following maximum ■ Valve shell parts are generally Pillar hydrants used in the public water
actuation torque values apply: constructed in spheroidal graphite supply system must meet the require-
- DN 65: 85 Nm, cast iron to EN 1563 [7.8-07] and steel. ments of EN 14384 [7.8-03], EN 1074-1
- DN 80: 105 Nm, In accordance with EN 14384 [7.8-03], [7.8-08], EN 1074-6 [7.8-05] and other
- DN 100: 130 Nm, other materials are also permissible. national regulations where applicable
- DN 150: 195 Nm. For example, upper sections in alumin- such as DVGW worksheet W 386 (P)
ium are also available (Fig. 7.8.2-01). [7.8-09].
6. Protection of the stem seal: ■ PUR (polyurethane) and EPDM (eth-
■ Protection against the ingress of sur- ylene propylene diene monomer) 7.8.3.1 Construction
face water and dirt above the seal are used as materials for shut-off
(O-rings). elements. ■ Pillar hydrants project above ground
level and have a main shut-off valve
7. No deadwater spaces: and one or more water take-off points.
■ All parts which come into contact
with drinking water must be within ■ Pillar hydrants consist of two parts:
the flow zone during opening or when the bottom section of the hydrant
in the open position. which contains the main valve and is
installed underground plus the top
8. Internal and external coating: part of the hydrant which is gener-
■ Internal and external coating is ally flanged onto the bottom part at
covered in Chapter 7.2. ground level.
Fig. 7.8.2-01:
Pillar hydrant – upper part in aluminium
05.2014
■ Pillar hydrants are equipped with a

predetermined breaking point which
is normally located in the connection
flange between the top and bottoms
parts of the hydrant. This protects the
bottom part of the hydrant and the
pipeline to which it is connected.
■ The majority of pillar hydrants are

in nominal sizes DN 80 and DN 100,
designed for a allowable operating
pressure PFA = 16 bar. They have
a vertical or horizontal inlet with a
flanged, push-in or spigot end joint
(Figs. 7.8.3-01 and 7.8.3-02).
■ The pipe covering usually varies

between 1.25 m and 1.5 m. This
ensures that, even with a minimum
volume of residual water, the main
valve cannot freeze up. Shallower
pipe coverings down to a minimum
of 0.2 m can be found in tunnels with Fig. 7.8.3-01: Fig. 7.8.3-02:
restricted space (Figs. 7.8.3-03 and DN 100 pillar hydrant – Design examples – DN 100 pillar hydrant –
7.8.3-04). 2 B outlets 2 B outlets, 1 A outlet with flanged joint
05.2014
Fig. 7.8.3-03: Fig. 7.8.3-04: Fig. 7.8.3-05:

Tunnel hydrant with adjustable height, Tunnel hydrant with a hand-wheel DN 100 pillar hydrants with flanged joint –
inlet bend and assembly base as the operating element height-adjustable bottom part
■ The bottom part of hydrants is nor- In Switzerland, the majority of hydrants

mally designed for a fixed depth of have height-adjustable bottom parts
pipe cover. (Fig. 7.8.3-05).
05.2014
■ Pillar hydrants differ in the type

of protection of their B outlets –
without drop jacket (Fig. 7.8.3-06) or
with drop jacket (Figs. 7.8.3-07 and
7.8.3-08).
Fig. 7.8.3-06: Fig. 7.8.3-07: Fig. 7.8.3-08:

Cross-section of Examples of DN 100 pillar hydrants Pillar hydrant with
a DN 100 pillar with 2 B outlets and 1 A outlet open drop jacket –
hydrant with 2 B with closed drop jacket 2 B outlets and 1 A
outlets and 1 A outlet
outlet with stain-
less steel column
05.2014
■ Fig. 7.8.3-09 shows a pillar hydrant 7.8.4 Underground hydrants

without a drop jacket and with B out-
lets which can be shut off. Underground hydrants used in public
■ Operation is by means of a hydrant water supply systems must meet the
key which is specific to each country. requirements of EN 14339 [7.8-04],
■ Pillar hydrants can have single or EN 1074-1 [7.8-08], EN 1074-6 [7.8-05]
double shut-off devices. The double and other national regulations where
shut-off version is usually a ball or applicable such as DVGW worksheet
cone design. W 386 (P) [7.8-09].
7.8.3.2 Connection options 7.8.4.1 Construction
Pillar hydrants are used in different The majority of underground hydrants

piping and pipe joint systems. Different are in nominal sizes DN 80 and DN 100.
joints are available for these: They are usually housed in surface boxes
in the road as per DIN 4055 [7.8-10]
■ Hydrant with flanged joint, and can be operated from there. A stand-
■ Hydrant with spigot ends and various pipe according to DIN 14375-1 [7.8-11]
restrained joint systems (Novo SIT®, is always required in order to take off
TYTON SIT PLUS®, BLS®, VRS®-T, water and this is connected to the locking
BAIO®, vonRoll HYDROTIGHT, claw. In addition to the locking claw
threaded sockets or similar). connection there are also different types
of connection specific to the individual
Fig. 7.8.3-09: region; in Switzerland, for example,
The upper part of a pillar hydrant without there are also round-thread connections.
drop jacket and with B outlets which can
be shut off
05.2014
The main shut-off device is actuated by

applying a hydrant key. The design of the
hydrant key varies from region to region, Square cap
e.g. in accordance with DIN 3223 [7.8-12].
Locking claw cover
Underground hydrants consist of a one
or two-part shell, also referred to as a
jacket pipe or standpipe, the lower part Self-closing locking claw
of which houses the shut-off device. The
opening movement may be against or Actuating rods
with the direction of flow. Underground
hydrants can have single or double
shut-off devices. The double shut-off
version is usually a ball or cone design
(Figs. 7.8.4-01 and 7.8.4-02). Main shut-off device
The double shut-off version has the Automatic draining

advantage that the shut-off device device
including its drive elements can be
replaced in the surface box with the line Double shut-off device
under full pressure. When hydrants with
a double shut-off system are used there
is no need for an up-stream gate valve.
Fig. 7.8.4-01: Fig. 7.8.4-02:
DN 80 underground hydrant – double shut-off, DN 80 underground hydrant –
opening against the direction of flow – coating with double shut-off, opening
epoxy resin powder against the direction of flow –
fully enamelled
05.2014
As underground hydrants are usually 7.8.5 Industrial hydrants

located in surface boxes there is the risk
that, with insufficient maintenance and The field of application for industrial
in unfavourable locations (road sub- hydrants, as the term suggests, in indus-
sidence) road grit, stones or other small trial plants, power stations, airports
objects may get into the shell and damage and any locations where large volumes
the shut-off device. In order to minimise of extinguishing water are required
this risk, two systems are used in the (Figs. 7.8.5-01 and 7.8.5-02).
area of the locking claw: sealing flap
and cover.
7.8.4.2 Connection options
Underground hydrants are used in

different piping and pipe joint systems.
Different joints are available for these:
■ Hydrant with flanged joint,
■ Hydrant with spigot ends and various
restrained joint systems (Novo SIT®,
TYTON SIT PLUS®, BLS®, VRS®-T,
BAIO®, vonRoll HYDROTIGHT,
threaded sockets or similar).
Fig. 7.8.5-01: Fig. 7.8.5-02:

Industrial hydrant for the supply of Industrial hydrant for the supply of
extinguishing water in industrial plants extinguishing water in industrial plants
05.2014
Industrial hydrants have a DN 150,

PN 16 flanged joint, 2 upper B outlets
and, characteristically for industrial
hydrants, 2 lower A outlets. There are
industrial hydrants with or without drop
jackets (Figs. 7.8.5-03 and 7.8.5-04).
Industrial hydrants are usually of the

same construction as pillar hydrants.
A particular design is the industrial
hydrant with a ball valve (Chapter 7.4.3)
as the shut-off device (Fig. 7.8.5-05).
Fig. 7.8.5-03: Fig. 7.8.5-04: Fig. 7.8.5-05:

Industrial hydrant with DN 150 ball valve Industrial hydrant with DN 150 ball valve A ball valve as the shut-off device for a
and without drop jacket and drop jacket DN 150 industrial hydrant
05.2014
7.8.6 References Chapter 7.8 [7.8-05] EN 1074-6 [7.8-08] EN 1074-1

Valves for water supply – Valves for water supply –
[7.8-01] DVGW-Arbeitsblatt W 331 Fitness for purpose require- Fitness for purpose require-
Auswahl, Einbau und Betrieb ments and appropriate verifi- ments and appropriate
von Hydranten cation tests – verification tests –
[DVGW worksheet W 331 Part 6: Hydrants Part 1: General requirements
Selection, installation and [Armaturen für die Wasserver- [Armaturen für die Wasser-
operation of hydrants] sorgung – Anforderungen versorgung –
2006-11 an die Gebrauchstauglichkeit Anforderungen an die
und deren Prüfung – Gebrauchstauglichkeit
[7.8-02] DVGW-Arbeitsblatt W 405 Teil 6: Hydranten] und deren Prüfung –
Bereitstellung von Löschwasser 2008 Teil 1: Allgemeine Anfor-
durch die öffentliche Trink- derungen]
wasserversorgung [7.8-06] DVGW-Prüfgrundlage VP 325 2000
[DVGW worksheet W 405 Hydranten in der Trinkwasser-
Provision of extinguishing verteilung – Anforderungen [7.8-09] DVGW-Prüfgrundlage W 386
water by the public drinking und Prüfung Entwurf Hydranten in der
water supply system] [DVGW test specification VP 325 Trinkwasserverteilung –
2008-02 Hydrants in drinking Anforderungen und Prüfungen
water distribution – [DVGW test specification W 386
[7.8-03] EN 14384 Requirements and testing] Draft Hydrants in drinking
Pillar fire hydrants 2008-01 water distribution –
[Überflurhydranten] Requirements and testing]
2005 [7.8-07] EN 1563 2014-01
Founding –
[7.8-04] EN 14339 Spheroidal graphite cast irons
Underground fire hydrants [Gießereiwesen –
[Unterflurhydranten] Gusseisen mit Kugelgraphit]
2005 2011
05.2014
[7.8-10] DIN 4055

Wasserleitungen; Straßenkappe
für Unterflurhydranten
[Water pipelines; valve box for
underground hydrants]
1992-02
[7.8-11] DIN 14375-1

Standrohr PN 16; Standrohr 2 B
[Double outlet standpipes,
nominal pressure 16]
1979-09
[7.8-12] DIN 3223

Betätigungsschlüssel für
Armaturen
[Handling keys for valves]
2012-11
05.2014
05.2014
E-Book – Ductile iron pipe systems Chapter 8: Push-in joints 8/1
8 Push-in joints
8.1 General
8.2 Types of joint
8.3 Fields of use
8.4 References
10.2010
8 Push-in joints It is therefore the manufacturer’s respon-

sibility to design and produce the joint in
such a way that the stringent functional
Push-in joints act as axially movable joints and are able to withstand requirements are met.
high loads. They remain leak tight even when the pipes are non-aligned
or angularly deflected to the maximum extent. In EN 545 [8.1] and EN 598 [8.2], the
following functional requirements are
laid down for movable, non-restrained
joints:
8.1 General ■ angular deflection (as a function of
nominal size, Table 8.1),
For hundreds of years now, cast iron pipes ■ axial mobility (declared by manufac-
have been fitted together with push-in turer)
joints to form pipelines. Modern-day ■ test conditions for the following pres-
push-in joints (Fig. 8.1) are quick and sures:
easy to connect and also provide some 1. positive internal hydrostatic
major technical and economic advantages pressure
when being installed. 2. negative internal pressure
3. positive external hydrostatic
With the introduction of European pro- pressure
duct standards EN 545 [8.1] and EN 598 Fig. 8.1: 4. cyclic internal hydrostatic
[8.2] for ductile iron pipes, functional Ductile iron sewer pipes pressure.
requirements for the joints were laid with the TYTON® push-in joint
down for the first time. For reasons of The maximum angular deflections
compatibility, all that remained fixed was for push-in joints can be seen from
the diameter of the spigot end. Table 8.1.
10.2010
Table 8.1: When type tests are made to ensure that

Angular deflection of the most important push-in joints the functional requirements are met, the
following binding limiting conditions have
DN Maximum angular deflection to be met (Table 8.2).
TYTON® STANDARD
80 – 150 5° Table 8.2:
5°
200 – 300 4° Limiting conditions for the type tests
on push-in joints
350 – 400 4°
3°
500 – 600
1 Joint of maximum annulus
700 – 800 3° 2°
2 Maximum angular deflection
900 – 1000
3 Maximum axial withdrawal
1200 – 1400 1,5° 1,5°
4 Mean thickness of pipe wall
1600 – 2000 —
5 Aligned position with shear
Note: On a 6 m long pipe, an angular deflection of 3° produces a deflection of load
about 30 cm off the axis of the pipe or fitting installed previously.
The programme of tests provided for

restrained movable joints is substan-
tially the same (Chapter 9). Nominal
sizes representative of given groupings
of nominal sizes (Table 8.3) have to be
tested in these tests.
10.2010
Table 8.3: Under DVGW testing specification DVGW A joint of the present type will remain
Groupings of nominal sizes for type tests on Arbeitsblatt GW 337 [8.4], which is man- leak tight even under the highest loading
push-in joints under EN 545 [8.1] datory for ductile iron pipes and fittings from internal pressure and even when the
DN grouping Preferred DN in in Germany, the tests on the functional end of a pipe is mis-aligned and angularly
each grouping fitness for purpose of joints are carried deflected to the maximum in the socket.
out as externally monitored type tests. The test certificates for the type tests
80 – 250 200 This attestation of conformity is an impor- which have to be carried out show this to
300 – 600 400 tant part of the FGR® quality seal by be the case. The high dimensional stability
which the members of EADIPS® (Euro- of the sockets is one of the ways in which
700 – 1000 800
pean Association for Ductile Iron Pipe these characteristics are achieved
1100 – 2000 1600 Systems) provide evidence of the suitabi-
lity of their products (ductile iron pipes, What all the push-in joint systems have
fittings and valves) with regard to the in common is that they are able to move
In Germany, the standard which governs safety, security, fitness for purpose, quality, and act as longitudinally displaceable
designs of joints which meet the require- hygiene and environmental compatibility joints. Hence they do not transmit bending
ments described above is DIN 28603 [8.3]. required in water supply. moments or longitudinal forces.
The dimensions and permitted devia- The requirements in these respects which
tions (tolerances on dimensions) given are laid down by standards documents If longitudinal forces have to be trans-
in this standard are important for ensu- are fundamental to the ability of the duc- mitted from pipe to pipe or from pipe to
ring that the functional requirements tile iron pipe system to perform properly fitting/valve, restrained designs of joint
are met. By specifying these characte- and they can only be met by ensuring the have to be used. These are dealt with
ristics, DIN 28603 [8.3] becomes one of following: in detail in Chapter 9. The long-term
the significant bases of DVGW Arbeits- ■ The dimensions of the individual parts absence of leaks at the joints is ensured by
blatt GW 337 [8.4], which is the document of the joint have to be properly mat- the permanently elastic properties of the
governing certification. ched to one another. gasket itself but also by the match achie-
■ The elastomeric gaskets have to with- ved by design between the spigot end of
stand high stresses. the pipe, the socket and the gasket.
Even when the permitted tolerances pro-
duce a worst-case pairing of dimensions
at the joint and the spigot end is mis-
10.2010
aligned to the maximum in the socket, the 8.2 Types of joint The significant dimensions of this joint
joint will remain leak tight under all the are laid down in DIN 28603 [8.3] for the
types of pressure-induced stress which nominal sizes from DN 80 to DN 1400.
may occur. 8.2.1 The TYTON® push-in joint
The sealing function in the TYTON®
Because of their axial mobility and The push-in joint most widely used in push-in joint is performed by a profiled
angular deflectability and because of the Germany is the TYTON® push-in joint gasket which consists of a softer rubber
elasticity of the gaskets used, the joints system. There are standards for it over mixture (the sealing part) and a harder
are able to follow even large movements the range from DN 80 to DN 1400. Since rubber mixture (the retaining part).
of the ground, e.g. mining subsidence or it was launched on the German market
earthquakes, and to remain leak tight in 1957, it has proved its worth a million The design of the gasket can also be seen
as they do so. A limit is set to the mis- times over in pipelines for drinking water, from Fig. 8.2. On being fitted into the
aligning travel by the structural design, raw water, wastewater and sewage. socket, the gasket is seated in the sea-
whereby forces due to differences in set- ling chamber with a small amount of pre-
tlement are transmitted to the spigot end Fig. 8.2 is a cross-section showing the compression, i.e. the outside diameter of
by the centralising collar and the gasket structural design of the joint. its softer sealing part is larger than the
plays only a small part in transmitting inside diameter of the sealing chamber
the load. in the socket. The result of this is that,
at the sealing bead which it forms, about
Its sealing function is no more affected by 30 % of the gasket projects into the cross-
high internal pressures than it is by par- TYTON® gasket sectional area into which the spigot end
tial vacuums or by pressures above atmos- Retaining part Sealing part of the pipe is going to be pushed. The sui-
pheric acting on the joint from outside. tably matched diameters of the sealing
Centralising collar chamber, the sealing bead and the pipe
For fitting in water and wastewater pipe- cause the gasket to be highly deformed
lines and sewers, the quality of the gaskets and hence a high pressure to be applied
complies with EN 681-1 [8.5] to the sealing surfaces.
More detailed information on the gaskets Fig. 8.2: If the spigot end of the pipe is mis-aligned,
can be found in Chapter 13. TYTON® push-in joint system the gasket cannot be compressed to an
10.2010
excessive degree by an external load on 8.2.2 The STANDARD push-in joint The maximum angular deflections for the
the pipe because a structural limit is set TYTON® and STANDARD push-in joints
for the mis-aligning travel firstly by the The structural design and the operation can be seen from Table 8.1.
centralising collar and secondly by the of the STANDARD push-in joint are com-
limiter in the sealing chamber. Behaviour parable to those of the TYTON® push-in
is similar when there are movements joint. In Germany, the dimensions of the 8.3 Fields of use
producing angular deflections, for which joint are laid down in DIN 28603 [8.3]
structural limits are likewise set. (Form C) for nominal sizes from DN 80
to DN 2000. The purpose of joints between pipes is
The harder annular part of the gasket (the to help to provide a supply of satisfac-
retaining part) is moulded to a claw-like A schematic view of the joint is shown tory drinking water, to help to ensure
shape and engages in the retaining groove in Fig. 8.3. that wastewater and sewage are safely
in the socket. It holds the gasket firmly disposed of and to help to protect bodies
in position when the end of the pipe is The gasket consists of rubber of a single and watercourses of surface and under-
pushed in and also later when a load is hardness. ground water. Other fields of use for duc-
applied by the internal pressure. tile iron pipes with push-in joints are in
Under a load applied by internal pressure, the transportation of raw water and pro-
the retaining part is supported against cess water and they are also used in irri-
the centralising collar and, by being so gation and in systems for fire-fighting and
supported, closes off the gap between the snow-making – although it is mainly in a
STANDARD gasket
centralising collar and the pipe. It thus restrained form in which they are used in
prevents the gasket from being forced these latter cases (Chapter 9).
out even at very high internal pressures. Centralising
The joint remains sealed even up to the collar In the case of pressure pipes of ductile
bursting pressure of the pipe system. iron, the TYTON® system and STANDARD
system push-in joints are used in water
The bead-like sealing part composed of pipelines to EN 545 [8.1] and in sewers
softer rubber is compressed when the spi- and pipelines for sewage and wastewater
got end is pushed in in such a way that a Fig. 8.3: to EN 598 [8.2].
reliable seal is obtained. STANDARD push-in joint system
10.2010
Pipes and fittings for ductile iron sewers

TYTON® gasket STANDARD gasket and wastewater pipelines are designed for
the operating pressures given in Table 5
Angular deflection chamber Angular deflection chamber
of EN 598 [8.2]. A wide variety of stres-
ses result from joints being used in, for
example, gravity pipelines, pressure pipe-
lines for sewage and wastewater, pres-
sure pipelines for sludge and pipelines
for leakage water. The joints have to with-
Fig. 8.4: Fig. 8.5: stand these stresses and to remain leak
TYTON® long socket STANDARD long socket tight for decades.
This is also particularly true where pipe-

Ductile iron fittings with the TYTON® or longer axial displacements than the usual lines are positioned in groundwater and
STANDARD push-in joint system are also form A socket (Figs. 8.4 and 8.5). when they are installed with large heights
covered by the above standards. of cover.
As a percentage of the laying length of
Ductile iron pipes and fittings with push- the pipe, axial displaceability increases A requirement which is particularly dif-
in joints are used in pressure pipelines as to 0.8 % in the nominal size range from ficult to meet for push-in joints used
a function of the diameter of the pipes and DN 700 to DN 1000. A marking line which in sewage and wastewater pipelines is
the wall-thickness classes for allowable can still be seen outside the socket shows resistance to root intrusion.
operating pressures as given in the above the neutral position of the joint. If it is Extensive investigations carried out all
product standards and also in the manu- known exactly what axial movements over the world have shown that tree
facturers’ catalogues. can be expected, the spigot end can be roots are able to penetrate into push-in
inserted as far as the beginning or end, as joints sealed by rubber if the compres-
For pipelines installed in unstable ground the case may be, of the angular deflection sion of the gasket is not high enough to
or in areas subject to mining subsidence, chamber. resist the pressure exerted by the tip of
the TYTON® and STANDARD push-in the root. This is the case with lip seals
joints are produced with a long socket for example. Because of the high tensile
(DIN 28603 [8.3], form B) which allows strength of ductile iron, it was possible
10.2010
for the compression of the TYTON® and [Rohre, Formstücke, Zubehörteile [8.5] EN 681-1
STANDARD gaskets to be selected, by aus duktilem Gusseisen und ihre Elastomeric seals –
design, to be so high that it can be relied Verbindungen für die Abwasser- Material requirements for pipe joint
upon that roots will not grow into the entsorgung – seals used in water and drainage
joint. Anforderungen und Prüfverfahren] applications –
Root intrusion has in fact never been 2007+A1:2009 Part 1: Vulcanized rubber
found in sewage or wastewater pipelines [Elastomer-Dichtungen –
with properly assembled TYTON® push- [8.3] DIN 28603 Werkstoff-Anforderungen für
in joints [8.6]. Rohre und Formstücke aus Rohrleitungs-Dichtungen für Anwen-
duktilem Gusseisen – dungen in der Wasserversorgung
Steckmuffen-Verbindungen – und Entwässerung –
8.4 References Zusammenstellung, Muffen und Teil 1: Vulkanisierter Gummi]
Dichtungen 1996 + A1:1998 + A2:2002 +
[Ductile iron pipes and fittings – AC:2002 + A3:2005
[8.1] EN 545 Push-in joints –
Ductile iron pipes, fittings, Survey, sockets and gaskets] [8.6] Köhne, H.:
accessories and their joints for 2002-05 Verwurzelungsschäden in
water pipelines – Entwässerungsleitungen in
Requirements and test methods [8.4] DVGW-Prüfgrundlage GW 337 Gelsenkirchen
[Rohre, Formstücke, Zubehörteile Rohre, Formstücke und Zubehör- [Damage from root penetration
aus duktilem Gusseisen und ihre teile aus duktilem Gusseisen für in drainage pipelines in
Verbindungen für Wasserleitungen – die Gas- und Wasserversorgung – Gelsenkirchen]
Anforderungen und Prüfverfahren] Anforderungen und Prüfungen awt abwassertechnik 5 (1991),
2006 [DVGW test specification GW 337 S. 37 u. 38
Ductile cast iron pipes, fittings
[8.2] EN 598 and accessories for gas and
Ductile iron pipes, fittings, water supply –
accessories and their joints for Requirements and tests]
sewerage applications – 2010-09
Requirements and test methods
10.2010
E-Book – Ductile iron pipe systems Chapter 9: Restrained socket joints 9/1
9 Restrained socket joints

9.1 General
9.2 Types of joint
9.3 Bases for the design and dimensioning
of restrained socket joints
9.4 Types of restrained joint
9.5 Type tests
9.6 Determining the forces which occur
and the lengths of pipe to be restrained
9.7 Examples of installed pipelines
9.8 Notation in equations
9.9 References
07.2011
9 Restrained socket joints The internal pressure acts evenly in all

directions. If the right-hand end of the
closed-off pipe is imagined to be cut off
Restrained socket joints are needed when the forces generated by the internal and replaced by a flange socket and a
pressure are not to be absorbed by thrust blocks or when the pipes and fittings blank flange (Fig. 9.1), the force which
are still to have a degree of mobility or flexibility. There are a number of differ- acts on the area to which pressure is
ent restraining systems. A variety of forces act on the pipeline and the resultant applied (the blank flange) is N:
force arising from these has to be calculated. Some examples of installed pipe- di2
lines are described. A further application is in the field of trenchless installation N ′ = p ⋅ [ kN ] (9.1)
4
and replacement techniques (see Chapter 22).
da2
N = p⋅
4
[kN ] (9.2)
9.1 General The internal forces are produced by

whichever is the internal pressure in the
A large number of forces, which can be given case (PEA or PFA).
divided into internal and external forces, PEA is the maximum hydrostatic pressure
ø di
N´ p N´
act on pipelines and their joints. that a newly installed component is capa-
ble of withstanding for a relatively short
External forces occur in the case of bur- duration, in order to insure the integrity
ied pipelines, e. g. in the form of stresses and tightness of the pipeline.
which are generated during the filling of PFA is the maximum hydrostatic pressure
the trench and the compaction of the fill; that a component is capable of withstand-
added to these there are the earth-load ing continuously in service.
ø da
N p N
and the static and dynamic loads arising
from the top cover and from traffic. The internal pressure generates the fol-
lowing internal forces. In the wall of a pipe
which is closed off at both ends, the inter-
nal pressure generates stresses which are Fig. 9.1:
in equilibrium within the pipe. Forces due to internal pressure
07.2011
The axial force has to be transmitted to The internal pressure also gives rise to
the soil by thrust blocks installed at the forces R which have to be transmitted
left and right ends or by restrained joints. into the soil at changes of direction and
R
In this way, as in pressure testing as shown cross-section and at branches and valves,
in Fig. 9.2 for example, the axial force doing so at bends for example in the way p 2
N
has to be transmitted to the soil over an shown in Fig. 9.3.
da
N
enlarged area by suitable means in such
a way that the allowable pressure per unit
αR
area on the soil is not exceeded. R = 2 ⋅ N ⋅ sin
2
[kN ] (9.3)
p
N
The resultant force R can be transmitted
into the soil either via thrust blocks, e. g. of da
concrete, or, via friction between the pipe
and the soil, by means of restrained joints,
From the pressure pump
or in other words by activating the passive Fig. 9.3:
Steel plate
soil pressure. The sizing and construction Resultant force R at a bend
Thrust block of concrete thrust blocks are dealt with in
Chapter 11.
Jack
Fig. 9.2:
How a dead end is supported
in a pressure test
07.2011
9.2 Types of joint city areas where there is not much room ■ In the testing of restrained joints,
for thrust blocks, or where pipelines are it is permissible for slight displace-
pulled in in any trenchless installation ments (of a few millimetres) to occur
If the joints which are used to install duc- techniques. Restrained socket joints are between the socketed ends of pipes
tile iron pressure pipes and fittings are used in cases like these. Chapter 22 and the plain ends. However, visible
considered, they can be divided into the on trenchless installation techniques deformations of parts of restrained
following two groups: provides detailed information on these joints (tie-rods and the like) are not
■ Socket joints are used mainly for techniques. permissible.
buried pipelines. They are consider- ■ All parts of restrained joints must be
ably more economical to make and adequately protected against corro-
install than flanged joints. They can be 9.3 Bases for the design and sion.
deflected angularly and normally they dimensioning of restrained ■ In new pipelines, it is not enough for
are not restrained (Chapter 8). The socket joints only the joint between a bend and the
forces described above can be trans- next pipe to be restrained. The number
mitted into the soil by using concrete of joints which need to be restrained
thrust blocks (Chapter 11). DVGW-Arbeitsblatt GW 368 [9.1] specifies depends on how high the test pressure
■ Flanged joints are used mainly in the following requirements to be met by is, on the friction between the outer
installations where the pipelines restrained joints: wall of the pipes and the surround-
are not buried, such for example as ■ Restrained joints must safely transmit ing soil, on the level of the water table
in pipeline-carrying tunnels, pump the longitudinal forces which occur and on the length of the next directly
houses, waterworks, service reservoirs during the installation phase of pipe- adjoining pipe on either side of the
and industrial plants. They are rigid lines, while they are being tested, and bend. A minimum of 12 m on either
and restrained. while they are in operation. side must have restrained joints (mini-
■ The joints must withstand the forces mum dimensioning under GW 368
However, in practice there are cases which arise at the allowable test [9.1]). If a pipe connected to the bend
where on the one hand restrained socket pressure is shortened, additional restraints are
joints are required but on the other hand PTyp = 1.5 · PFA + 5 bars. necessary.
the joints need to be capable of deflect-
ing angularly, e. g. in unstable soils where
thrust blocks are not possible, in inner-
07.2011
A practical tip: 9.4 Types of restrained joint copper ring is fitted round the pipe as a
Do not use the shortened length of pipe guide and the bead is applied alongside
at the bend itself (Fig. 9.4). it (Fig. 9.5).
A basic distinction which is made is
between positive locking and friction Rather than a welded bead, what may also
locking designs. In positive locking joints, be used is a BLS® / VRS®-T clamping ring
Poor solution E the forces are transmitted by elements (Fig. 9.15).
sh
which are formed to be integral with the
E
pipes (e. g. welded beads on the spigot
ends) in combination with force-trans-
mitting elements. In the friction locking
Shortened length of pipe
designs, the forces are transmitted by a
E frictional connection, e.g. by toothed ele-
ments which take a firm grip on the sur-
sh
face of the spigot end.
sh
E
9.4.1 Positive locking joints

Good solution
This type of restrained joint has existed

since the end of the sixties.
Fig. 9.4:
Increasing the activated soil resistance by At a fixed distance from the end of the
connecting a pipe of the original length to pipe, a surrounding welded bead is
the bend applied to the spigot end. This is normally
a factory applied build-up welding under
a shielding gas.
Detailed information on determining the In the case of cut pipes, the bead can Fig. 9.5:
length L [m] of pipeline which has to be be applied on the installation site by A welded bead being applied
restrained can be found in section 9.6. manual arc welding. For this purpose, a on the installation site
07.2011
In the case of fittings which have a spigot Positive locking restrained joints
end, the bead which transmits force may with an external retaining chamber
also be integrally cast and machined. Its
dimensions are the same as in the case of A design which has an external retain-
pipes of the nominal size concerned. ing chamber which has to be fixed sepa-
rately to a collar on the socket is shown
In the BAIO® positive locking system, in Fig. 9.13. At the end face of the socket,
the force-transmitting elements consist the pipes have a collar extending round
of integrally cast lugs on the spigot end in a circle to which a ring containing the
and recesses in the sockets into which the retaining chamber is fixed by means of
lugs fit. The two parts are locked together hooked bolts. The longitudinal forces are
by turning after the fashion of a bayonet transmitted from the welded bead on the
joint. The system is used on fittings and spigot end, via a thrust-restraint ring, to
valves. the retaining chamber and from there
via the hooked bolts to the socket of the
Positive locking restrained joints next pipe.
with an internal retaining chamber
Table 9.1 is an overview of the types of
The positive locking joints with an inter- joint, their ranges of application and their
nal retaining chamber which are widely allowable angular deflections.
used at the moment are the BLS® / VRS®-T,
the Universal Ve and the BAIO® push-
in joints. They cannot be combined with
one another because there are differences
between the force-transmitting elements,
the form of the welded bead and the dis-
tance of the latter from the end of the
pipe.
07.2011
Table 9.1: Type of joint Range of DN Allowable operating pressure Allowable angular
Overview of nominal sizes PFA [bar] deflection [°]
positive locking
Positive locking TIS-K® 100 –300 As stated by manufacturer 3
push-in joints
restrained joints with UNIVERSAL Ve 350–400 3
an internal retaining
chamber 500–800 2
900 As stated by manufacturer 1,5
1000 1,2
1200 1,1
BLS® / VRS®-T 80–150 5
200 –300 4
400 3
As stated by manufacturer
500 3
600 2
800 –1000 1,5
BAIO® 80 –300 As stated by manufacturer 3,
Positive locking Hydrotight 400 –500 3
restrained joints with 600 –700 2
an external retaining
chamber
07.2011
The TIS-K® system The UNIVERSAL Ve system The BLS® /VRS®-T system
In the TIS-K® restrained joint (Fig. 9.6), Longitudinal force is transmitted by The positive locking BLS® / VRS®-T sys-
force is transmitted from one pipe to the the retaining ring of the TIS-K® system allows the two assembly operations
next, or from a fitting, via the welded bead tem, whereas the gasket is part of the ■ make a seal, and
and the retaining ring, into the socket. STANDARD system (form C under ■ lock,
The retaining ring is slit or in segments DIN 28603 [9.2]) (Fig. 9.7). to be broken down into two separate steps
and is matched to the outside diameter The allowable angular deflections for which have to be performed and checked
of the pipes. pipes are given in Table 9.1. one after the other. In the first step, the
The construction of the TIS-K® restrained push-in joint (TYTON® or VRS®-T)
push-in joint is the same for both pipes is assembled. In a second step, it is then
and fittings. made restrained by the insertion of lock-
ing elements.
The joint still has the full original
angular deflectability of the TYTON® joint In the nominal size range from DN 80 to
(Table 9.1). DN 500, the locking elements are locks
(Figs. 9.8 and 9.9), whereas from DN 600
to DN 1000 they are wide plate-like seg-
ments (Fig. 9.10). In the case of the locks,
a distinction has to be made between the
TIS-K® retaining ring TIS-K® retaining ring “right” and “left” types and they have to
TYTON® gasket STANDARD gasket be inserted as detailed in the installation
instructions. When the assembly process
has been completed, a rubber catch is
inserted in the opening in the socket face
which is still open to prevent the locks
from shifting (Fig. 9.9).
Fig. 9.6: Fig. 9.7:

The TIS-K® restrained push-in joint The UNIVERSAL Ve restrained push-in joint
07.2011
Locking
chamber
Welded bead
Rubber Locking TYTON® gasket
catch segment Socket
Left lock Right lock
Clamping strap Spigot

High-pressure
lock Socket face
Fig. 9.9:
Locking Welded bead
chamber Layout of the locks and the rubber catch Insertion openings
TYTON®/VRS®-T gasket in the BLS® / VRS®-T joint (DN 80 to DN 500
Left lock Socket nominal sizes); high-pressure lock only for
DN 80 to DN 250 nominal sizes
In the case of the DN 600 to DN 1000 nomi-

nal sizes, the wide plate-like locking seg-
ments are inserted in the axial direction
Rubber catch through the twin openings in the socket
Right lock face and are then evenly distributed
around the circumference. The openings
Fig. 9.8: should preferably be positioned at the Fig. 9.10:
BLS® / VRS®-T restrained push-in joint with crest of the pipe to simplify the process BLS® restrained push-in joint with insertion
locks (DN 80 to DN 500 nominal sizes) of inserting the locks (Fig. 9.10). openings in the socket face and a clamping
strap (DN 600 to DN 1000 nominal sizes)
07.2011
Retaining ring (A) Nuts (D)

Hooked Securing
Socket face bolts (C) ring (B)
Insertion openings
Fig. 9.11: Fig. 9.12: Fig. 9.13:

Fixing in place of the locking segments BIAO® system flanged socket (left) and Cross-section through the Hydrotight
by a clamping clip spigot-ended dead end (right) positive locking external joint
Once the locking segments have all been openings which match the lugs on the The Hydrotight system
inserted in the gap at the socket, they are spigot end. Once the spigot end has been
all moved around the circumference until inserted in the socket, it is turned through Fig. 9.13 is a cross-section through a joint
none of the humps on them can be seen an eighth of a revolution and thus locked, of this kind when it has been completely
through the openings in the socket and on the bayonet principle. assembled. Before the joint is assem-
they are then fixed in place with a clamp- bled, the retaining ring (A) and the slit
ing strap or a clamping clip (Fig. 9.11). Fig. 9.12 shows a positive locking BAIO® securing ring (B) are slid onto the spigot.
socket and the matching BAIO® spigot end When the joint has been made, the two
The BAIO® system of a dead end of the kind which is used as rings are drawn up against the socket and
an end closure in a pressure test. For this screwed tight with the hooked bolts (C)
The positive locking BAIO® system is used purpose, the dead end has a screw-thread and nuts (D). The joint is then extended
for fittings and valves. On their outer face, for a venting plug and two hand-levers to so that all the force-transmitting members
the spigot ends carry four lugs evenly dis- allow it to be turned. are resting against one another.
tributed around the circumference, while
the sockets have a retaining chamber
whose front wall contains four receiving
07.2011
9.4.2 Friction locking Type of joint Range of DN Allowable operating pressure Allowable angular
push-in joints nominal sizes PFA [bar] deflection [°]
BRS®/ TYTON SIT 80–300 3
Table 9.2 provides an overview of the As stated by manufacturer
PLUS® 350–600 2
types of friction locking push-in joint and
their ranges of application and allowable BLS® / VRS®-T 80–150 5
angular deflections. with clamping 200–300 4
ring As stated by manufacturer
400 3
500 3
STANDARD Vi 350–400 3
500–600 2
Novo SIT® 80–400 3
450–700 As stated by manufacturer 2
800 1
Universal Vi 350–400 3
500–700 2
BAIO-SIT 80–300 As stated by manufacturer 3
Hawle-STOP 80–200 As stated by manufacturer 3
Hydrotight 80–300 3
internal 400 As stated by manufacturer 3
500 2
Hydrotight 80–500 3
external As stated by manufacturer
600–700 2
Table 9.2: The manufacturer’s applications engineering department should be consulted before these joints are used in culverts or
Overview of friction locking push-in joints above-ground pipelines and before they are installed on slopes or in casing tubes or pipes or in utility tunnels.
07.2011
The BRS® system The BLS® /VRS®-T system On their inner side, the clamping rings
with a clamping ring have toothed pressure-applying surfaces.
In this system, a TYTON SIT PLUS® gas- Under the rules shown below, their use is
ket which has stainless steel segments With this system, the application of welded confined to buried pipelines and the rules
vulcanised into it (Fig. 9.14) is used in beads to pipes which have been shortened also state that they may only be used in
place of the usual gasket. These segments on site can be dispensed with. Instead of pipe sockets (Fig. 9.16).
have sharp, hardened teeth which cut into the locks, two halves of a clamping ring
the surface of the end of the pipe. are inserted in the insertion openings Clamping rings should not be used for
in the socket and are clamped onto the trenchless installation techniques or in
spigot end with bolts (Fig. 9.15). culvert or bridge-carried pipelines or on
slopes or in casing tubes or pipes or in
utility tunnels.
Fig. 9.14: Fig. 9.15:

The BRS® friction The BLS® / VRS®-T friction locking push-in
locking push-in joint joint with a clamping ring
07.2011
The TYTON SIT PLUS® system

Factory-applied A Pipe spigot
welded bead On-site cut with welded bead
With the introduction of the TYTON SIT
B + C Pipe spigot PLUS® system (Fig. 9.17) in 2003, the
without welded bead range of application of the Tyton SIT®
friction locking joint was effectively wid-
A B C
ened when it was replaced by the TYTON
SIT PLUS® joint.
Clamped joint
Direction (without welded bead)
of installation
Uncut pipe with
B A welded bead
Joint made with locks Clamped joint Joint made with locks
(with welded bead) (without welded bead) (with welded bead)
Identifying ring
Fig. 9.16: TYTON SIT PLUS® gasket
Rules for the use of clamping rings
Fig. 9.17:
The TYTON SIT PLUS®
friction locking push-in joint
07.2011
The STANDARD Vi system The Novo SIT® system The UNIVERSAL Vi system
The STANDARD Vi system operates on The socket has a integrally cast retaining In this case too the sealing and longi-
a similar principle (Fig. 9.18). Stainless chamber. In contrast to the TYTON SIT tudinal-force-transmitting functions are
steel segments with hardened teeth which PLUS® system, the sealing and retaining separate from one another. The retain-
have been ground to a sharp edge are vul- functions are separate from one another. ing, i. e. transmitting, function is per-
canised into the STANDARD gasket. The The design of the retaining ring causes formed by the Novo SIT® ring whereas
teeth engage in the surface of the spigot it always to remain resting against the the STANDARD gasket does the sealing
end and thus transmit the longitudinal retaining chamber as the spigot end is (Fig. 9.20).
forces. inserted, which means that the travels
for extending the joint are only short.
(Fig. 9.19).
Identifying ring Novo SIT® retaining ring Novo SIT® retaining ring
STANDARD Vi gasket
TYTON® gasket STANDARD gasket
Fig. 9.18: Fig. 9.19: Fig. 9.20:

The STANDARD Vi friction The Novo SIT® friction The UNIVERSAL Vi friction
locking push-in joint locking push-in joint locking push-in joint
07.2011
The BAIO-SIT and Hawle-STOP The retaining chamber holds a rubber

systems ring which has stainless steel segments
vulcanised into it. These have sharp, hard-
In this case too the sealing and longitu- ened teeth which cut into the surface of
dinal-force-transmitting functions are the spigot end.
separate from one another. The retaining,
i.e. transmitting, function is performed In the Hawle-STOP joint the retaining
by an annular retaining chamber which teeth are inset into a polyamide ring
is locked on the bayonet principle to the (Fig. 9.22).
external retaining cams on the BAIO®
socket (Fig. 9.21).
Fig. 9.21: Fig. 9.22:

The BAIO-SIT friction The Hawle-STOP friction locking joint
locking push-in joint
07.2011
Hydrotight
2807 thrust restraint gasket
Fig. 9.23: Fig. 9.24: Fig. 9.25:

The Hydrotight internal friction locking View in section of the Hydrotight internal The Hydrotight external
joint (double-chambered socket) friction locking joint (twin-chambered friction locking joint
socket)
The Hydrotight internal system The Hydrotight external system

(double-chambered socket) Ductile iron ring
Elastomer
A thrust-restraint ring of ductile iron retaining ring Hooked bolts
with integral
There are two chambers extending round is fastened to the external collar on the toothed Hydrotight gasket
in a circle in the socket. One chamber socket by hooked bolts. This ring, together segments
of steel
holds the Hydrotight gasket while the with the socket face, creates a chamber
thrust-restraint ring, an elastomer ring in which an elastomer ring with toothed
with toothed segments vulcanised into it, segments vulcanised into it is seated. This
is seated in the second chamber. This ring ring also has small sealing lips which stop
also has a sealing lip which stops soil and soil and moisture from penetrating into
moisture from penetrating into the joint. the joint. The toothed segments transmit Fig. 9.26:
(Figs. 9.23 and 9.24). the longitudinal forces from the socket to View in section of the Hydrotight external
the next pipe (Figs. 9.25 and 9.26). friction locking joint
07.2011
9.4.3 Friction locking screwed- In the case of the restrained screwed- The screwed-socket systems which use
socket joints socket joint which uses locking elements, a clamping ring exist in two variants:
the collar of the screwed ring, to which the variant using a single clamping ring
Friction locking screwed-socket joints a wrench can be applied, contains tan- (Fig. 9.28) and the variant using a special
are used mainly for repairs. In the case of gential insertion passages, rectangular in clamping ring (Fig. 9.29).
these joints a distinction is made between cross-section, which are inclined in the
systems using locking elements and ones inward direction in the opposite direc- Table 9.3 provides an overview of the
using a clamping ring. tion to that in which the ring is screwed friction locking designs of screwed-socket
in. Toothed wedges are driven in through joint and of their ranges of application,
these insertion passages and these cut into operating pressures and allowable deflec-
the spigot end and produce a restrained tions.
joint (Fig. 9.27).
Screwed socket
Screwed socket Screwed ring

Rubber gasket Screwed socket Clamping Screwed
Rubber gasket ring ring
Screwed ring Slide ring Clamping ring
Locking element Slide ring Special
Slide ring screwed ring
Rubber gasket
Fig. 9.27: Fig. 9.28: Fig. 9.29:

A restrained screwed-socket joint using A screwed-socket A screwed-socket joint using
locking elements joint using a single clamping ring a special clamping ring
07.2011
Table 9.3: Table 9.4:

Range of application and angular deflectability of friction locking screwed-socket joints Range of application of the type M clamp
Type of joint Range of DN Allowable operating Allowable angu- Nominal Allowable oper- Angular
nominal sizes pressure PFA [bar] lar deflection [°] size DN ating pressure deflection
PFA [bar] [°]
Using locking elements 80–300 As stated by manufacturer 2
Using clamping ring 80–300 As stated by manufacturer 3 80 – 300 As stated by
3
Using special clamping ring 300–400 As stated by manufacturer 3 400 manufacturer
9.4.4 Clamps for 9.5 Type tests

retrospective fitting
The clamp consists of two or three iden- The manufacturer has to demonstrate the
tical parts which are clamped together fitness for use of restrained joint systems
by bolts. The restraint is produced by the by carrying out tests under EN 545 [9.3].
interaction between the retaining part,
which engages behind the socket, and The requirements and testing conditions
the toothed pressure-applying plates, for this demonstration are dealt with in
which are pressed against the pipe. detail in Chapter 8 “Push-in joints”. For
Clamps (type M) (Fig. 9.30) can be used the “Tested” mark of the DVGW (German
for TYTON® joints and screwed-socket Technical and Scientific Association for
joints. Fig. 9.30: Gas and Water) to be obtained, these fit-
A restrained push-in joint fitted with ness tests have to be carried out under
Clamps are fitted once the socket joint clamps (type M) external monitoring. In the final analysis,
has been connected; the joint retains its it is the details given in the manufactur-
full capacity for angular deflection. ers’ catalogues which determine the field
The range of application of the type M of application of restrained joints.
clamp is shown in Table 9.4.
07.2011
9.6 Determining the forces which

RN E E
occur and the lengths of pipe
to be restrained sh
At changes of direction and cross-section sh 2

l
N 3
and at branches, the internal pressure
generates forces which have to be trans- E
E
mitted into the ground. N
In DVGW Arbeitsblatt GW 368 [9.1],

detailed rules for calculating these forces
are given and are printed there in the
form of easily used tables for the standard
cases. The most important steps in the cal-
culation process will be explained below Fig. 9.31: Fig. 9.32:
by taking a bend fitting as an example. Activation of the soil resistance E by a shift Soil resistance E that is activated
of the bend on the line bisecting the angle
At the bend, a resultant force RN acts in the
direction of the line bisecting the angle of
2
the bend. The projected area of the bend Because the pipe ends inserted in the all .Vh l DE
3
acts on the compacted filling of the trench sockets of the bend are locked but are able E >kN @ (9.4)
2
with this force. The pressure per unit area to deflect, the first two pipes undergo a
which this produces is generally higher sideways displacement when this shift in
than the compressive strength of the soil position occurs; as they are displaced, they
resting against the bend. activate the soil resistance E over their For safety reasons, only two thirds of the
projected lateral area (diameter · length), length of the pipes is used in the equa-
The soil deforms and the bend shifts in as shown in Fig. 9.31. tion (Fig. 9.32).
the direction of the resultant RN.
07.2011
A practical tip The other restrained pipes which follow Frictional force from the earth load
The shift of the bend which causes the the two mentioned will only be displaced at the top of the pipe
soil resistance to be activated results in axially, when the skin friction R will be
angular deflection of the two pipes in the activated. This friction depends on the The first frictional force R1 is determined
sockets of the bend. If the two pipes are to length L [m] of the restrained section of from the earth load above the pipe
deflect to a neutral angle, the shift of the the pipeline and on the weights of the (Fig. 9.35).
bend can be anticipated by setting the two earth load, the pipe and the filling of
pipes to a negative deflection (Figs. 9.33 water.
and 9.34). R1 P GB P DE H J B > kN/m@
(9.5)
Frictional forces from the earth load,

filling of water and weight of pipe at
the underside of the pipe
ER
The second frictional force R2, due to
the earth load above the pipe and to
the weight of the pipe and its filling of
water, acts on the underside of the pipe
(Fig. 9.35). The full length of the pipe is
used in the calculation in this case.
Fig. 9.33: Fig. 9.34:

Anticipating the shift of the bend – Negative angular deflections at a bend –
negative angular deflections at the bend Checking the shift of the bend to the
neutral-angle position
07.2011
GR S DE emin J R > kN/m@ (9.9)

N
a

2
The weight GR [kN/m] of the pipe can be
a

H found from the handbooks issued by duc- 2
GB tile iron pipe manufacturers. E
EQ = E · cot a

2
Frictional forces
GR
due to soil resistance
GW
The third frictional force R3 derives from
the soil resistance E against the first pipes,
multiplied by the coefficient of friction.
DE
N
Fig. 9.35: R3 = μ ⋅ E [ kN ] (9.10) Fig. 9.36:

To calculate the friction due to the earth Determining the transverse force
load and to the weight of the pipe and its due to the soil resistance E
filling of water Note: this frictional force acts only on the
first pipe after the bend.
α
EQ = E ⋅ cot
2
[kN ] (9.11)
R2 = μ ⋅ (GB + GW + GR ) [ kN/m] (9.6) The soil resistance E acting on the pipe
is transmitted to the bend as a transverse
α EQ
force EQ. This transverse force EQ acts in cot = (9.12)
2 E
GB DE H J B > kN/m@ (9.7) opposition to the normal force N produced
by the internal pressure (Fig. 9.36).
S
DE J W > kN/m@
2
GW (9.8)
4
07.2011
Balance of the forces at the bend

ER = 2E · cos a

2
For a balanced state (Figs. 9.37 and 9.38),
the forces due to the internal pressure N
a N
and the restraining forces due to the total E · cot 2
EQ =
E E a
friction R and the transverse force EQ must
be equal to one another (equation 9.16).
m·E
m·E a
m·L
· SG 2 · SG
m·L
Fig. 9.37: Fig. 9.38:

Determining the resultant soil resistance ER Interaction of thrust forces and soil
at the bend resistance at the bend
ER
α α
cos = 2 (9.13) N = μ ⋅ L ⋅ ∑ G + μ ⋅ E + E ⋅ cos [kN ]
2 E 2
(9.16)
ER α
= E ⋅ cos [ kN ] (9.14)
2 2
α ∑G = 2⋅G B + GW + GR [ kN/m] (9.17)

ER = 2 ⋅ E ⋅ cos [ kN ] (9.15)
2
07.2011
From this, the length L of pipeline which DVGW Arbeitsblatt GW 368 [9.1] brings
has to be restrained can be found. the results of these calculations together
in tables, which saves one from having to
Taking a pipe length of 6 m and the follow- do a vast amount of calculating work.
ing values For calculations which are not covered
by the values in the tables, an online
JB = 18 kN/m3 calculating program is available un-
JW = 10 kN/m3 der “Tools for calculations”, button
JR = 70.5 kN/m3 (ductile cast iron) “DVGW GW 368“, on the www.eadips.org
website of the European Association for
the length L of pipeline which needs to Ductile Iron Pipe Systems · EADIPS® /
be restrained can be calculated as follows Fachgemeinschaft Guss-Rohrsysteme
for ductile iron water pipelines and for a (FGR®) e.V.
system test pressure STP.
After installation, individual socket joints
§ D·
0 ,79 STP DE 2 all .Vh ¨ P cot ¸ are often in an unextended state and make
1 © 2¹
L > m@ (9.18) it necessary for extension to be performed
P 36 H 7 ,85 DE 221 ,5 emin before the ends of the pipeline are con-
nected to fixed points (e. g. structures, bur-
ied pipelines) (Fig. 9.39). The extension
Where pipelines are within the water zero. In these cases, it is recommended travels of the individual restrained joint
table, the resulting buoyancy reduces the that the entire pipeline be safeguarded systems are a few millimetres.
forces due to weight and the soil resistance with restrained joints.
and hence the frictional force. At changes in direction in a vertical plane, During the planning phase and in the
Where installation takes place within the the resultant force acts outwards at the course of installation, particular care must
water table in cohesive soils and where outside of the bend. As a result the forces be taken to follow the manufacturer’s
there are cohesive soils of soft and stiff Gw and GR due to weight in equation 9.17 installation instructions and any special
consistency which are difficult to compact may tend towards zero. directions (Chapters 19 and 22).
(soil types B 2 to B 4 under GW 310 [9.4]),
the coefficient of friction μ tends towards
07.2011
9.7 Examples of installed

pipelines
R
The follow examples are taken from prac-
tical installation work done over the past
few years. They are all applications where
restrained joints were used as a replace-
ment for concrete thrust blocks.
Dangerous: The entire pipeline cannot be extended – There is a risk of one
or more of the socket joints along the pipeline separating The use of restrained socket joints in
Forces R from internal pressure; joint deflected, ends fixed trenchless installation and replacement
techniques is dealt with in Chapter 22.
■ DN 700 ductile iron sewer pipes were

used to install the drainage pipeline
for ground water and rainwater at the
R new Berlin Brandenburg International
N N Airport (Fig. 9.40). During the con-
struction phase, the pipeline is being
operated as a pressure pipeline at an
The entire pipeline can be extended – operating pressure of several bars. The
none of the socket joints along the pipeline will separate use of Novo SIT® restrained push-in
Forces R from internal pressure; joint deflected, ends closed off joints enabled expensive concrete
thrust blocks to be dispensed with at
Fig. 9.39: changes of direction and the installa-
Effects of extension travels in restrained pipelines tion time to be considerably shortened
in this way.
07.2011
Fig. 9.40: Fig. 9.41:

DN 700 ductile iron sewer pipes with Parallel installation of DN 600 ductile iron
Novo SIT® push-in joints pressure wastewater pipelines with BRS® /
TYTON SIT PLUS® push-in joints
■ Sewage pressure pipeline, a DN 600 in operation until the Elbe floods to a

twin pipeline, between Heidenau and certain level, even though the ground
Dresden runs through the flood zone may have become so soft at this time
of the river Elbe (Fig. 9.41). The pos- that the pipeline can be expected to be
sibility of the soil being washed off buoyant. For this reason, all the push-
the pipeline in at least parts of certain in joints have to be restrained. The
sections of the route cannot be ruled joint system selected was the BRS® / Fig. 9.42:
out in this case. Also, it is intended to TYTON SIT PLUS® system which, at Installation of restrained
be possible for the pipeline to remain a rated pressure of PN 10, can be used ductile iron bends
07.2011
tions 2 km long are being bypassed at

a time by a DN 600 bypass pipeline of
restrained ductile iron pipes mounted
above ground (Fig. 9.43). Once the
renovation work on the given section
is completed, the ductile iron pipes
are disconnected and used again for
the next section, which is being done
at least eight times. Max. test pressure
for the bypass: 30 bars. Forces at the
45° bend: 720 kN. DN 600 pipes and
fittings with BLS® push-in joints have
been used (Fig. 9.10).
■ Flangeless restrained gate valves with

Fig. 9.43: Fig. 9.44: restrained sockets, and transition fit-
A DN 600 ductile iron bypass pipeline with Renovation of a gate-valve-equipped pipe- tings to old pipelines of different mate-
BLS® push-in joints line intersection with BAIO® restrained joints. rials, were used to replace a complete
gate-valve-equipped pipeline inter-
section which had had conventional
for nominal sizes of up to DN 600. The throughout with restrained joints flanged gate valves. There were four
design of this system combines the and because of this there was no need gate valves and a hydrant and with the
sealing and retaining functions in a for expensive pressure-distributing new components the number of indi-
single ring. walls (i. e. thrust blocks) to absorb the vidual parts dropped from 546 to 47;
forces. the installation time went down by a
■ There was a shortage of time and factor of 5 (Fig. 9.44).
installation space for the replacement ■ 6 km of a DN 1200 trunk main needs to
and relaying of an old DN 1000 drink- be renovated by lining it with cement
ing water main in Leipzig (Fig. 9.42). mortar without the transportation of
The new pipelines were installed drinking water being interrupted. Sec-
07.2011
■ When there is a considerable differ-

ence in height between the intake
structure at a spring and the com-
munal service reservoir for drinking
water, the local water supply can be
combined with electricity genera-
tion at drinking water hydroelectric
power stations. With a state-guaran-
teed remuneration for electricity fed
onto the grid, the cost of installing the
station is soon paid off. Ductile iron
pipes with restrained push-in joints
are equal to the high operating pres-
sures and are easy to install, and the
rugged material of which they are
made will stand up to any external Fig. 9.45:
loads (Fig. 9.45). A DN 400 turbine pipeline
07.2011
9.8 Notation in equations GW [kN/m] on the underside of the pipe

Force due to the weight of the filling
of water R3 [kN]
DE = da [m] Frictional force due to soil resistance
Outside diameter of pipe H [m]
Height of cover above the pipe STP [kN/m2]
DI = di [m] System Test Pressure
Inside diameter of pipe l [m] (1 bar = 100 kN/m2)
Length of pipe
emin [m] D [°]
Minimum wall thickness depending on L [m] Angle of the bend
the choosen pipe type Length of pipeline to be restrained
JB [kN/m3]
E [kN] N (N’) [kN] Specific weight of the soil
Soil resistance Axial force due to internal pressure
JR [kN/m3]
ER [kN] p [bar] Specific weight of ductile iron
Resultant soil resistance on Internal pressure in a pipeline
the line bisecting the angle (1 bar = 100 kN/m2) JW [kN/m3]
Specific weight of water
EQ [kN] R [kN]
Transverse force due to Resultant force from the μ
soil resistance internal pressure Coefficient of friction between
pipe and soil
GB [kN/m] R1 [kN/m]
Weight of the soil above the pipe Frictional force from the earth load all.Vh [kN/m2]
on the top of the pipe Allowable horizontal pressure on soil
GR [kN/m] R2 [kN/m]
Force due to the weight of the pipe Frictional force from the earth load, the
filling of water and the weight of the pipe,
07.2011
[9.3] EN 545
9.9 References
Ductile iron pipes, fittings,
accessories and their joints for
water pipelines –
[9.1] DVGW-Arbeitsblatt GW 368 Requirements and test methods
Längskraftschlüssige Muffenverbin- [Rohre, Formstücke, Zubehörteile aus
dungen für Rohre, Formstücke und duktilem Gusseisen und ihre Verbin-
Armaturen aus duktilem Gusseisen dungen für Wasserleitungen –
oder Stahl Anforderungen und Prüfverfahren]
[DVGW worksheet GW 368 2010
Restrained socket joints for
ductile iron and steel pipes, [9.4] DVGW-Arbeitsblatt GW 310
fittings and valves] Widerlager aus Beton –
2002-06 Bemessungsgrundlagen
[DVGW worksheet GW 310
[9.2] DIN 28603 Concrete thrust blocks –
Rohre und Formstücke aus Principles of sizing]
duktilem Gusseisen – 2008-01
Steckmuffen-Verbindungen –
Zusammenstellung, Muffen und
Dichtungen
[Ductile iron pipes and fittings –
Push-in joints –
Survey, sockets and gaskets]
2002-05
07.2011
07.2011
E-Book – Ductile iron pipe systems Chapter 10: Mechanical joints – wide-tolerance couplings and flange adaptors 10/1
10 Mechanical joints –
wide-tolerance couplings
and flange adaptors
10.1 General
10.2 Construction and operation
10.3 Wide-tolerance couplings
10.4 Wide-tolerance flange adaptors
10.5 Preloading of gasket
10.6 Ranges of pipe outside diameters
10.7 Allowable angular deflection
10.8 Restraint
10.9 References
02.2011
10 Mechanical joints – Table 10.1:

Bolt tightening torques
wide-tolerance couplings and flange adaptors (the example is for MEGA-Flex joints)
Technical development has progressed and, as a result, dedicated types of joint, Nominal Bolt tightening torques
such as push-in socket joints or welded joints are now the norm for pipe systems size in Nm
of all materials. In addition, the latest technology includes dedicated couplings for Up to DN 80 55 – 165
specific materials. However, given the wide variety of materials used in the water
industry, connecting pipeline components of different materials with long term DN 100
reliability is a real challenge. This is a job which can be done by couplings which and above 95 – 120
are able to cover pipe diameters of quite a wide tolerance range or ones which
are even capable of adapting different connecting systems to each another.
10.2 Construction and operation
10.1 General Mechanical joints can be made without

any high axial assembling forces because A characteristic feature of mechanical
the gaskets offer hardly any resistance to joints is the seal between the inside sur-
Mechanical joints are used amongst other the pushing-in of the pipe, but in return face of the socket and the outside surface
things for repairs, transitions between the bolts have to be tightened in a further of the pipe made by mechanical compres-
materials or connections to pipes of old operation. To ensure that the requisite sion of the gasket. A gland is usually tig-
dimensions, or for applications in which connecting forces exist, manufacturers htened against the body of the coupling
the connecting forces have to be kept lay down bolt tightening torques in the or flange adaptor by means of axially
low. installation instructions (Table 10.1). positioned connecting bolts. When this is
A basic distinction which can be made These torques are often given as a range done, the axial movement of the gasket is
in the case of mechanical joints is bet- because they are affected by the dimen- re-directed radially onto the surface of the
ween specific-size joints, such as those sions of the pipe being connected. pipe by means of conical guiding surfaces.
in Gibault couplings, and wide-tole- Such designs are therefore, in principle,
rance joints, conforming respectively to developments of the bolted gland joint
EN 12842 [10.1] and EN 14525 [10.2]. covered by DIN 28602 [10.3].
02.2011
10.3 Wide-tolerance couplings
Gasket
Wide-tolerance couplings (Fig. 10.1 and
Fig. 10.2) connect two plain pipe-ends by
making a mechanical joint to each pipe.
Due to the angular deflection possible at

the two sockets, these couplings can even Gland
compensate for a limited amount of dis-

placement between the pipes. The allowa- Body Lug for bolts integrally
cast on body
ble axial gap between the pipes is found
from the minimum depth of engagement
required for the mechanical joints and the Fig. 10.1: Fig. 10.2:
overall length of the couplings. Flexible wide-tolerance coupling View in section of an assembled
wide-tolerance coupling
Minimum values for the allowable
joint gap are laid down in EN 14525 Table 10.2:
[10.2] for wide-tolerance connectors of Minimum values for the allowable joint gap under EN 14525 [10.2]
nominal sizes from DN 50 to DN 600 for wide-tolerance connectors
(Table 10.2).
Maximum OD or DN of the pipes to be connected Joint gap (mm)
OD (mm) DN Coupling Flange adaptor
OD 110 DN 100 20 15
110 < OD 225 100 < DN 200 25 20
225 < OD 315 200 < DN 300 35 30
315 < OD 400 300 < DN 400 55 40
400 < OD 630 400 < DN 600 70 50
02.2011
10.3.1 Through-bolts (single bolts)
There are designs of coupling and flange

adaptor where the bolts either pull the
glands at opposite ends directly towards
one another or where they pull the gland
towards the flange (Fig. 10.3), the body of
the coupling floating as it is clamped in
between. The bodies of the couplings and
flange adaptors may be single in this case
but in couplings the same pre-loading
force acts in both joints, i.e. the joints can-
not be individually set.
Fig. 10.3: Fig. 10.4:
The shortening of the distance bet- Through-bolts: the gland is pulled directly Wide-tolerance coupling for transitions
ween the glands causes a lengthening towards the flange between materials (fibre-cement pipe on
of the distance for which the bolts pro- the left, PE pipe on the right) where bolts
ject beyond the nuts. In couplings of the are fastened to the body
present kind, the change in length at the
two sockets adds up at the bolts, meaning
that there may be cases where socket 10.3.2 Bolts fastening to the body In these designs, each joint has a set of
wrenches using standard-depth sockets (double bolts) bolts of its own which are fastened to lugs
cannot be used. Deep sockets giving a lon- (Fig. 10.2) integrally cast on the body of
ger depth of penetration for bolts may be To enable the length of bolt needed to be the coupling.
necessary to enable torque wrenches to reduced and the joints at opposite ends In this case, the lengthening of the pro-
be used to check that torques are as laid to be made in succession and if required jecting part of the bolt is the result of the
down by the manufacturer. with different connecting forces, there shortening of the mechanical joint at only
are alternative systems using double bolts one end of the coupling; also the applied
(Fig. 10.4). pressure can be matched to the pipe
connected to the given end (Fig. 10.4).
02.2011
10.4 Wide-tolerance
flange adaptors
Gasket
Wide-tolerance flange adaptors (Fig. 10.5

and Fig. 10.6) enable plain pipe ends to
be connected to flanges and are therefore
equipped with a mechanical joint at the
end to which the pipe is connected and Gland
with a flange to EN 1092-2 [10.4] at the
opposite end.
Body of flange adaptor
There are flange adaptors which are slid
completely onto the pipes to be connected, Fig. 10.5: Fig. 10.6:
but because of this the full area of the Flexible wide-tolerance flange adaptor View in section of an assembled
flange gasket may possibly not be covered wide-tolerance flange adaptor
because of the increase in inside diameter
at the flange.
02.2011
10.5 Preloading of gasket tion, i.e. higher bolt tightening torques are 10.6 Ranges of pipe outside
required for reliable long-term operation diameters
even though considerably lower values
The self-augmenting sealing action as the may produce a short-term seal.
internal pressure rises which is known to Specific-size mechanic joints, such
occur as a result of the socket geometry in For this purpose, manufacturers draw as Gibault couplings for example, are
the case of TYTON® rubber gaskets does attention in their documentation to designed for a relatively small range of
not occur in mechanical joints. In wide- clearly specified requirements. It has pipe outside diameters and can thus often
tolerance couplings and flange adap- to be ensured that these requirements only be used for a single type of pipe.
ters, the pressure with which the gasket are complied by the use of suitable tools Under DN 14525, wide-tolerance coup-
system is applied must therefore make (torque wrenches) (Table 10.1). lings (Fig. 10.4) and flange adapters are
allowance for the long-term relaxation of designed for defined minimum working
the elastomer even at the time of connec- diameter ranges for each nominal size up
to DN 600 (Table 10.3).
Table 10.3:
Minimum working diameter range under EN 14525 [10.2]
Maximum OD or DN of the pipes to be connected Minimum working diameter

range
OD (mm) DN (mm)
OD 110 DN 100 10
110 < OD 225 100 < DN 200 15
225 < OD 315 200 < DN 300 20
315 < OD 400 300 < DN 400 25
400 < OD 630 400 < DN 600 30
02.2011
10.7 Allowable angular deflection Unless some additional support is provi- GW 368 [10.6] in Germany. Depending
ded, wide-tolerance couplings adjust to on the installation and operating condi-
the displacement by “floating”. tions, there are pipe materials, such as
The minimum value of angular deflection polyethylene for example, which may be
defined in EN 14525 [10.2] relates to the It needs to be borne in mind in this case subject to considerable expansion when
entire tolerance range of the given wide- that where pipes of widely differing out- there are wide variations in temperature.
tolerance connector. The bodies of wide- side diameters are connected, experience The resulting changes in length may make
tolerance couplings and flange adaptors shows that there tends to be considerably it necessary for there to be restrained
have to be designed for an angular deflec- more angular deflection at the connection joints in a pipe system, possibly even
tion of at least 3° in the case of pipes of to the smaller pipe. This is because of the when there are no thrust forces from the
the maximum allowable outside diameter. amount of space available in the body and internal pressure.
Because of this, pipes of smaller outside also because of the smaller overlap bet-
diameters have considerably more space ween the parts of the joint. On the basis of their construction, wide-
for angular deflection in the body of the tolerance joints of restrained design can
wide-tolerance coupling or flange adap- be divided into integrated and indepen-
tor. Where required, it may therefore be 10.8 Restraint dent systems.
necessary for the user to set a limit on
the possible angular deflection to enable
the joint to maintain its full sealing per- In most applications, flexible joints such
formance, which becomes less good the as MEGA-Flex joints are adequate regard-
more the angular deflection specified by less of their nature.
the manufacturer is exceeded.
In the case of non-restrained pressure
A sideways, heightwise or angular dis- pipe systems, thrust blocks are installed.
placement between the pipe ends to be In Germany these are designed as speci-
connected can be compensated for by a fied in DVGW-Arbeitsblatt GW 310 [10.5].
wide-tolerance coupling within the limits Restrained pressure pipe systems do not
set by the allowable angular deflections require any thrust blocks. The number of
at the two joints. restrained joints between pipes is calcu-
lated as specified in DVGW-Arbeitsblatt
02.2011
Linked ring
Gland of plastic bodies
Gasket Restraining
elements
Minimum allowable
pipe outside Maximum allowable
Fig. 10.7: diameter pipe outside diameter
BAIO® - Multijoint® cut-in sleeve
transition fitting
Body of coupling
10.8.1 Integrated restraint system

Fig. 10.8:
In this compact design (Figs. 10.7 and Coupling with mechanical joints and integrated restraint system
Fig. 10.8), the gasket and restraint ring (double bolts)
are both compressed in a single opera-
tion.
The connecting force is transmitted to the bodies which can be moved relative to
body of the gasket by the restraint ring in one another, and the dimensions of the
this case. The gap between the socket and gasket and the restraining elements are
the surface of the pipe is filled by plastic reduced to the minimum required.
02.2011
10.8.2 Independent restraint system

Gland
In independent systems (Fig. 10.9), the
Gland for restraint ring
gasket and restraint ring operate inde-
for gasket Independent
pendently of one another. At the time of
Gasket restraint ring
connection, the gasket is first compressed
against the pipe to be connected, and the
restraint ring is then able to act on the
Minimum
pipe with whatever connecting forces allowable pipe
are required in the given case regard- Maximum allowable
outside diameter pipe outside diameter
less of the force with which the gasket
is applied.
Because the gap between the gasket and

pressure ring and the pipe has to be filled Body of coupling
solely by the rubber gasket, these systems
are fitted with rubber gaskets of very large Fig. 10.9:
volume. Coupling with mechanical joints and independent restraint system
This system is less compact and requires

higher effort in installation but, if carefully
handled, it does allow optimum settings to
be made for the given application.
02.2011
10.9 References [10.3] DIN 28602 [10.5] DVGW-Arbeitsblatt GW 310

Rohre und Formstücke Widerlager aus Beton –
aus duktilem Gusseisen – Bemessungsgrundlagen
[10.1] EN 12842 Stopfbuchsenmuffen- [DVGW worksheet GW 310
Ductile iron fittings for PVC-U Verbindungen – Concrete thrust blocks –
or PE piping systems – Zusammenstellung, Muffen, Principles of sizing]
Requirements and test methods Stopfbuchsenring, Dichtung, 2008-01
[Duktile Gussformstücke für Hammerschrauben und Muttern]
PVC-U- oder PE-Rohrleitungs- [Ductile iron pipes and fittings – [10.6] DVGW-Arbeitsblatt GW 368
systeme – Bolted gland joints – Längskraftschlüssige Muffenver-
Anforderungen und Assembly, sockets, counter ring, bindungen für Rohre, Formstücke
Prüfverfahren] sealing ring, bolts and nuts] und Armaturen aus duktilem
2000 2000-05 Gusseisen oder Stahl
[DVGW worksheet GW 368
[10.2] EN 14525 [10.4] EN 1092-2 Restrained socket joints for
Ductile iron wide tolerance Flanges and their joints – ductile iron and steel pipes,
couplings and flange adaptors Circular flanges for pipes, fittings and valves]
for use with pipes of different valves, fittings and accessories, 2002-06
materials: Ductile iron, grey iron, PN designated –
steel, PVC-U, PE, fibre-cement Part 2: Cast iron flanges
[Großbereichskupplungen und [Flansche und ihre Verbindungen –
-flanschadapter aus duktilem Runde Flansche für Rohre,
Gusseisen zur Verbindung von Armaturen, Formstücke und
Rohren aus unterschiedlichen Zubehörteile, nach PN bezeichnet –
Werkstoffen: Duktiles Gusseisen, Teil 2: Gußeisenflansche]
Grauguss, Stahl, PVC-U, PE, 1997
Faserzement]
2004
02.2011
E-Book – Ductile iron pipe systems Chapter 11: Safeguarding with concrete thrust blocks 11/1
11 Safeguarding with concrete

thrust blocks
10.2010
E-Book – Ductile iron pipe systems Chapter 11: Safeguarding with concrete thrust blocks 11/2
11 Safeguarding with concrete thrust blocks

10.2010
E-Book – Ductile iron pipe systems Chapter 12: Durability 12/1
12 Durability
10.2010
E-Book – Ductile iron pipe systems Chapter 12: Durability 12/2
12 Durability
10.2010
E-Book – Ductile iron pipe systems Chapter 13: Gaskets 13/1
13 Gaskets
13.1 General
13.2 Types of gaskets
13.3 Properties
13.4 Gaskets for drinking water pipelines
13.5 Gaskets for sewage drains and pipelines
13.6 References
10.2013
13 Gaskets By far the largest number of iron pipes

are used in buried pipelines with push-in
joints. Because of this the TYTON® and
Buried ductile iron pipelines are almost without exception assembled using STANDARD systems have gained huge
push-in joints. The gaskets for the TYTON® and STANDARD systems are significance over the course of decades
extremely important. They are chambered compression gaskets with special of practical applications.
fixing profiles. Their sealing function is ensured throughout the entire working
life of the pipeline. The requirements for the material of the gasket concentrate A decisive factor in the tightness of
on tightness over the long term. By using different source materials the rubber push-in joints is the adaptability of a
can be adapted to the requirements of the relevant medium. profiled rubber gasket. Because of its
high degree of elasticity and durability,
rubber is a particularly good sealing
material.
13.1 General Gaskets are also a reliable means of Although in the past only gaskets made
preventing impurities and pollution of of vulcanised natural rubber (NR) were
the groundwater caused by the escape used, over the last 25 years or so gas-
It is not possible to provide constant of waste water and gases. The different kets have been exclusively made of syn-
checking and monitoring of buried pipe- fields of application often demand the thetic rubber, which is superior to
lines. Therefore the long-term reliability use of different types of gaskets which natural rubber in terms of chemical
of the gaskets in the pipe joints is particu- need to be produced from high quality and temperature resistance as well as
larly important. elastomer materials. The need for durability. EPDM (ethylene propylene
joints which are going to remain tight diene monomer) is used for drinking
The reliability and durability of the over the long term is reflected in a water and NBR (acrylonitrile butadiene
sealing material used contributes to a range of requirements for strength, elastomer) is used for waste water. The
high degree to the security of the pipeline. resistance to deformation under pres- field of application for push-in joints
This security serves to protect our most sure (resilience), ageing characteristics according to EN 545 [13.01], e.g. for drink-
essential food – drinking water. and chemical resistance. ing water, ranges from 0 °C to 50 °C for
EPDM gaskets.
10.2013
For waste water as per EN 598 [13.02] the In the context of European construction 13.2 Types of gaskets
upper limit for NBR gaskets depending on products regulations, EN 681-1 [13.03]
nominal sizes 45 °C (up to and including has since been harmonised to include the
DN 200) and 35 °C (above DN 200). CE marking requirement. The national 13.2.1 TYTON® gasket
requirements for the production and
For applications above these tempera- testing of gaskets for push-in joints in The profile of the TYTON® gasket is
tures it is recommended that other syn- ductile iron pipes are summarised in shown in cross-section in Fig. 13.1. It
thetic elastomers are used, such as FPM DVGW test specification VP 546 [13.04], to consists of a combination of two types
(fluoro rubber) because of their resistance become DVGW worksheet W 384 [13.05]. of rubber: the one with a hardness of
at higher temperatures. 55 IRHD (International Rubber Hard-
ness Degree) is designed for optimum
Materials standard EN 681-1 [13.03] sealing function and long-term elasticity
applies to gaskets in drinking water and (sealing part).
waste water pipelines.
Holding part Sealingpart
Fig. 13.1: Fig. 13.2:

®
Cross-section of a TYTON gasket TYTON® gasket DN 300
10.2013
Fig. 13.3: Fig. 13.4:

Cross-section of a STANDARD gasket STANDARD gasket DN 300
The other part, with a hardness of The TYTON® gasket (Fig. 13.2) is
85 IRHD, has the job of keeping the standardised in DIN 28603 [13.06] for The gasket consists of a homogenous
gasket in place during the assembly of the the nominal sizerange from DN 80 to rubber material with a hardness of
joint (holding part). DN 1400. Depending on the area of use, 67 IRHD. The STANDARD gasket
as a rule it consists of synthetic rubber (Fig. 13.4) is standardised in DIN 28603
Because the sealing part adapts itself qualities EPDM or NBR. [13.06] for the nominal sizerange from
to fit between the inside of the push-in DN 80 to DN 2000.
joint and the outside of the pipe, high 13.2.2 STANDARD gasket
restoring forces are produced. The effect 13.2.3 Flat gaskets
is to seal the joint, not only under low and Fig. 13.3 shows the STANDARD gasket
high internal pressures but also in case of in cross-section. As with the TYTON® Flat gaskets are used for sealing
positive and negative outside pressures. gasket the joint is sealed by the flanged joints (Fig. 13.5). The sealing
restoring force of the radially compressed effect is produced by the fact that
ring. two flanges are pressed against each
10.2013
other by means of bolts and nuts.

Between the two flanges is the gasket,
which ensures the sealing function by
means of high contact pressure.
Flat gaskets generally consist of rubber

with a hardness of < 80 IRHD. A steel core
vulcanised into the rubber effectively
prevents the joint from being displaced
or blown out under high stresses.
Flat gaskets are available for all current

nominal sizes, e.g. DN 80 to DN 2000,
and for nominal pressures up to PN 63
(depending on nominal size). Their
dimensions are specified in EN 1514-1
[13.08]. National requirements for
production and testing can be found
in DVGW test specification VP 547
[13.09], to become DVGW worksheet
W 385 [13.10].
Fig. 13.5:
Example of a flat gasket to DIN EN 1514-1 [13.07]
10.2013
13.3 Properties more complicated. Therefore it is only

used if there are higher requirements
set for the measurement in terms of
Elastomer gaskets have the task of reli- precision and reproducibility. The hard-
ably sealing pipe joints over decades. ness depends on the composition of the
The following properties are essential: rubber and its vulcanisation. Because
■ hardness, these parameters necessarily modify
■ tensile strength, other properties of a rubber material
■ elongation at break, as well, the requirements for gasket
■ compression set, materials are often summarised as hard-
■ stress relaxation, ness classes. The hardness of push-in
■ resistance to ageing, joint gaskets is coordinated with the
■ behaviour in the cold, geometric shape and construction of the
■ ozone resistance, pipe joint.
■ chemical resistance.
Hardness is determined over the whole
13.3.1 Hardness ring or on standard test pieces taken from
the gasket or on sample plates of the
The hardness of rubber is its relative mixture used.
resistance to the penetration of an
object. In order to test hardness, the
test methods according to Shore-A
and IRHD are used. In EN standards,
rubber hardness is stated according to
IRHD.
In order to determine rubber hardness

according to Shore-A, simple hand-held Fig. 13.6:
test apparatus can be used (Fig. 13.6). Durometer for measuring rubber
Measurement according to IRHD is hardness according to Shore-A
10.2013
13.3.2 Tensile strength and ultimate of all connection parts and when select- With an ideal elastic behaviour, the
elongation ing the quality of rubber to be used. specimen would resume its initial
dimensions after the pressure is
b
Tensile strength and ultimate elongation CS = ⋅100 [%] (13.1) released. However the test shows that
a
are properties of rubber which are easily the specimen retains a slight perma-
determined. Ageing effects, which can be The compression set according to Equa- nent deformation (Fig. 13.7, b), which is
traced back to oxidative degradation, can tion 13.1 is determined on cylindrical referred to as the compression set and
easily be recognised by changes in tensile specimens which are pressed together stated as a % of the total deformation a.
strength and ultimate elongation among for a specified length of time at a given
other things. temperature in the axial direction by 25 %
(Fig. 13.7, a).
13.3.3 Compression set
b
e.g. 0.32 mm
Good compression behaviour is neces- = 8 % of a
a
sary in order to ensure the function of the e.g. 4 mm
gasket even when the joint moves. = 25 %
deformation
Specimen
The sealing chamber gap of the pipe joint e.g. 16 mm
= 100 %
which is formed between socket and pipe
must be permanently filled with rubber
even during the settlement of the pipe
in such a way that the gasket applies
sufficient contact pressure force to the
sealing surfaces.
Plastic (= permanent) deformations

of the gasket, referred to as the com-
pression set (CS), are to be taken into Fig. 13.7:
account right from the point of deter- Definition of the compression set (CS)
mining the dimensions and tolerances according to equation 13.1
10.2013
13.3.4 Stress relaxation 13.3.5 Ageing The change in properties brought about
by cooling should however not exceed a
As well as the compression set, stress For a joint to remain tight and problem- certain level with rubber gaskets so that
relaxation is another measure of the free over decades, in addition to the elastic no difficulties occur during assembly at
elasticity of a rubber gasket. For the seal properties, the ageing behaviour of the low temperatures. The following note
to have good durability, the gasket must rubber has a decisive role to play. Ageing has therefore been included in the
have the lowest possible degree of stress is essentially influenced by light, oxygen, assembly instructions for gaskets for
relaxation. temperature and medium. ductile iron pipes:
Compressive stress relaxation (CSR) Therefore ISO 2230 [13.11] specifies that Practical tip:
and compression set (CS) are identically gaskets should be stored in cool and dark At temperatures below 0 °C gaskets may
loaded in the test period (25 % defor- conditions. be subject to a certain increase in hard-
mation). While with the CS it is the ness. With assembly temperatures below
deformation path which determines the The ageing behaviour is usually tested 0 °C the gaskets should therefore be
result, with CSR it is the residual stress by means of a 7-day ageing test at stored at a temperature above +10 °C
which gives the result. +70 °C. Here the changes in hardness, wherever possible in order to simplify
tensile strength and elongation at assembly. The gaskets should only
Stress relaxation is more difficult and breakmeasurements are compared be taken out of storage (e.g. in a heated
expensive to determine and requires with the condition as new. contractor’s shed) shortly before
a longer time, which is why the com- assembling the joints. In order to test the
pression set is preferred for routine 13.3.6 Behaviour in the cold behaviour of the gaskets when cold, the
testing. increase in hardness after storage in the
At low temperatures, the hardness of rub- cold is measured (70 hours at -10 °C).
The restoring force occurring with a con- ber increases. This behaviour is rever- For higher requirements there is also the
stantly held deformation is measured as sible and does not cause any loss of qua- possible option of cold testing at -25 °C
a function of time. The decrease in the lity. When it warms up again the rubber as per EN 681-1 [13.03].
restoring force over time, measured as a % reverts to its original properties.
of the initial value, is the stress relaxation.
10.2013
13.3.7 Ozone resistance This is tested and evaluated on the basis In individual cases this may lead to
of the change in volume of a specimen in storage for a number of years; however,
A particular form of oxidative degradation – accordance with ISO 1817 [13.12] after because of the special formulation of the
ozone cracking – is tested by checking 7 days storage in distilled or deionised gaskets as regards their length of use,
ozone resistance. water at 70 °C. More far-reaching require- this is possible without problem as long
ments are to be determined in accordance as the prescribed storage conditions are
For the test, a specimen of rubber is with EN 681-1 [13.03]. observed.
stretched and exposed to an ozone-
charged atmosphere at a specified 13.3.9 Time of storage According to ISO 2230 [13.11] the
temperature and for a certain time. At storage period should not exceed the
the end of the test, no cracks should be In order to guarantee a supply of gaskets storage times stated in Table 13.1
visible on the surface of the rubber. which meets market requirements, longer- (extract).
term storage is usual and necessary.
13.3.8 Chemical resistance

Table 13.1:
When they are used in drinking, un- Extract from storage times as per ISO 2230 [13.11]
treated and industrial water pipelines,
gaskets for push-in joints are not subject Material a Storage time b Extended storage time b
to any particular stresses as regards their NR, SBR 5 years + 2 years
chemical resistance.
NBR, HNBR, IIR, CIIR, BIIR 7 years + 3 years
However, for use in sewage drains and EPDM, FKM, VMQ 10 years + 5 years
pipelines the gasket’s resistance to waste
a
water is to be established in accordance Selection specific to application as per ISO 2230 [13.11]
b
with EN 681-1 [13.03]. Checking and evaluation as per ISO 2230 [13.11]
10.2013
13.4 Gaskets for drinking 13.5 Gaskets for sewage

water pipelines drains and pipelines
TYTON® and STANDARD gaskets for Sewage drains and pipelines must be
use in drinking water pipelines are pre- durably tight. For this reason, in addition
dominantly in EPDM as per EN 681-1 to a functioning pipe and joint system, the
[13.03]. They should not affect the colour, gasket requires a rubber quality which
the odour, the taste and the bacteriological offers the most durable possible resist-
properties of the drinking water. ance to the conditions to be expected in
a sewage pipeline, above all from aggres-
The requirements for these gaskets are sive media. As a rule, gaskets in NBR are
determined in DVGW test specification used for this.
VP 546 [13.04], to become DVGW work-
sheet W 384 [13.05] in future. This defines In order to provide evidence of the resist-
the requirements with respect to hygiene ance of NBR material against the organic
in the rubber guidelines of the German impurities most commonly found in waste
Environmental Agency (UBA) [13.13] and water, extensive investigations have been
the requirements with respect to micro- carried out [13.15], [13.16] and [13.17].
biology of DVGW worksheet W 270
[13.14]. More far-reaching information on gaskets
as regards technique and application can
be found in Chapters 8 and 9.
10.2013
13.6 References [13.03] EN 681-1 [13.05] Gelbdruck, DVGW-Arbeitsblatt W 384

Elastomeric seals – Dichtungen für Muffenverbindungen
Material requirements for pipe joint in Rohrleitungen aus duktilem
[13.01] EN 545 seals used in water and drainage Gusseisen oder Stahl in der
Ductile iron pipes, fittings, accessories applications – Wasserversorgung;
and their joints for water pipelines – Part 1: Vulcanized rubber Anforderungen und Prüfungen
Requirements and test methods [Elastomer-Dichtungen – [Draft, DVGW worksheet W 384
[Rohre, Formstücke, Zubehörteile Werkstoff-Anforderungen für Gaskets for push-in joints in ductile
aus duktilem Gusseisen und ihre Rohrleitungs-Dichtungen für iron or steel pipelines for water supply;
Verbindungen für Wasserleitungen – Anwendungen in der Wasser- Requirements and test methods]
Anforderungen und Prüfverfahren] versorgung und Entwässerung – 2013-04
2010 Teil 1: Vulkanisierter Gummi]
1996 + A1:1998 + A2:2002 + [13.06] DIN 28603
[13.02] EN 598 A3:2005 Rohre und Formstücke aus
Ductile iron pipes, fittings, accessories duktilem Gusseisen –
and their joints for sewerage [13.04] DVGW-Prüfgrundlage VP 546 Steckmuffen-Verbindungen –
applications – Dichtungen für Muffenverbindungen Zusammenstellung, Muffen
Requirements and test methods in Rohrleitungen aus duktilem und Dichtungen
[Rohre, Formstücke, Zubehörteile Gusseisen oder Stahl – [Ductile iron pipes and fittings –
aus duktilem Gusseisen und ihre Anforderungen und Prüfungen Push-in joints –
Verbindungen für die Abwasser- [DVGW test specification VP 546 Survey, sockets and gaskets]
Entsorgung – Gaskets for push-in joints in ductile 2002-05
Anforderungen und Prüfverfahren] iron or steel pipelines –
2007 + A1:2009 Requirements and test methods]
2007-06
10.2013
[13.07] DIN EN 1514-1 [13.09] DVGW-Prüfgrundlage VP 547 [13.11] ISO 2230

Flansche und ihre Verbindungen – Dichtungen für Flanschverbindungen Rubber products –
Maße für Dichtungen für Flansche in Rohrleitungen aus duktilem Guidelines for storage
mit PN-Bezeichnung – Gusseisen – [Produkte aus Gummi –
Teil 1: Flachdichtungen aus nicht- Anforderungen und Prüfungen Leitlinie für die Lagerung]
metallischem Werkstoff mit oder [DVGW test specification VP 547 2002-04
ohne Einlagen Gaskets for flange connections in
[Flanges and their joints – ductile iron pipelines – [13.12] ISO 1817
Dimensions of gaskets for Requirements and test methods] Rubber, vulcanized –
PN-designated flanges – 2002-03 Determination of the effect
Part 1: Non-metallic flat gaskets with of liquids
or without inserts] [13.10] Gelbdruck, DVGW-Arbeitsblatt W 385 [Elastomere – Bestimmung des
1997-08 Dichtungen für Flanschverbindungen Verhaltens gegenüber Flüssigkeiten]
in Rohrleitungen aus duktilem 2005
[13.08] EN 1514-1 Gusseisen oder Stahl in der Wasser-
Flanges and their joints – versorgung; [13.13] Umweltbundesamt, Deutschland
Dimensions of gaskets for Anforderungen und Prüfungen UBA-Elastomerleitlinie
PN-designated flanges – [Draft, DVGW worksheet W 385 Leitlinie zur hygienischen Beurteilung
Part 1: Non-metallic flat gaskets with Gaskets for flange connections in von Elastomermaterialien im
or without inserts ductile iron or steel pipelines for Kontakt mit Trinkwasser
[Flansche und ihre Verbindungen – water supply; Requirements and test (Elastomerleitlinie)
Maße für Dichtungen für Flansche methods] [UBA-Rubber Guideline
mit PN-Bezeichnung – 2013-04 Guideline for the hygienic assessment
Teil 1: Flachdichtungen aus nicht- of elastomer materials in contact
metallischem Werkstoff mit oder with drinking water
ohne Einlagen] (Elastomer Guideline)]
1997 2012-05
10.2013
[13.14] DVGW-Arbeitsblatt W 270 [13.16] Eignungsprüfungen von Tyton-

Vermehrung von Mikroorganismen Dichtringen aus Nitrilkautschuk für
auf Werkstoffen für den Raffinerie-Abwasserleitungen
Trinkwasserbereich – Bericht des Engler-Bunte-Instituts der
Prüfung und Bewertung Universität Karlsruhe
[DVGW worksheet W 270 [Suitability testing of TYTON sealing
Enhancement of microbial growth on rings in nitrile rubber for waste water
materials in contact with drinking lines in refineries.
water – Test methods and assessment] Report by the Engler-Bunte Institute
2007-11 of the University of Karlsruhe]
1975
[13.15] Wolf, W.:
Untersuchungen über das Verhalten [13.17] Bächmann, K.:
von TYTON-Dichtungen in CKW- Diffusionsverhalten chlorierter und
gesättigtem Wasser aromatischer Kohlenwasserstoffe
[Investigations into the behaviour durch NBR-Dichtringe in TYTON-
of TYTON gaskets in CHC saturated Verbindungen
water] [Diffusion behaviour of chlorinated
FGR GUSSROHR-TECHNIK, and aromatic hydrocarbons by NBR
Heft 24 (1989), S. 4 ff sealing rings in TYTON joints]
FGR GUSSROHR-TECHNIK,
Heft 28 (1993), S. 16 ff
10.2013
10.2013
E-Book – Ductile iron pipe systems Chapter 14: Coatings 14/1
14 Coatings
14.1 General
14.2 Works-applied coatings on pipes
14.3 Coating of fittings and valves
14.4 On-site measures
14.5 References
10.2010
14 Coatings rent variants of zinc-based active coatings

are being selected attention must be paid
to the soil parameters laid down for these
Coatings provide lasting protection for ductile iron pipelines. Coatings which are coatings. These soil parameters have been
applied to pipes, fittings and valves in the works cater for soil conditions and are selected in such a way as to rule out the
added to on site if necessary. Corrosion protection provisions specific to ductile use of the given variant. A table providing
iron pipes, and their fields of use, are described below. an overview of the fields of use follows in
section 14.2.1.
Under the German rules, a systematic

14.1 General which encourage the corrosion of ductile approach is adopted as follows: after a
iron and these parameters include: thorough investigation of the soil under
As a general principle, pipes, fittings ■ resistivity of the soil, DIN 50929-3 [14.7] along the route to be
and valves are supplied with works- ■ pH, followed by the pipeline, the soil is clas-
applied coatings which are added to on ■ reserve of acidity, sified as belonging to one of three classes
site if necessary. It is important for the ■ position relative to the water table, of corrosiveness.
provisions for corrosion protection to be ■ heterogeneity (mixed soils),
selected in such a way as to ensure dura- ■ presence of refuse, cinders, slag, pol- DIN 30675-3 [14.8] then governs the fields
bility for the pipeline. lution from wastes or industrial efflu- of use of the different types of corrosion
ents, protection for underground pipelines of
For this, it is necessary for an accurate ■ peaty soils, ductile iron. The standard provides an
knowledge to exist of the types of soil in ■ occurrence of stray currents. overview of works-applied coatings and
which the pipelines are going to be laid. on-site measures as a function of the level
Whereas the polyethylene (EN 14628 of corrosiveness of the soil.
The European product standards EN 545 [14.3]), polyurethane (EN 15189 [14.4])
[14.1] and EN 598 [14.2] include an infor- and epoxy (EN 14901 [14.5]) coatings, The fields of use for coatings for pipes,
mative Annex D in which the limits of use which give high-resistance electrical fittings and valves are grouped together
are given for different coating systems insulation, and the conductive cement in table 14.1.
for pipes, fittings and accessories. These mortar coating (EN 15542 [14.6]) can be
limits relate to important soil parameters used in soils of all kinds, when the diffe-
10.2010
Table 14.1:
Fields of use for underground pipelines of ductile iron with coatings to EN 14628 [14.3], EN 15189 [14.4],
EN 15542 [14.6], DIN 30674-3 [14.9] and -5 [14.10], EN 14901 [14.5], DIN 51178 [14.14] in conjunction with
DIN 30675-2 [14.8] for pipes, and EN 14901 [14.5] and DIN 51178 [14.14] for fittings and valves.
No. Coating on pipes Thickness of Coating recommended Suitable bedding for Fields of
coating for joints corrosion protection use in the
form of soil
classes
1 Zinc coating with finishing 130 g/m2 of zinc None Not provided I, II
layer (cover coating), to with finishing layer
DIN 30674-3 [14.9] to EN 545 [14.1] Provided I, II, III 2)
2 Zinc coating with 200 g/m2 of zinc None Not provided I, II
finishing layer, to with 100 μm
OENORM B 2560 [14.11] polyurethane Provided I, II, III 2)
finishing layer
3 Cement mortar coating 5.0 mm Heat-shrinkable material or Not provided I, II, III
to EN 15542 [14.6] B-50M1) coating to DIN 30672
[14.12] or rubber collars
4 Polyethylene coating 1.8 to 3.0 mm Heat-shrinkable material or Not provided I, II, III
to EN 14628 [14.3] B-50M1) coating to DIN 30672
[14.12]
5 Polyurethane coating 700 μm None Not provided I, II, III
to EN 15189 [14.4]
6 Polyethylene sleeving to 0.2 mm Same as pipes Provided3) I, II, III
DIN 30674-5 [14.10] in
conjunction with
DIN 30674-3 [14.9]
10.2010
No. Coating on pipes Thickness of Coating recommended Suitable bedding for Fields of
coating for joints corrosion protection use in the
form of soil
classes
7 Epoxy coating to 250 μm ■ None if pipes are zinc Not provided I, II, III
EN 14901 [14.5] coated (nos. 1 and 2)
■ Heat-shrinkable material or
B-50M1) coating to DIN 30672
[14.12] or rubber collars, if
pipes are coated as in
nos. 3 to 5
8 Coating of technical 250 μm ■ None if pipes are zinc Not provided I, II, III
enamel to DIN 51178 [14.14] coated (nos. 1 and 2)
■ Heat-shrinkable material or
B-50M1) coating to DIN 30672
[14.12] or rubber collars, if
pipes are coated as in
nos. 3 to 5
1)
At sustained temperatures of T 330 °C, the B-50M coating to DIN 30672 [14.12] or
the C-30M coating to DIN 30672 [14.12] may be used for joints.
2)
Not suitable when there is constant exposure to eluates of pH < 6 and in peaty, boggy, muddy and marshy soils
3)
The directions given in section 4.1 need to be followed.
Note: By agreement, materials for corrosion protection covered by DIN 30672 Part 1
[14.12] may be used for coating ductile iron pipes away from the joints
10.2010
There is also standard DIN 30675-2 [14.8] aluminium by mass 15 %) and an epoxy of corrosion protection, then the poly-
which provides information on provisi- finishing layer has been available. For this ethylene coating to EN 14628 [14.3], the
ons for corrosion protection when there is coating, the mass of metal is increased to cement mortar coating to EN 15542 [14.6]
an electrochemical action. As part of this 400 g/m2. or the polyurethane coating to EN 15189
it also deals with electrically insulating [14.4] may be used, as desired.
socket joints. Another of the active protective systems is
zinc applied in a mass of 200 g of Zn/m2 The “zinc coating with protective finishing
with a polyurethane finishing layer at layer” corrosion protection system is sta-
14.2 Works-applied least 100 μm thick. There is a standard ble in its field of use, the cast iron being
coatings on pipes for this coating in Austria in the form of separated from the soil by the finishing
OENORM B 2560 [14.11]. layer.
14.2.1 Zinc coating with The fields of use of these active protec- Pores in the finishing layer or injuries
finishing layer tive systems are laid down in Annex D of to the coating when the pipes are being
EN 545 [14.1] in the form of exclusion cri- installed “heal” and close due to the pro-
The standard coating given to ductile iron teria and they are shown in Table 14.2. ducts of reaction produced by the zinc,
pipes is a zinc coating with a finishing which are only sparingly soluble in moist
layer, to EN 545 [14.1] and EN 598 [14.2]. Under the German rules, these stipula- ground (a dielectric). These products form
In the majority of soils, this active coa- tions are supplemented by DIN 30675-2 when metallic zinc reacts with constitu-
ting provides lasting protection against [14.8]; Germany also recognises what is ents of the surrounding soil.
damage by corrosion. The zinc coating known as bedding suitable for corrosion
and the finishing layer act synergistically, protection. This consists of chemically Fig. 14.1 shows the remote action of the
i.e. the combined effect they have in pro- neutral sands which stop the pipeline zinc coating: in the rectangular areas, the
tecting against corrosion is better than from coming into direct contact with cor- coating had been injured by removing it
the sum of the effects that the individual rosive types of soil. before the test pipes were buried for nine
coatings would have. years in a test field.
Table 14.1 shows the fields of use for the
For some years now, a coating which com- systems, the soil classes being determined
prises a zinc-aluminium layer (proportion as indicated in DIN 50929-3 [14.7]. If the
of zinc by mass 85 % and proportion of soil conditions call for a higher standard
10.2010
Table 14.2:
Fields of use and soil conditions for zinc-based active coatings,
as specified in Annex D of EN 545 [14.1]
Type of protection Soils in which protection of the given

under section 4.4.2 of EN 545 [14.1] type is not to be used
Zinc coating 130 g of Zn/m2 ■ Soils with a resistivity < 1,500 :cm when laid above the water table,
and finishing layer 70 μm < 2,500 :cm when laid below the water table
■ Mixed soils. i.e. comprising two or more soil natures
■ Soil with a pH < 6 and a high reserve of acidity
■ Soils containing refuse, cinders, slag or polluted by waste or industrial effluents
■ If stray currents occur
Zinc coating 200 g of Zn/m2 ■ Soils with a resistivity < 1,500 :cm when laid above or below the water table
and finishing layer 100 μm ■ Mixed soils. i. e. comprising two or more soil natures
■ Soil with a pH < 6 and a high reserve of acidity
■ Soils containing refuse, cinders, slag or polluted by waste or industrial effluents
Zinc coating 400 g of ZnAl/m2 ■ Acidic peaty soils
and finishing layer 70 μm ■ Soils containing refuse, cinders, slag or polluted by waste or industrial effluents
■ Soils below the marine water table with a resistivity < 500 :cm
10.2010
activated should any injuries occur at a

Deposit of zinc salts later date, due say to movements of the
++
ground or to subsequent digging work.
Zn Current
Finishing
layer Under EN 545 [14.1] and EN 598 [14.2],
Oxide skin
Zinc the zinc coating on ductile iron pipes
may also be provided with an at least
Cast wall Injury
70 μm thick coating of bituminous paint.
Fig. 14.3 shows ductile iron sewer pipes
Fig. 14.2: to EN 598 [14.2] which have a reddish-
Cathodic protective effect of the zinc brown coloured finishing layer of bitu-
at injuries to the protective layer minous paint.
By passing through the porous finishing

layer for a few millimetres, the zinc ions
are able to protect the exposed surface
by depositing products of reaction which
are hard to dissolve (a scarring or auto-
genous healing process). Fig. 14.2 is a
simplified schematic representation of
the process.
All the relevant requirements for the pipe
Fig. 14.1: system are brought together in DVGW
Autogenous healing of artificial injuries Arbeitsblatt GW 337 [14.13]. An additional
by products of reaction of zinc requirement is that the mean mass of zinc
per unit area must be at least 200 g/m2 and Fig. 14.3:
for the Zn 85 – Al 15 system must be at Ductile iron sewer pipes to EN 598 [14.2]
least 400 g/m2. In this way there is enough with a zinc coating and a reddish-brown
metallic zinc available for the zinc to be coloured finishing layer of bituminous paint.
10.2010
14.2.2 Cement mortar coating 14.2.3 Polyethylene coating
Ductile iron pipes with a cement mortar The polyethylene coating forms a layer of
coating, Fig. 14.4, can be used in soils of high electrical resistance separating the
all types. The cement mortar coating stops cast iron from the native soil. The layer
corrosive media from penetrating and needs to be at least 1 mm thick purely
withstands mechanical stresses during to provide corrosion protection and the
transport and installation. This coating rest of its thickness serves to improve the
has proved its worth particularly for the ability of the protective layer to withstand
trenchless installation techniques of mechanical loads. Fig. 14.5 shows ductile
which increasing use is now being made. iron pipes with a polyurethane coating.
Under EN 15542 [14.6], the ability of
the cement mortar coating to withstand Fig. 14.4:
mechanical loads is determined by two Ductile iron pipes with a
requirements: cement mortar coating
■ bond strength
■ impact strength.
Should injuries nevertheless happen to
These requirements are formulated in occur (e.g. when installation is by the
such a way that the possibility of damage burst lining technique), the damaged
to the layer of cement mortar can be ruled areas are protected by the layer of zinc
out both in the course of proper transport and the remote action which it has.
and when installation takes place even
in the most difficult terrain. For the pro- The joint regions are protected after
duction of the cement mortar coating see assembly, see section 14.4.2.
Chapter 3, section 3.5. Ductile iron pipes
with a cement mortar coating are shown
in Fig. 14.4. Fig. 14.5:
Ductile iron pipes with a
polyethylene coating
10.2010
EN 14628 [14.3] makes a distinction bet- 14.3 Coating of fittings and valves
ween the standard thickness coating and
the increased thickness coating.
Fittings and valves come in a wide variety
The requirements and tests specified in of shapes and designs and because of this
EN 14628 [14.3] are formulated in such the characteristic feature of the methods
a way that the polyethylene coating will and processes for coating them is often
withstand the usual stresses which occur that the coating materials are applied
during transport, storage and installa- simultaneously to all the surfaces of the
tion. The joint regions are protected after components, i.e. both the internal and
assembly, see section 14.4.2. external surfaces, in a single step.
14.2.4 Polyurethane coating Fig. 14.6: Automated processes employing pro-

Ductile iron pipes with a grammed manipulators are increasingly
The polyurethane coating (Fig. 14.6) polyurethane coating being used for this purpose.
forms a layer of high electrical resistance
separating the cast iron from the native 14.3.1 Epoxy coating
soil. Polyurethane resins are members adequate for the normal stresses occur-
of the thermoset family whose mecha- ring during transport, storage and instal- For use in both the drinking water field
nical properties vary only slightly with lation. The polyurethane coating has also and for carrying sewage and wastewater,
temperature and which are not subject proved its worth for trenchless installa- fittings and valves are usually given an
to cold flow. tion techniques. There is no need for the epoxy coating (Figs. 14.7 and 14.8). The
joint region to be provided with protec- coating is applied internally and externally
The two-component resin system is tion on site. in a mean thickness of at least 250 μm,
sprayed onto the surface of the cast iron EN 15189 [14.4] lays down requirements predominantly in the form of epoxy
pipe, which has been blast-cleaned and and tests for the polyurethane coatings powder, and the standard which applies
heated, without solvents. Because of its of ductile iron pipes. to the coating is EN 14901 [14.5].
relatively high hardness, impact resis-
tance and resistance to indentation, a
layer of a nominal thickness of 900 μm is
10.2010
Fig. 14.7: Fig. 14.8:

Epoxy coated resilient seated Epoxy coated fittings for sewage and wastewater
gate valve
The quality and testing requirements extensive system of in-house and external 14.3.2 Enamel coating of fit-
for powder coatings of valves and fit- monitoring ensures that the quality of the tings and valves
tings which are laid down in RAL-GZ 662 coating remains consistently high.
[14.20] are more demanding than those Technical enamel can be used as a coating
in EN 14901. The bond strength is higher The method of producing the coating is material for fittings and valves in soils
than in EN 14901 (12 N/mm2 as compared described in section 3.5.2. of all types. DIN 51178 [14.14] , English
with 8 N/mm2) and the test voltage for title: Vitreous and porcelain enamels –
freedom from pores is 3 kV rather than The coating can be used in soils of any Inside and outside enamelled valves and
1.5 kV. Also, the cathodic disbonding test desired corrosiveness. pressure pipe fittings for untreated and
was introduced as an indicator of resis- potable water supply – Quality require-
tance to undermining of the coating at ments and testing, was published in Octo-
injuries. The layer thickness and impact ber 2009.
resistance are of the same levels. An
10.2010
The enamelling creates a strong physical The properties of the internal and exter- Recently there has been an increasing
and chemical bond (an ion bond) to the nal enamel coatings are as follows: trend towards this type of coating being
ductile iron. It is formed by processes of ■ internal corrosion protection of proven replaced by the epoxy coating to EN 14901
diffusion from the substrate material to effectiveness, [14.5].
the enamel and vice versa. Requirements ■ high resistance to corrosion in all
and tests are given in DIN 51178 [14.14]. soils, Fig. 14.10 shows fittings with an external
Fig. 14.9 shows some fully enamelled ■ coating is continuous internally and coating of bituminous paint and a variety
fittings. externally, of linings.
■ high resistance to mechanical stres-
ses,
■ secure against undermining of coa-
ting, even when the surface is injured
c
locally,
■ resistance to ageing a
The enamelling process is described in b

section 3.5.2. Enamel coatings can be
used in soils of any desired corrosive-
ness.
14.3.3 Bitumen coating of fittings

d
Ductile iron fittings are also available with
an external coating of bituminous paint. Fig. 14.10:
Fittings with an external coating
The thickness of the layer is at least of bituminous paint and a
70 μm. Fittings coated in this way are variety of linings
generally provided with a cement mor- a) enamel
Fig. 14.9: tar lining (section 3.5.2). b) & c) cement mortar
Fully enamelled fittings d) bituminous paint
10.2010
14.4 On-site measures tion should not be used where there is

constant exposure to eluates whose pH
is < 6 or in peaty, boggy, clayey or marshy
Main backfill
A distinction is made between measures soils.
at installation and repair measures in the
case of the on-site measures. 14.4.2 Corrosion protection of
joint regions
Initial backfill
Measures at installation supplement
works-applied coatings which are already Side fill
Once the joints have been assembled,
present. The pipeline or a section of the Upper bedding the joint regions of pipelines with poly-
pipeline is provided with additional pro- Lower bedding ethylene or cement mortar coatings are
tection in this case. In the case of pipe coated as directed in the manufacturer’s
coatings such as cement mortar or poly- installation instructions (DIN 30675-2
ethylene coatings, it is the fittings which [14.8]) (Fig. 14.12).
are provided with this later protection. Pipeline zone Native soil
What have proved successful for the pro-
14.4.1 Bedding suitable for Fig. 14.11: tection of socket joints in polyethylene
corrosion protection Terms relating to the bedding of pipes coated pipes is heat shrinkable mate-
rial and, as an alternative for cement
Bedding suitable for corrosion protec- mortar coated pipes, rubber collars
tion is a layer of soil of soil class 1 (non- backfill, the side fill and the upper and (Fig. 14.13).
corrosive or only slightly corrosive under lower bedding (Fig. 14.11). This measure
DIN 50929-3 [14.7]) which rests in a produces a homogeneous zone surroun-
homogenous form against the surface of ding the pipeline, particularly in highly
the pipeline on all sides. corrosive heterogeneous soils.
Under DIN 30675-2 [14.8] it is used as As a result of this, spatially separated

a supplement to the zinc plus finishing anode and cathode regions, which might
layer system. Under EN 805 [14.15] and cause deep or shallow pitting, do not form.
EN 1610 [14.16], it consists of the initial Bedding suitable for corrosion protec-
10.2010
14.4.3 Measures when there is ■ maintaining of an adequate distance

electrochemical action from systems which have cathodic
protection, by following the recom-
Corrosion protection when there is elec- mendations of the DVGW/VDE
trochemical action is dealt with in detail Working Party on Questions of Corro-
in DIN 30675-3 [14.8]. “Generally spea- sion (the AfK) given in AfK 2 [14.17],
king, electrochemical action should not ■ drainage or forced drainage of
be expected in ductile iron pipelines with stray currents in accordance with
non-restrained joints due to the electrical DIN EN 50162 and VDE 0150 [14.18].
break caused by the rubber-sealed joint
between the pipes which occurs roughly Corrosion of buried ductile iron pipelines
Fig. 14.12: every 6 m. Any measures to protect against due to alternating current is dealt with
Application of a shrink sleeve electrochemical action can therefore be in [14.19].
dispensed with.”
It is stated in the above article that
What this standard mentions as causes the position is similar to that stated in
of electrochemical actions are “Formation DIN 30675-2 [14.8] for direct currents,
of electrochemical couples with extra- namely that the only pipelines with res-
neous cathodes and stray currents from trained joints which are at risk from cor-
direct current systems”. The above is also rosion are ones more than about 100 m
true of pipelines with restrained joints long which have metal conductive joints
where the restrained joints act as electri- and whose coatings act as electrical insu-
cal insulators. It is only in pipelines with lators to alternating currents.
restrained joints where the joints are
metal and conductive that provisions need
to be made for electrochemical protection,
Fig. 14.13: such for example as:
Ductile iron pipes with a cement mortar ■ installation of pipe joints which act
coating and with rubbers collars to as electrical insulators approximately
protect the socket joints every 100 m,
10.2010
14.4.4 Repair measures 14.5 References [14.3] EN 14628

Ductile iron pipes, fittings
The coatings of pipes, fittings and valves and accessories –
are selected to be sufficiently robust for [14.1] EN 545 External polyethylene coating
no significant injuries to occur to them Ductile iron pipes, fittings, for pipes –
provided they are properly handled. accessories and their joints for Requirements and test methods
water pipelines – [Rohre, Formstücke und Zube-
If repairs nevertheless have to be Requirements and test methods hörteile aus duktilem Gusseisen –
made, e. g. if incorrect handling occurs [Rohre, Formstücke, Zubehörteile aus Polyethylenumhüllung von Rohren –
or tapping or cutting is necessary, the duktilem Gusseisen und ihre Verbin- Anforderungen und Prüfverfahren]
manufacturer’s installation instructions dungen für Wasserleitungen – 2005
must be followed. Anforderungen und Prüfverfahren]
2006 [14.4] EN 15189
Ductile iron pipes, fittings
[14.2] EN 598 and accessories –
Ductile iron pipes, fittings, External polyurethane coating
accessories and their joints for for pipes –
sewerage applications – Requirements and test methods
Requirements and test methods [Rohre, Formstücke und Zubehör
[Rohre, Formstücke, Zubehörteile aus duktilem Gusseisen –
aus duktilem Gusseisen und ihre Polyurethanumhüllung von Rohren –
Verbindungen für die Abwasser- Anforderungen und Prüfverfahren]
entsorgung – 2006
Anforderungen und Prüfverfahren]
2007+A1:2009
10.2010
[14.5] EN 14901 [14.7] DIN 50929-3 [14.9] DIN 30674-3

Ductile iron pipes, fittings and Korrosion der Metalle – Umhüllung von Rohren aus
accessories – Korrosionswahrscheinlichkeit duktilem Gusseisen –
Epoxy coating (heavy duty) of metallischer Werkstoffe bei äußerer Teil 3: Zink-Überzug mit
ductile iron fittings and accessories – Korrosionsbelastung – Deck-Beschichtung
Requirements and test methods Rohrleitungen und Bauteile in [Sheathing ductile cast iron pipes –
[Rohre, Formstücke und Zubehör Böden und Wässern Part 3: Zinc coating with protective
aus duktilem Gusseisen – [Corrosion of metals – sheathing]
Epoxidharzbeschichtung (für erhöhte probability of corrosion of metallic 2001-03
Beanspruchung) von Formstücken materials when subject to corrosion
und Zubehörteilen aus duktilem from the outside – [14.10] DIN 30674-5
Gusseisen – Buried and underwater pipelines Umhüllung von Rohren aus
Anforderungen und Prüfverfahren] and structural components] duktilem Gsseisen –
2006 1985-09 Polyethylen-Folienumhüllung
[External protection of ductile
[14.6] EN 15542 [14.8] DIN 30675-2 cast iron pipes –
Ductile iron pipes, fittings Äußerer Korrosionsschutz von Polyethylene sleeving]
and accessories – erdverlegten Rohrleitungen – 1985-03
External cement mortar coating Schutzmaßnahmen und Einsatz-
for pipes – bereiche bei Rohrleitungen [14.11] OENORM B 2560
Requirements and test methods aus duktilem Gußeisen Duktile Gussrohre –
[Rohre, Formstücke und Zubehör [External corrosion protection Deckbeschichtung aus Polyurethan
aus duktilem Gusseisen – of buried pipes – oder Epoxidmaterialien –
Zementmörtelumhüllung Corrosion protection systems Anforderungen und Prüfungen
von Rohren – for ductile iron pipes] [Ductile iron pipes –
Anforderungen und Prüfverfahren] 1993-04 Finishing paints of polyurethane
2008 or epoxy materials –
2004-04-01
10.2010
[14.12] DIN 30672 [14.14] DIN 51178 [14.17] AfK-Empfehlung Nr. 2

Organische Umhüllungen für den Emails und Emaillierungen – Beeinflussung von unterirdischen
Korrosionsschutz von in Böden Innen- und außenemaillierte metallischen Anlagen durch Streu-
und Wässern verlegten Rohrleitun- Armaturen und Druckrohrform- ströme von Gleichstromanlagen
gen für Dauerbetriebstempera- stücke für die Roh- und Trinkwasser- [Interference of stray currents
turen bis 50 °C ohne kathodischen versorgung – from DC-installations with
Korrosionsschutz – Qualitätsanforderungen und Prüfung buried metallic structures]
Bänder und schrumpfende [Vitreous and porcelain enamels – 2009-09
Materialien Inside and outside enamelled valves
[External organic coatings for and pressure pipe fittings for un- [14.18] DIN EN 50162; VDE 0150:2005-05
the corrosion protection of treated and potable water supply – Schutz gegen Korrosion durch
buried and immersed pipe- Quality requirements and testing] Streuströme aus Gleich-
lines for continuous operating 2009-10 stromanlagen;
temperatures up to 50 °C – Deutsche Fassung EN 50162:2004
Tapes and shrinkable materials] [14.15] EN 805 [Protection against corrosion by stray
2000-12 Water supply – current from direct current systems;
Requirements for systems and German version EN 50162:2004]
[14.13] DVGW-Prüfgrundlage GW 337 components outside buildings 2005-05
Rohre, Formstücke und Zubehör- [Wasserversorgung –
teile aus duktilem Gusseisen für Anforderungen an Wasserversor- [14.19] G. Heim und Th. Heim:
die Gas- und Wasserversorgung – gungssysteme und deren Bauteile Wechselstrom-Korrosion von
Anforderungen und Prüfungen außerhalb von Gebäuden] erdverlegten Rohrleitungen
[DVGW test specification GW 337 2000 aus duktilem Gusseisen
Ductile cast iron pipes, fittings [Afterrating current corrosion of
and accessories for gas and [14.16] EN 1610 underground ductile iron pipelines]
water supply – Construction and testing of drains FGR GUSSROHR-TECHNIK,
Requirements and tests] and sewers Heft 28 (1993), S. 26 ff
2010-09 [Einbau und Prüfung von Abwasser-
leitungen und -kanälen]
1997
10.2010
[14.20] RAL – GZ 662

Güte- und Prüfbestimmungen –
Schwerer Korrosionsschutz von
Armaturen und Formstücken
durch Pulverbeschichtung –
Gütesicherung
[Quality and test provisions –
Heavy duty corrosion protection
of valves and fittings by powder
coatings –
Quality assurance]
2008
10.2010
10.2010
E-Book – Ductile iron pipe systems Chapter 15: Linings 15/1
15 Linings
15.1 General
for drinking water pipelines
15.3 Linings in pipelines for raw water
for pipelines for wastewater and sewage
15.5 Linings in pipelines for non-drinking
and cooling water
15.6 References
04.2008
15 Linings 15.1 General
Ductile iron pipelines are normally

What is meant by linings is protective coatings on the internal surfaces equipped with factory-applied linings,
of pipelines. Their purpose is to protect the material of the pipes against with the linings differing between pipes
chemical reactions with the medium flowing through the pipes. The aim is on the one hand and fittings and valves on
above all that drinking water, as a medium, will be transported to the end the other due to the application processes
consumer without suffering any adverse effects. Ductile iron pipes are lined used. Basically, the linings are matched to
as standard with cement mortar or polyurethane (PUR). These linings are the types of water or other mediums such
considered to be an integral part of the pipe. as sewage which are being transported.
Table 15.1 is a listing of the types of water
Ductile iron fittings and valves on the other hand are, in the majority of cases, and other mediums, together with their
coated internally and externally with epoxy, although polyurethane and special properties and the main require-
vitreous enamelling are becoming increasingly important in this application. ments which are important in each case.
Cement mortar linings however are becoming less frequently used in fittings.
Generally speaking, the types of lining depend on the applications for which
ductile iron pipe systems are used.
04.2008
Table 15.1:
Overview of types of water and similar media to be transported and the main requirements which the lining has to meet
Medium transported Main properties of the medium Requirements for the lining
Drinking water meeting the In lime-carbonic acid equilibrium ■ Corrosion protection
drinking water regulations ■ Drinking water hygiene
Water similar to drinking water In lime-carbonic acid equilibrium ■ Corrosion protection
such as water for non-drinking ■ Drinking water hygiene
use and cooling water
Raw water not meeting the Often lime-dissolving (acid) ■ Corrosion protection
drinking water regulations
Wastewater complying with DWA (German Meets the guideline values laid down ■ Corrosion protection in the submerged area
Association for Water, Wastewater in DWA Merkblatt M 115-2 [1] and in the atmosphere in the drainage sewer
and Waste) Merkblatt M 115-2 [1] ■ Abrasion resistance
■ Resistance to chemicals
■ Resistance to jet cleaning
Industrial wastewater which is outside Contains acid to alkaline components ■ Corrosion protection in the submerged area
the requirements of DWA (German and in the atmosphere in the drainage sewer
Association for Water, Wastewater ■ Abrasion resistance
and Waste) Merkblatt M 115-2 [1] ■ Resistance to chemicals
■ Resistance to jet cleaning
■ Temperature resistance
Brines High in salt ■ Corrosion protection
■ Abrasion resistance
04.2008
Tables 15.2 and 15.3 provide information Table 15.2:

on the linings commonly used for ductile Overview of the applications of linings for ductile iron pipes
iron pipelines for transporting water of
all kinds and sewage. The tables relate to Field of application Internal surfaces of pipes Surfaces in the joint region
the coatings used for the internal surface Drinking water Cement mortar lining based Coating based on bitumen
of pipes (Table 15.2) and of fittings and under EN 545 [2] on blast furnace cement or on epoxy paint
valves (Table 15.3) and to the coatings Polyurethane lining Coating based on
used on the surfaces in the joint region. to EN 15655 [3] polyurethane or epoxy paint
Sewage under EN 598 [4] Cement mortar lining based Coating based on epoxy paint
and other types of water on high-alumina cement
Polyurethane lining Coating based on poly-
to EN 15655 [3] urethane or epoxy paint
Industrial wastewater Cement mortar lining based Coating based on epoxy paint
on high-alumina cement
Polyurethane lining Coating based on poly-
to EN 15655 [3] urethane or epoxy paint
04.2008
Table 15.3:
Overview of the applications of linings for fittings and valves
Field of application Type of lining on

Internal surfaces of fittings Internal surfaces of valves Surfaces in the joint region
Drinking water Lining of polymer-modified Epoxy coating to DIN 3476 [7] Coating based on bitumen
under EN 545 [2] cement mortar and RAL GZ 662 [6] or on epoxy paint
Epoxy coating to EN 14901 [5]
and RAL GZ 662 [6]
Vitreous enamel to DIN 51178 [8] Vitreous enamel to DIN 51178 [8] As for internal surfaces
Polyurethane lining to EN 15655 [3] — As for internal surfaces
Sewage under Lining of polymer-modified Epoxy coating to DIN 3476 [7] Coating based on poly-
EN 598 [4] and other cement mortar and RAL GZ 662 [6] urethane or epoxy paint
types of water
Epoxy coating to EN 14901 [5]
and RAL GZ 662 [6]
Industrial wastewater Epoxy coating to EN 14901 [5] Epoxy coating to DIN 3476 [7] As for internal surfaces
and RAL GZ 662 [6] and RAL GZ 662 [6]
04.2008
15.2 Linings of pipes, fittings non-allowable changes in para-

and valves for drinking meters of the water (contamina-
water pipelines tion, discoloration or turbidity).
The fields of use and limits of use of

15.2.1 Cement mortar linings the cement mortar coating described
of pipes and fittings are given in informative Annex E to
EN 545 [2].
The cement mortar linings of ductile
iron pipes and fittings are considered to Under the above, the standard lining with
be an integral part of the product. The blast furnace cement mortar as a binder is,
requirements and test methods for them in general, suitable for unrestricted use in
are therefore given in the product stand- the field of drinking water if the drinking Fig. 15.1:
ard EN 545 [2]. water being transported complies with Charging the pipe with cement mortar
the European drinking water directive before the spin centrifuging
The purposes of the cement mortar lining or national drinking water regulations.
are as follows:
■ To optimise hydraulic properties For wastewater, sewage and other types of drying cracks in cement mortar linings
■ To prevent damage from corrosion. water (e. g. raw water, water for non-drink- and information on their self-healing
Such damage includes: ing uses), other cements can be used as characteristics.
– damage to the metallic material of binders as shown in Tables 15.2 and 15.3.
pipes due to reactions with water DVGW Arbeitsblatt W346 [10] provides
and with substances dissolved in DIN 2880 [9] provides a wide range of practical recommendations on the pres-
the water, information on the fields of use and sure testing, flushing, disinfection, run-
– adverse effects on the operation of special features of cement mortar linings ning-in and operation of drinking water
the pipeline caused by products of for metal pipes. It defines the behaviour pipelines with cement mortar linings.
reaction on the inner wall of pipes of and requirements for the linings for
(e.g. incrustation), all types of water, sewage, salt water
– adverse effects on the water and brines. In addition, it gives direc-
caused by products of reaction, e.g. tion for assessing shrinkage cracks and
04.2008
DVGW Arbeitsblatt W 347 contains drink- 15.2.3 Epoxy coating of

ing water hygiene requirements and test fittings and valves
methods for cementitious materials used
in the drinking water field and thus covers The technique usually employed for coat-
cement mortar linings for ductile iron ing with epoxy powder consists of the fol-
pipes and fittings. lowing steps:
■ activation of the surface of the fully
The methods by which linings are fettled castings by blasting with sharp-
produced are described in detail in edged steel grit – grade of cleanliness
Chapter 3, Production of pipes, fittings of the surface: SA 2 1/2,
and accessories. Fig. 15.1 shows a duc- ■ heating in a continuous preheating
tile iron pipe which is going to be lined oven,
with cement mortar, before the spin cen- Fig. 15.2: ■ application of the powder by auto-
trifuging. The polyurethane lining mated dipping into a fluidised bed of
being applied in a pipe powder (Fig. 15.3) or by applying the
15.2.2 Polyurethane linings powder with a spray gun (Fig. 15.4),
for pipes and fittings ■ cross-linking of the fused-on layer of
epoxy powder in a drying oven.
The polyurethane lining to EN 15655 [3] Where pipes are cut on the installation
is applied to the smoothed and abrasive site, the new cut face has to be re-coated
blasted internal surfaces of pipes and with an epoxy-based repair paint.
fittings by the two-component hot
spraying technique (Fig. 15.2). The lining meets the requirements of the
Guideline issued by the German Federal
The polyurethane lining acts as a high- Environmental Agency (UBA) on the
resistance electrical insulator between hygienic assessment of organic coat-
the medium flowing through and the iron. ings in contact with drinking water and
the requirements of DVGW-Arbeitsblatt
W 270 [12].
04.2008
15.2.4 Lining of fittings and valves

with vitreous enamel
Enamel coatings have long proved their

worth in the field of the lining of valves
for use in drinking water applications
(Fig. 15.5). This lining is also being
increasingly widely used for ductile iron
fittings (Fig. 15.6). There is a standard for
it in the form of DIN 51178 [8].
Fig. 15.3: Fig. 15.4:

Application of epoxy powder by robot, Electrostatic application of epoxy
using the fluidised bed technique powder by means of a spray gun
The process technology, the monitoring Association for the Heavy Duty Corro-
to ensure that the production param- sion Protection of Powder Coated Valves
eters laid down are observed and the and Fittings.
quality testing of the finished coating are
governed by the RAL-GZ 662 [6] quality The epoxy coating is also one of those
assurance test specifications entitled listed in standards EN 545 [2] and EN 598
“Heavy-duty corrosion protection of [4] and there are standards for the coating
powder coated valves and fittings” which itself in the form of EN 14901 [5] and
are issued by the GSK Quality DIN 3476 [7].
04.2008
15.2.5 Organic linings/coatings The requirements for bituminous paints

for the joint region in the joint region are included in DVGW-
Arbeitsblatt W 348 [13].
The surfaces in pipe joints are coated with
organic materials. Such coatings are gen- Generally speaking, all coatings and lin-
erally based on bitumen, epoxy or poly- ings which are in contact with drinking
urethane. water and which have organic constitu-
ents also have to be tested under DVGW-
Fig. 15.7 is a section through a push-in Arbeitsblatt W 270 [12] for their tendency
joint; it clearly shows that both the exter- to enhance microbial growth.
nal surface of one pipe and the internal
outline of the socket of the other pipe are
Fig. 15.5: in contact with drinking water.
Fully enamelled butterfly valve
The materials used for the epoxy coat-
ings have to meet the requirements of the
Guideline issued by the German Federal
TYTON® joint
Environmental Agency (UBA) on the Surface of interior of
hygienic assessment of organic coatings Retaining part Gasket socket in contact
with drinking water
in contact with drinking water. Locating
collar
External surface of spigot end

in contact with drinking water
Fig. 15.7:
Fig. 15.6: Surfaces in contact with drinking water
Fittings during the enamel firing in the region of the TYTON® joint
04.2008
15.2.6 European rules and 15.3 Linings in pipelines Cement mortar linings based on high-
regulations for raw water alumina cement have proved successful
for raw water which does not meet the
One special feature which exists in the drinking water directives. This lining is
field of drinking water is that there is a Raw water often does not meet the drink- applied in pipes by the spin centrifuging
standard for pipelines for drinking water ing water regulations. It is often highly technique and is therefore very highly
in the form of the European Construction lime-dissolving acid water. compacted. High-alumina cement mor-
Products Directive. The aim of this is to tar contains virtually no free lime and
prevent there from being trade barriers of In the course of time, lime-dissolving is resistant to lime-dissolving water.
the sort which would result from differing water may adversely affect the strength Polymer-modified cement mortar too is
national requirements. of cemetitious materials by dissolving the resistant to lime-dissolving water.
calcium carbonate containing in them.
The intention is however for the indi- Pipes with polyurethane linings to
vidual national rules and regulations to The processes which this involves are all EN 15655 [3], fittings and valves with
continue to exist. This means that a Euro- the more intensive the higher is the lime- epoxy coatings to EN 14901 [5] and fit-
pean approval procedure has to be set dissolving capacity and the lower is the tings and valves which are enamelled to
up under which requirements and test compaction of the lining. DIN 51178 [2] are likewise suitable for
methods for components in contact with transporting raw water.
drinking water will be developed which
can be adopted in all the member states
without the national levels of protection
having to be abandoned. Once this pro-
cedure comes into force, it will be pos-
sible for approval from the point of view
of drinking water hygiene to be obtained
for the component concerned in all the
states of the EU by the passing of a single
approval test.
04.2008
15.4 Linings of pipes, fittings This enables it to withstand not only 15.4.2 Polyurethane linings of
and valves for pipelines for chemical stresses such as those from soft, pipes and fittings
wastewater and sewage acid or very salt water but also mechanical
stresses caused for example by detritus There is a standard for ductile iron pipes
in the wastewater or sewage or by high- and fittings with polyurethane linings
Wastewater and sewage contain consider- pressure jet-cleaning. for sewerage applications in the form of
ably more materials than drinking water EN 598 [4]. The field of use in this case
or raw water. Wastewater in public drain- The lining of high-alumina cement mortar covers gravity and pressure sewers. In the
age systems must meet the guideline val- is highly compacted by the spin centrifug- long term, the lining must withstand dif-
ues given in DWA-Merkblatt M 115-2 [1]. ing process and is cured at high tempera- ferent mechanical and chemical stresses
This gives general guideline values for tures in special curing chambers in such a such as those from soft, acid or very
the most important criteria governing the way that the aluminium hydrates acquire salt water and also mechanical stresses
characteristics of, above all, non-domestic the stable cubic crystalline structure caused for example by detritus in the sew-
wastewater. which is the basis for the high resistance age or by high-pressure jet-cleaning.
However, there are many cases where of this lining.
these guideline values are exceeded by The polyurethane lining to EN 15655 [3]
industrial wastewater before it is treated. The joint region is protected against is applied to the smoothed and abrasive
attack by an epoxy coating. blasted internal surfaces of pipes and fit-
15.4.1 Cement mortar linings tings by the two-component hot spray-
of pipes and fittings ing technique. It acts as a high-resistance
electrical insulator between the medium
There is a standard for ductile iron pipes flowing through and the iron and ensures
and fittings for sewage disposal in the resistance to wastewater and sewage of
form of EN 598 [4]. The field of use in all kinds.
this case covers gravity and pressure sew-
ers. The lining must withstand different
mechanical and chemical stresses in the
long term. It is produced with high-alu-
mina cement as a binder.
04.2008
15.4.4 Lining of fittings and valves 15.5 Linings in pipelines

with vitreous enamel for non-drinking and
cooling water
Coatings and linings of vitreous enamel
complying with DIN 51178 [8] are a possi-
bility in the wastewater and sewage field. Pipes and fittings from the range intended
Fig. 15.9 shows an enamelled gate valve for drinking water can be used for trans-
for use in wastewater pressure pipelines. porting non-drinking and cooling water.
Where there is any doubt it has to be
established whether they are suitable.
The technical departments of the vari-
ous manufacturers provide advice on this.
Fig. 15.8:
Sewer fitting with epoxy powder coating With lime-dissolving water, what are
suitable are pipes with linings based on
high-alumina cement or polyurethane
15.4.3 Epoxy coating of fittings and linings. The fittings and valves in such
valves for the transport of pipelines have to be protected with epoxy
wastewater and sewage to EN 14901 [5] or vitreous enamel to
DIN 51178 [8].
In the wastewater and sewage field, fit-
tings are provided as standard with an
epoxy coating both internally and exter-
nally. The epoxy coating is listed in EN 598
[4] and the standard for it is EN 14901 [5].
Fig. 15.8 shows a TYTON® collar which
has an internal and external epoxy pow-
der coating. Fig. 15.9:
Enamelled gate valve for use in
wastewater pressure pipelines
04.2008
15.6 References [15.3] EN 15655 [15.5] EN 14901

Ductile iron pipes, fittings and Ductile iron pipes, fittings and
accessories – accessories –
[15.1] DWA Merkblatt M 115-2 Internal polyurethane lin- Epoxy coating (heavy duty) of
Indirekteinleitung nicht ing for pipes ductile iron fittings and accessories –
häuslichen Abwassers – and fittings – Requirements and test methods
Teil 2: Anforderungen Requirements and test methods [Rohre, Formstücke und Zubehör
[DWA technical information [Rohre, Formstücke und Zubehör aus duktilem Gusseisen –
sheet M 115-2 teile aus duktilem Gusseisen – Epoxidharzbeschichtung
Indirect discharging of Polyurethan-Auskleidung von (für erhöhte Beanspruchung)
non-domestic sewage – Rohren und Formstücken – von Formstücken und Zubehör-
Part 2: requirements] Anforderungen und Prüfverfahren] teilen aus duktilem Gusseisen –
2005-07 2009 Anforderungen und Prüfverfahren]
2006
[15.2] EN 545 [15.4] EN 598
Ductile iron pipes, fittings, Ductile iron pipes, fittings, [15.6] RAL – GZ 662
accessories and their joints for accessories and their joints for Güte- und Prüfbestimmungen –
water pipelines – sewerage applications – Schwerer Korrosionsschutz von
Requirements and test methods Requirements and test methods Armaturen und Formstücken durch
[Rohre, Formstücke, [Rohre, Formstücke, Zubehörteile Pulverbeschichtung –
Zubehörteile aus duktilem aus duktilem Gusseisen und ihre Gütesicherung
Gusseisen und ihre Verbindungen Verbindungen für die Abwasser- [Quality and test provisions –
für Wasserleitungen – entsorgung – Heavy duty corrosion protection
Anforderungen und Prüfverfahren] Anforderungen und Prüfverfahren] of valves and fittings by powder
2010 2007+A1:2009 coatings –
Quality assurance]
2008
04.2008
[15.7] DIN 3476 [15.9] DIN 2880 [15.11] DVGW-Arbeitsblatt W 270

Armaturen und Formstücke Anwendung von Zementmörtel- Vermehrung von Mikroorganismen
für Roh- und Trinkwasser – Auskleidung für Gußrohre, auf Werkstoffen für den
Korrosionsschutz durch EP-Innen- Stahlrohre und Formstücke Trinkwasserbereich –
beschichtung aus Pulverlacken (P) [Application of cement mortar Prüfung und Bewertung
bzw. Flüssiglacken (F) – lining for cast iron pipes, [DVGW worksheet W 270
Anforderungen und Prüfungen steel pipes and fittings] Enhancement of microbial growth
[Valves and fittings for untreated 1999-01 on materials in contact with
and potable water – drinking water –
Protection against corrosion by [15.10] DVGW-Arbeitsblatt W 346 Test methods and assessment]
internal epoxy coating of Guss- und Stahlrohrleitungs- 2007-11
coating powder (P) or liq- teile mit ZM-Auskleidung –
uid varnishes (F) – Handhabung [15.13] DVGW-Arbeitsblatt W 348
Requirements and Test] [DVGW worksheet W 346 Anforderungen an Bitumen-
1996-08 Pipeline components of cast iron beschichtungen von Formstücken
or steel with cement mortar lining – aus duktilem Gusseisen und im
[15.8] DIN 51178 Treatment] Verbindungsbereich von Rohren
Emails und Emaillierungen – 2000-08 aus duktilem Gusseisen, unlegier-
Innen- und außenemaillierte tem und niedrig legiertem Stahl
Armaturen und Druckrohr- [15.11] DVGW-Arbeitsblatt W 347 [DVGW worksheet W 348
formstücke für die Roh- und Hygienische Anforderungen an Requirements for bituminous
Trinkwasserversorgung – zementgebundene Werkstoffe coatings of ductile iron fittings
Qualitätsanforderungen im Trinkwasserbereich – and of the joint area of
und Prüfung Prüfung und Bewertung ductile iron pipes and pipes of
[Vitreous and porcelain enamels – [DVGW worksheet W 347 unalloyed or low-alloy steel]
Inside and outside enamelled valves Hygienic requirements for 2004-09
and pressure pipe fitting for untreat- cementitious products in
ed and potable water supply – contact with drinking water –
Quality requirements and testing] Test methods and assessment]
2009-10 2006-05
04.2008
E-Book – Ductile iron pipe systems Chapter 16: Structural design 16/1
16 Structural design
03.2011
E-Book – Ductile iron pipe systems Chapter 16: Structural design 16/2
16 Structural design
03.2011
E-Book – Ductile iron pipe systems Chapter 17: Hydraulic design 17/1
17 Hydraulic design
10.2010
E-Book – Ductile iron pipe systems Chapter 17: Hydraulic design 17/2
17 Hydraulic design
10.2010
E-Book – Ductile iron pipe systems Chapter 18: Welding of ductile iron pipes 18/1
18 Welding of ductile iron pipes
10.2010
E-Book – Ductile iron pipe systems Chapter 18: Welding of ductile iron pipes 18/2
18 Welding of ductile iron pipes

10.2010
E-Book – Ductile iron pipe systems Chapter 19: Transport, storage and installation 19/1
19 Transport, storage
and installation
19.1 General
19.2 Pipeline installation regulations
19.3 Transport of ductile cast iron pipes, fittings and valves
19.4 Installation of ductile iron pipe systems
19.5 Installation
19.6 Pipe trenches
19.7 Special pipeline installation cases
19.8 References
10.2015
19 Transport, storage and installation development of a training and test plan

for engineers installing metal pipes
If ductile cast iron pipelines are handled and installed correctly and profession- with push-in joints. DVGW worksheet
ally, a high degree of reliability and a long working life can be expected of them. W 339 [19.5] for specialists in joint
Because of their specific properties ductile cast iron pipes, fittings and valves are technology for metal piping systems is
suitable for various installation techniques and a large number of applications. applicable for this in Germany while
SVGW guideline W4-3 [19.4] applies in
Switzerland.
In Germany, civil engineering companies

19.1 General terms of standards EN 805 [19.1] are increasingly requiring certification
and EN 1610 [19.2]. The companies by the “Güteschutz Kanalbau” quality
used by the client must have the association for the installation of sewers
Pipelines for the transport of drink- necessary qualifications for carrying and wastewater pipelines. This or similar
ing water and wastewater, and also out the work. It is important for the certification is required for construction
such applications as turbine and snow- client to satisfy himself of the exist- work in drinking water protection zones,
making equipment, are civil engineer- ence of these qualifications. This also in accordance with ATV-DVWK-A 142
ing projects – ones which involve high applies accordingly for the choice [19.6].
investment costs. Also correspondingly of planning engineers.
high are expectations of operational
security and useful life. Therefore it is Suitable evidence of the contractor’s 19.2 Pipeline installation
understandable that great importance qualification may for example be regulations
is attributed to the choice of pipe ma- possession of DVGW certification
terial, manufacturing and above all correct according to DVGW worksheet GW 301
handling and installation. [19.3]. There is a comparable provision For the installation of pipelines, depend-
in SVGW guideline W4-3 [19.4]. ing on the medium being transported,
Experienced personnel need to be standards EN 805 [19.1] are to be followed
recruited for carrying out and super- The increasing use of restrained push- for water pipelines and EN 1610 [19.2]
vising such projects who are able to in joints, especially when using trench- for wastewater pipelines. For standards
assess the quality of the work in less laying techniques, prompted the EN 805 [19.1] and EN 1610 [19.2] there are
10.2015
supplementary sets of rules available in 19.3 Transport of ductile cast iron 19.3.1 Transport and storage of pipes
different European countries to complete pipes, fittings and valves
these. Table 19.1 provides a summary 19.3.1.1 Loading and unloading
for individual countries.
Ductile iron pipes, fittings and valves Ductile iron pipes d DN 350 are deliv-
With pipelines for transporting the food for drinking water and wastewater ered as pipe bundles and larger ones as
“drinking water”, the highest require- pipelines are to be protected by appro- single pipes. The precise number of pipes
ments are set not just for the components priate means against damage and pol- per bundle, as well as the weight in each
but also for the planning and construction lutions during transport and storage. case, can be found in the manufacturer’s
engineers. European directive 98/83/EC EADIPS®/FGR® standard 74 [19.14] is to documentation.
[19.13] on the quality of water intended be followed for the packaging of fittings
for human consumption has been and valves. When loading and unloading pipes and
implemented in the EU member states The manufacturer’s instructions for trans- pipe bundles by crane, lifting straps
and is to be observed. port, storage and installation must be are to be used. Where individual pipes
observed. are unloaded using crane hooks, this
must be done with wide, padded hooks
(Figure 19.1) which are attached to
the head ends as otherwise there is a
Table 19.1: danger of damaging the pipe and its
Summary of rules specific to individual countries as a supplement to coating.
EN 805 [19.1] and EN 1610 [19.2]
Country Supplementary rules for Figure 19.2 gives an idea of how lifting
tackle should be used for transporting
EN 805 [19.1] EN 1610 [19.2] pipes.
Germany DVGW worksheet DWA-A 139 [19.9];
W 400-2 [19.7]; ATV-DVWK-A 142 [19.6] As an alternative to loading and unload-
DIN 2000 [19.8] ing by crane, suitable forklift trucks can
Austria OENORM B 2538 [19.10] OENORM B 2503 [19.11] also be used.
Schwitzerland SVGW guideline W4-3 [19.4] SIA 190; SN 533190 [19.12]
10.2015
Fig. 19.1: Fig. 19.2:

Padded hook for pipe transport Attaching lifting tackle
Particular attention must be paid here Pipes and pipe stacks should only be
to ensure that set down on wooden beams or other
■ the pipes cannot tip sideways suitable materials.
over the fork They should
(the fork should be 1.5 m wide), ■ not be set down abruptly,
■ the pipes cannot roll off the fork, ■ not be shed by the vehicle,
■ the fork is sufficiently padded so ■ not be hauled or rolled, Fig. 19.3:
that damage to the pipe is avoided. ■ be secured against rolling and slipping, Sleeper for stacking ductile iron pipes
■ be stored on a level, load-bearing
During the loading and unloading surface.
process nobody must be beneath or on
top of the pipe or pipe bundle, or If ductile iron pipes are stored in a stack The ductile iron pipes are prevented from
within the hazard area of the crane. then they should be laid on wooden rolling off flat wooden beams by nailing
supports at least 10 cm wide, with a dis- on wooden wedges (Figure 19.6).
tance of approx. 1.5 m from the pipe ends
(Figures 19.3, 19.4 and 19.5).
10.2015
Fig. 19.4:
Arrangement of wooden supports for stacking ductile iron pipes
Fig. 19.5: Fig. 19.6:

Ductile iron pipes set down Ductile iron pipes stacked with the help of wooden supports
on wooden supports
10.2015
Stacking heights for ductile iron pipes Before cutting the steel straps it is slipping and rolling (Figure 19.8). The
are stated in the manufacturer’s informa- important to make sure that protection caps on drinking water pipes
tion. Stacking heights of more than 3 m ■ the pipe stack stands on firm ground should only be removed immediately
on the installation site are to be avoided which is as level as possible and does before installation (Figure 19.9).
for safety reasons. not slope,
■ the pipes are secured against rolling 19.3.2 Transport and storage
Individual pipes are to be secured using and slipping, of fittings
wooden wedges (Figure 19.7). ■ nobody is standing on or in front of
the stack of pipes. In accordance with EADIPS®/FGR®
19.3.1.2 Opening up pipe bundles standard 74 [19.14] fittings should
19.3.1.3 Distributing the pipes preferably be dispatched in cage pallets
The pipe bundles are secured with steel along the installation site (Figure 19.10). Consignment on dis-
or plastic straps. The straps should only posable pallets is permissible for site
be cut using suitable tools (plate shears If the pipes are laid out alongside the pipe deliveries (Figure 19.11). Fittings must
or side cutters) to avoid damage to the trench before being installed, they are to be stacked and arranged in such a way
pipes and the risk of injury to personnel. be placed on wooden supports or similar that they cannot damage each other.
as already described and secured against
Fig. 19.7: Fig. 19.8:

Securing individual pipes Securing ductile iron pipes
on the installation site
10.2015
Fig. 19.9:
The protective caps of ductile iron pipes for drinking water supply are only to be removed directly before installation
Fig. 19.10:
Ductile fittings in a cage pallet ready for dispatch
10.2015
Fig. 19.11:
Preparation of fittings ready for dispatch on disposable pallets
Individual parts or articles which do not ■ As from DN 350 openings are also
fit into a cage pallet are to be packed and to be closed by suitable means,
dispatched on Europallets or disposable e.g. covers in weather-resistant
pallets. Wherever possible the individual materials, shrink film or similar.
parts should not project beyond the edge When using steel straps, the coating
of the pallet. of the fittings is to be protected at
the points of contact with the steel
The following advice [19.14] should also straps.
be followed for fittings:
■ Up to DN 300 openings should

be closed with the corresponding
EADIPS®/FGR® protective caps.
10.2015
19.3.3 Transport and storage

of valves
According to EADIPS®/FGR® stand-

ard 74 [19.14] it is preferable for valves
to be dispatched in cage pallets
(Figure 19.12). Consignment on dis-
posable pallets is permissible for site
deliveries (Figure 19.13).
The stacking and arrangement must

ensure that the parts cannot damage
Fig. 19.12: each other.
Valves in a cage pallet ready for dispatch
Fig. 19.13:
Arrangement of valves on disposable pallets ready for dispatch
10.2015
The body ends must be protected in order Explanations about the storage condi- 19.4.1.1 Cutting of pipes
to prevent the ingress of foreign matter tions for gaskets can be found in Chapter
and moisture. For valves with polymer 13.3.9, taking account of ISO 2230 [19.16]. The outside diameter of pipes up to
or elastomer seats, it is important that DN 300 is at least up to 2/3 of the pipe
these seats are also protected against UV length away from the spigot end in the
radiation. The protective caps for valves 19.4 Installation of ductile permissible area (Table 19.2), i.e. these
with flange connections must correspond iron pipe systems pipes can be cut on site within this area.
to EN 12351 [19.15]. Valves with polymer Individual manufacturers also allow
or elastomer seats must be delivered in larger cutting areas (Figure 19.14).
such a way that the sealing material is The most important condition for the
not put under compressive stress. With successful construction of these sys-
all other valves, the closing device must tems lies in following the manufactur-
be in the closed position during delivery. er’s installation instructions.
Individual parts or articles which do not The condition of pipes, fittings and valves
fit in cage pallets are to be packed and in ductile cast iron as well as accessories
dispatched on Europallets or disposable needs to be checked before installation.
pallets. Wherever possible the individual
parts should not project beyond the edge 19.4.1 Installation of pipes
of the pallet.
DVGW worksheet W 346 [19.17] supple-
19.3.4 Storage of accessories ments the specific instructions and rec-
ommendations for cement mortar linings.
The manufacturer’s instructions contain
information about the storage of parts For ductile iron pipes with restrained
such as gaskets. flexible push-in joints the allowable
operating pressure marking (PFA) is Fig. 19.14:
to be observed in accordance with Example of marking on a ductile iron pipe –
EADIPS®/FGR® standard 75 [19.18] the pipe can be cut in the area with a
(Chapter 3.6.1). longitudinal stripe
10.2015
Table 19.2:
Permissible outside pipe diameters for cutting ductile iron pipes in mm
DN Dextmax Dextmin Cmax Cmin

80 99 95.3 311.0 299.4
100 119 115.2 373.8 361.9
125 145 141.2 455.5 443.6
150 171 167.1 537.2 525.0
Fig. 19.15:
200 223 219.0 700.6 688.0 Ductile iron pipes > DN 300 suitable
250 275 270.9 863.9 851.1 for cutting on site – marked with
a longitudinal white stripe
300 327 322.7 1027.3 1013.8
400 430 425.5 1350.9 1336.7
500 533 528.2 1674.5 1659.4
600 636 631.0 1998.1 1982.3
700 739 733.7 2321.6 2305.0
800 843 837.5 2648.4 2631.1
900 946 940.2 2971.9 2953.7
1000 1049 1043.0 3295.5 3276.7
Dext = external diameter, C = circumference
Fig. 19.16:
Cuttable ductile iron pipes > DN 300 –
marked with a red stripe on the socket –
cutting of the pipes from the spigot end
to up to 1 m before the socket end-face
10.2015
Cuttable pipes above DN 300 are

identified with longitudinal stripes
(Figures 19.15 and 19.16). All pipes are
cuttable with certain manufacturers.
When shortening (cutting) the pipes,

attention must be paid to accident pre-
vention rules. For example angle grind-
ers with resin-bonded stone disks, e.g.
type C 24 RT Special in silicon carbide
are used for cutting pipes (Figure 19.17).
The swarf produced when cutting the Fig. 19.17: Fig. 19.19:
pipes is to be removed. Separation cut on a pipe Spigot end with insertion marking
The cut surfaces of the shortened pipes

must be sealed again according to
the manufacturer’s instructions. The new
spigot end is to be chamfered accord-
ing to the original spigot end. The
manufacturers provide directions for
this in the installation instructions
(Figure 19.18).
After cutting and chamfering the pipe,

the insertion marking (e.g. two white
lines) is to be transferred to the new
spigot end (Figure 19.19). Fig. 19.18:
Example of how to chamfer a spigot end
10.2015
19.4.1.2 Repair of any deformation Shaped Wood 19.4.1.3 Assembling push-in joints
of pipe ends occurring
after cutting (rounding) Non-restrained push-in joints are
Force applied
described in Chapter 8.2 and restrained
The spigot ends of larger diameter pipes push-in joints in Chapter 9.2.
or the cut ends produced after shorten-
ing pipes may not be perfectly round. Information is provided in the installa-
However, by taking advantage of the elas- tion instructions from ductile iron pipe
tic properties of the material, rounding manufacturers for the installation of
the pipes is possible. To do this, e.g. a Shaped Wood push-in joints covering cleaning, apply-
jack is put on the inside of the pipe. So ing suitable lubricants, inserting rubber
as not to damage the cement mortar Fig. 19.20: gaskets and checking the correct seating
lining by this process, the jack is tight- Rounding a pipe spigot end with a jack of the rubber gasket.
ened between pieces of hardwood which
are shaped to fit the inside of the pipe Appropriate assembly equipment is listed
(Figure 19.20). for the various nominal size ranges by
the manufacturers of ductile iron pipes
Pipes with push-in joints > DN 1000 (Figures 19.21, 19.22 and 19.23).
can generally be assembled without
difficulty without any rounding device, When assembling pipe joints using an
even if some ovalisation has occurred excavator, a suitable intermediate layer is
due to storage and transport. to be provided between pipe and excavator
shovel, e.g. a shaped wooden block.
Fig. 19.21:
Example of assembly equipment for pulling
ductile iron pipes d DN 300 together
10.2015
Insertion must be done smoothly and

slowly. This ensures that the gasket is
not pushed out of the retaining groove.
The correct seating of the gasket can be
checked by feelers after assembly. With
all assembly techniques, the pipes must
be aligned centrally and axially before
and during the assembly of the pipes.
19.4.1.4 Assembling screwed

socket joints
Fig. 19.22: Fig. 19.24:
Screwed socket joints are described in Example of assembly equipment for pulling Screwed socket joint
Chapter 1.3.3 (Figure 1.7) and Chap- ductile iron pipes t DN 350 together
ter 9.4.3. For the assembly of screwed
socket joints (Figure 19.24) special
tools are required (Figure 19.25). The
manufacturer’s installation instruc-
tions are to be followed.
Fig. 19.23: Fig. 19.25:

Assembly equipment for pulling Hook wrench for assembling
pre-insulated pipes together screwed socket joints
10.2015
19.4.1.5 Assembling flanged 19.4.1.7 Welding onto ductile

joints iron pipes
Flanged joints are described in Chap- Chapter 18 (this chapter is being pre-
ter 1.3.1 (Figure 1.4) and Chapter pared) contains explanations about
9.2. Flanged pipes are dealt with in welding onto ductile iron pipes, such
Chapter 3.3.5 (Figure 3.13). The manu- as the welding on of flanges, branches,
facturer’s installation instructions are outlets and puddle flanges as well as
to be observed for the assembly of the application of welding beads for
flanged joints; recommendations for restrained pipes.
the screw lengths for flanged joints can Fig. 19.26:
be found in EADIPS®/FGR® standard 30 19.4.2 Installation of fittings Representation of a bolted gland joint
[19.19].
Fittings must not be cut, ground or
19.4.1.6 Assembling bolted otherwise processed.
gland joints
19.4.2.1 Assembling push-in joints
Bolted gland joints are described in
Chapter 1.3.4 (Figure 1.8). The manu- With all assembly techniques, the
facturer’s installation instructions are to fittings are to be aligned centrally and
be observed for the assembly of bolted axially before and during the assembly
gland joints (Figure 19.26). of the push-in joint pipes. For the correct
assembly of the joint the use of assembly
equipment (Figures 19.27 and 19.28)
is advisable. The manufacturer’s instal-
lation instructions are to be followed.
Fig. 19.27:
Use of assembly equipment specific to
nominal diameter
10.2015
19.4.2.2 Assembly of a connection

branch
The assembly of a connection branch is

done in a number of stages:
1. Drilling with the core bit
(Figure 19.30),
2. Drilling the holes for the retaining
screws (Figure 19.31),
3. Inserting the gasket, fixing the retain-
Fig. 19.28: ing screws (Figure 19.32),
Example of assembly equipment for 4. Final assembly of the connection
nominal sizes DN 350 to DN 700 branch (Figure 19.33).
Burrs are to be removed from the drill

holes. The cut surfaces of the drill holes Fig. 19.30:
are to be sealed according to the manu- Drilling with the core bit
facturer’s instructions.
Only carbide-tipped drill or core bits are

to be used for drilling.
Fig. 19.29:
Assembly of a double socket tee on 19.4.2.3 Welding on connection
the spigot end of a ductile iron pipe pieces and outlets
When assembling fittings using an exca- Explanations for welding on connec-

vator, a suitable intermediate layer is to tion branches and outlets can be found
be provided between pipe and excavator in Chapters 18.3.3 and 18.3.4 (these Fig. 19.31:
shovel, e.g. a shaped wooden block (Fig- chapters are being prepared). Drilling the holes for retaining
ure 19.29). screws of the connection branch
10.2015
19.4.3 Installation, servicing and concentric. The connecting bolts must be

maintenance of valves tightened evenly, taking them crosswise,
to avoid distortion strain. The pipeline is
19.4.3.1 Installation to be assembled tension-free. Adaptor
and extension pieces facilitate assembly
All packaging materials are to be as well as removal for subsequent main-
removed from the valve. In order to pro- tenance purposes. In Germany the instal-
tect e.g. gate valves from damage they lation guidelines according to DVGW
should be transported using suitable worksheet W 332 [19.20], part IV are to
lifting equipment such as wide belts. be observed, as well as EN 805 [19.1].
Chains and wire cables are to be avoided.
Fig. 19.32: Before installation the pipeline is to be Installation of socket valves for ductile
Gasket inserted and retaining screws fitted inspected for contamination and foreign iron pipes
matter and cleaned if necessary. Care Gaskets specific to the pipe are to be
must be taken to ensure that the valves used (Chapter 13). The spigot ends
are accessible for operation and mainte- must be cleaned. Assembly should be
nance. For installation in the open air, the carried out according to the manufac-
valves should be protected on site from turer’s installation guidelines. It is to
direct exposure to the weather. keep in mind that different types of
gaskets do not have a restraining effect
Installation of flanged valves (Chapter 8). If necessary thrust resist-
Steel-reinforced rubber gaskets are ance systems are to be used (Chapter 9)
recommended for sealing the flanges. or thrust blocks installed, e.g. according
When assembling the valve the distance to DVGW worksheet GW 310 [19.21].
between pipeline flanges should be at SVGW guidelines W4-2 [19.22] and W4-5
least 20 mm greater than the face-to-face [19.23] apply for Switzerland.
Fig. 19.33: length of the valve to prevent damage to
The connection branch is positioned and the mating surfaces and allow the gaskets
then fixed to the ductile iron pipe with to be inserted. The counter flanges of
retaining screws the pipeline must be plane-parallel and
10.2015
Installation of weld-end valves 19.4.3.2 Servicing and maintenance 19.5 Installation

With weld-end valves care must be
taken to ensure that parts which are heat The relevant manufacturer’s instructions
sensitive (e.g. coatings or elastomers) are are to be followed for the servicing of 19.5.1 Installation in an
not damaged. valves. Functional capability and tightness unshored trench
should be monitored in regular cycles at
Installation of tapping valves intervals of d 4 years e.g. in accordance The planning principles of EN 805 [19.1]
The tapping process for tapping valves with DVGW technical information sheet and EN 1610 [19.2] are to be observed. For
is described in Chapter 7.5.4. Only W 392 [19.24]. Before commencing main- construction work in Germany, for exam-
carbide-tipped drill or core bits are to be tenance work all pressurised pipelines are ple, account should be taken of DIN 4124
used for tapping (Figure 19.34). to be depressurised and secured against [19.25] and ZTV A-StB 2012 [19.26].
repressurisation! Once the maintenance
work has been completed, all connections Pipe trenches which are deeper than
are to be checked for tightness and firm 1.25 m must be secured against the
seating. risk of collapse. This can be done by
means of sloping or shoring the trench
(Figure 19.35). For unshored trenches
up to a depth of 1.25 m there are no addi-
tional instructions to be followed for
installing the pipes.
Fig. 19.34: Fig. 19.35:

Tapping ductile iron pipe using a tapping valve Sloped trench
10.2015
19.5.2 Installation in a shored trench
19.5.2.1 Inserting the pipe

within one shoring unit
Two slings are placed around the pipe

(one approximately in the middle and
one in the socket area) and it is threaded
into the trench beneath the lowest level
of struts (Figure 19.36).
19.5.2.2 Inserting the pipe Key:

within two shoring units HV1 height of ground shoring IV length of shoring unit TE installation depth (= HV3 – Ü) Shoring panels
HV2 height of top unit Ic pipe passage length Ü protrusion of shoring unit Vertical bars
Where the lowest level of struts is very HV3 height of shoring unit hc pipe passage height above ground level Horizontal struts
OK top (= 0.1 m)
deep, geometric factors may mean that
the pipe cannot be threaded in within Note:
The pipe manufacturer’s installation instructions are to be observed; in Germany TB Bau specifications are also to be observed
just one shoring unit but that two units
are required for this. In this case the
slings have to be attached and removed. Fig. 19.36:
A secure fixing of the pipe must always Threading in within one shoring unit
be ensured here (Figure 19.37).
Deeper anchoring of the shoring may Another possibility for avoiding thread- shoring unit, but should only be used in
mean that insertion over two shoring ing over two shoring units is making the areas where this makes sense. The pipes
units and the deep layer of struts are bottom of the trench deeper. In this case can then be threaded in at these locations
not necessary. attention must be paid to the anchor- and transported horizontally within the
ing depth of the shoring. These alterna- shored trench.
tives do not necessarily apply for every
10.2015
19.5.2.4 Swinging in
To swing in the pipe a sling is attached

to its centre of gravity. By changing
its inclination while simultaneously
guiding it horizontally the pipe is posi-
tioned on the pipe bed inside a shoring
unit (Figure 19.39).
As the inclination and guiding of the pipe

is assisted manually, attention needs to
Key: be paid to the secure attachment of the
HV1 height of ground shoring IV length of shoring unit TE installation depth (= HV3 – Ü) Shoring panels pipe; inclining the pipe too steeply is to
HV2 height of top unit Ic pipe passage length Ü protrusion of shoring unit Vertical bars be avoided.
HV3 height of shoring unit hc pipe passage height above ground level Horizontal struts
OK top (= 0.1 m)
Note:
The pipe manufacturer’s installation instructions are to be observed; in Germany TB Bau specifications are also to be observed
Fig. 19.37:
Threading in within two shoring units
19.5.2.3 Head-on installation To do this, the lifting gear takes up the

Note:
pipe a number of times, each time lay- The pipe manufacturer’s installation instructions
With this technique the pipes are ing it down on the slope until the bottom are to be observed; in Germany TB Bau specifi-
not introduced only after the shor- of the trench is reached. This instal- cations are also to be observed
ing has been completed to its final lation method is suited above all for
depth but as the shoring is gradually so-called travelling shoring in sections Fig. 19.38:
lowered to graduated depth levels. (Figure 19.38). Head-on installation
10.2015
19.6 Pipe trenches
19.6.1 Execution, working space
For the execution of excavation pits and

trenches using traditional techniques,
accident prevention regulations are
applicable along with EN 805 [19.1] and
EN 1610 [19.2] as well as their national
supplements and regulation sheets as
Key:
per Table 19.1.
HV1 = HV3 height of ground shoring IV length of shoring unit TE installation depth (= HV3 – Ü) Shoring panels
= height of shoring unit Ic pipe passage length Ü protrusion of shoring unit Vertical bars
hc pipe passage height above ground level Horizontal struts
In rural areas, away from roads, the use
OK top (= 0.1 m) of trench cutters is becoming increas-
ingly more common. Pipes in ductile
Note:
The pipe manufacturer’s installation instructions are to be observed; in Germany TB Bau specifications are also to be observed.
cast iron can be installed in trenches
produced in this way without problem.
Fig. 19.39: Because of the high load bearing capacity

Swinging in the pipe of these pipes, there may be no need for
“pipe benching” if local conditions per-
mit; beneath roads, homogeneous com-
pacting of the laying zone is necessary
to prevent subsidence.
10.2015
19.6.2 Trench bottom According to EN 805 [19.1], determining

the thickness of the lower bedding layer
The pipe trench is to be produced in is left to the planning engineer.
such a way that the pipeline is supported
along its whole length. Corresponding In EN 1610 [19.2] the thickness of the
depressions (head access holes) are to lower bedding layer is stated as 10 cm Fig. 19.40:
be excavated in the trench bottom for with normal soil conditions; with rocky Trench bottom with head access holes
the pipe joints (Figure 19.40). or consolidated subsoils it should be at
least 15 cm.
19.6.3 Pipe bed
Figure 19.41 includes the terms used
The pipe bed must ensure an even disin EN 805 [19.1] and EN 1610 [19.2] for
tribution of pressure in the supporting the subdivisions of the pipe-laying zone.
area. As a rule, the existing soil is suitable
as a pipe bed. Stone, rock and non-load Table 19.3 gives a summary of the thick-
bearing soils are not suitable for direct nesses of the lower bedding layer in the
bedding. various national and European regula-
tions. For pipes in ductile cast iron, the
If the trench bottom is suitable for bed- pipe manufacturers state a standard
ding the pipes, then the trench bottom minimum value of 100 mm for the thick-
becomes the lower bedding. If a lower ness of the lower bedding layer for all
bedding of compactable sand, gravel sand types of external protection of pipes.
or sieved soil has to be introduced, in its
compacted condition it should be to a
height of 100 mm + 1/10 of the outside
diameter of the pipe, but at least 15 cm
below the pipe shaft and at least 10 cm Fig. 19.41:
under flanges, sockets, attachments and Pipeline zone and cover –
fittings. terms according to EN 805 [19.1]
and EN 1610 [19.2]
10.2015
Table 19.3:
Thickness of the lower bedding layer
Thickness of the lower bedding layer [mm]

DWA
EN 805 DVGW EN 1610
Example A 139 EADIPS®/FGR®
[19.1] W 400-2 [19.7] [19.2]
[19.9]
100 + 0,1 da min. 100 (normal) 100 + 0.1 DN (normal)

DN No Data All type of coating
min. 150 min. 150 (firm) 100 + 0.2 DN (firm)
100 (normal) 125 (normal)

250 – 150 100
150 (firm) 150 (firm)
100 (normal) 160 (normal)
600 – 163 100
150 (firm) 220 (firm)
19.6.4 Embedding the pipes The thickness of the cover in the 19.6.5 Cover height
compacted state should reach a height
Embedding is very important in deter- of 15 cm above the crown of the pipe The cover height is the distance between
mining the load and stress distribution when more lightweight compaction the crown of the pipe and ground level.
over the circumference of the pipe. equipment is used and 30 cm with For drinking water pipelines it is impor-
heavier compaction equipment before tant that they are installed at a frost-
For embedding purposes, suitable soil starting on the compaction of the main free depth. The limit values for cover
which will not damage the parts of the filling. heights at which ductile iron pipes can
pipeline and the coating is to be filled in be installed without structural analysis
layers on either side of the pipeline and Pipelines which are subject to a risk of are given in the applicable standards
sufficiently compacted. floating must be provided with buoyancy EN 545 [19.27] and EN 598 [19.28].
protection.
10.2015
For cover heights outside the areas 19.7 Special pipeline 19.7.2 Laying pipes uphill
stated or more favourable installation installation cases
conditions, separate static calculations Where the soil is sufficiently firm, there
may be necessary. Structural design is are cross supports which can support a
stipulated in e.g. ATV-DVWK-A 127 The features of certain important pipeline on a steep slope. In such a case
[19.29], Austrian standard B 5012 [19.30], application cases are described below. a concrete thrust block secures the bot-
[19.31] and SIA 190 [19.12]. Otherwise the Technical Department of tom bend (at the foot) and the pipes to be
the cast iron pipe manufacturer should installed upwards from there are driven
19.6.6 Bedding material be consulted for help with technical so far into the socket that they stand in
problems. the base of the socket.
A homogenous, well-compactable fill-
ing material is to be used as the pipe 19.7.1 Pipelines in sloping On the hillside itself then, depending
bedding material. The permissible and steep areas on the gradient, every 2nd or 3rd pipe is
grain sizes depend on the pipe coating secured behind the socket with a con-
and can be found in the pipe manufac- When installing pipes in sloping and crete block which is anchored in the
turer’s installation instructions. Before steep areas, additional forces come into natural soil (Figure 19.42). At the same
use, the bedding material is to be evalu- play which require corresponding safe- time the concrete blocks act as protec-
ated with respect to its corrosion likeli- guarding measures depending on the tion against the undercutting of the pipe-
hood according to DIN 50929-3 [19.32], gradient, such as restrained push-in line. Their dimensions are based on e.g.
[19.33], DVGW worksheet GW 9 [19.34] joints and cross supports. As a rule this DVGW worksheet GW 310 [19.21]. Slopes
or Austrian standard B 5013-1 [19.35] is necessary with gradients of more than on which landslides are to be expected
and tested as regards its suitability for 15°. require the installation of geotextiles as a
the pipe coating envisaged according to slidable pipe surround in order to release
DIN 30675-2 [19.36]. The installation of concrete, wood or the pipe from ground forces.
heavy clay barriers prevents the back-
filled pipe trench from acting like a
drainage ditch and so allowing water to
run under the pipeline.
10.2015
19.7.3 Laying pipes downhill In most cases this can be managed by

improving the subsoil, e.g. soil replace-
If a pipeline is to be installed down- ment, ballast beds or geotextile-gravel
hill, then pipes with restrained push-in cushions. If these measures are not
joints are to be assembled in such a way sufficient there is the possibility of
that the restrained locking is direct and installation on pile heads (Figure 19.44).
prevents the slipping of the pipes. In normal cases ductile iron pipes only
require one support per pipe (Figures
The entire pipeline must then be secured 19.45, 19.46 and 19.47).
Fig. 19.42: at the upper end either by a fixed point
Uphill installation of pipes – ductile iron (concrete thrust block or structure) or by In areas affected by mining, in some
pipeline on a slope with concrete blocks a restrained push-in joint (Figure 19.43). cases considerable subsidence can occur
if the seams are not filled after mining
A thrust block at the lower bend is not is finished. As a rule, this causes trac-
necessary if the horizontal section of tive strains in the marginal zones of the
pipeline leading to the inflexion point subsidence and compressive strains in
is fitted with restrained push-in joints the middle. These can amount to up to
over a sufficient length. 15 mm/m. Ground subsidence of up to
7 cm in five days has been observed,
19.7.4 Installation in unstable ground with gradient changes of 36 cm over a
length of 40 m occurring in one month.
In soils with poor load-bearing char- Under these circumstances, pipelines
acteristics, particular measures are to should not be rigid. Pipes in ductile cast
Fig. 19.43: be taken to prevent the sinking of the iron with their flexible push-in joints
Downhill installation of pipes – restrained pipeline. Particularly susceptible to are particularly suitable. According to
ductile iron pipeline with a concrete subsidence are pipelines in boggy and product standards EN 545 [19.27] and
thrust block at the upper inflexion point peaty ground and in silty and organic EN 598 [19.28] deflections in pipe and
soil types. fitting sockets of up to 5° are possible.
10.2015
19.7.5 Installation in groundwater
With high groundwater levels, the pipes

are to be secured against buoyancy.
With the kind of high groundwater lev-
els which are often found in lowlands
close to bodies of water, ductile iron
pipes with restrained push-in joints
can be assembled alongside the trench
over a long stretch of pipeline and
then lowered with a number of lifting
Fig. 19.44: Fig. 19.46: devices (Figure 19.48).
Pipeline on pile heads – double mounting Example of a construction drawing
for a concrete support saddle
Fig. 19.45: Fig. 19.47: Fig. 19.48:

Single mounting of ductile Concrete support saddle with neoprene Pre-assembled pipeline being
iron pipes on piles support for ductile iron pipes lowered into the trench
10.2015
19.8 References [19.3] DVGW-Arbeitsblatt GW 301 [19.5] DVGW-Arbeitsblatt W 339

Unternehmen zur Errichtung, Fachkraft für Muffentechnik
Instandsetzung und Einbindung metallischer Rohrsysteme –
[19.1] EN 805 von Rohrleitungen – Lehr- und Prüfplan
Water supply – Anforderungen und Prüfungen [DVGW worksheet W 339
Requirements for systems and [DVGW worksheet GW 301 Qualifications in jointing technol-
components outside buildings Companies for construction, repair ogy of metallic piping systems –
[Wasserversorgung – and connection of pipelines – Training and test plan]
Anforderungen an Wasserversor- Requirements and testings] 2005-10
gungssysteme und deren Bauteile 2011-10
außerhalb von Gebäuden] [19.6] ATV-DVWK-A 142
2000 [19.4] SVGW-Richtlinie W4-3 Abwasserkanäle und -leitungen
Richtlinie für Wasserverteilung – in Wassergewinnungsgebieten
[19.2] EN 1610 Planung, Projektierung, [Sewers and drains in water
Construction and testing of drains Bau, Prüfung sowie catchment areas]
and sewers Betrieb und Instandhaltung 2002-11
[Verlegung und Prüfung von der Trinkwasserverteilung
Abwasserleitungen und -kanälen] außerhalb von Gebäuden – [19.7] DVGW-Arbeitsblatt W 400-2
2015 Teil 3: Bau und Prüfung Technische Regeln Wasserver-
[SVGW guideline W4-3 teilungsanlagen (TRWV) –
Guideline for water distribution – Teil 2: Bau und Prüfung
Planning, project development, [DVGW worksheet W 400-2
construction, testing as well as Technical rules on water
operation and maintenance distribution systems –
of drinking water distribution Part 2: Construction and testing]
systems outside buildings – 2004-09
Part 3: Construction and testing]
2013-3
10.2015
[19.8] DIN 2000 [Long-distance, district and [19.13] Council Directive 98/83/EC
Zentrale Trinkwasserversorgung – supply pipelines of water Council Directive 98/83/EC
Leitsätze für Anforderungen supply systems – of 3 November 1998 on the
an Trinkwasser, Planung, Bau, Additional specifications con- quality of water intended
Betrieb und Instandhaltung cerning OENORM EN 805] for human consumption
der Versorgungsanlagen – 2002-11-01 [Richtlinie 98/83/EG
Technische Regel des DVGW Richtlinie 98/83/EG des Rates
[Central drinking water supply – [19.11] OENORM B 2503 vom 3. November 1998
Guide lines regarding require- Kanalanlagen – über die Qualität von Wasser für
ments for drinking water, plan- Planung, Ausführung, den menschlichen Gebrauch
ning, construction, operation Prüfung, Betrieb – http://www.bmub.bund.de/filead-
and maintenance of plants – Ergänzende Bestimmungen zu min/bmu-import/files/pdfs/allge-
Technical rule of the DVGW] den OENORMEN EN 476, EN 752 mein/application/pdf/wasserrl.pdf]
2000-10 und EN 1610 1998-11-03
[Drain and sewer systems –
[19.9] DWA-A 139 Design, construction, [19.14] EADIPS®/FGR®-Norm 74
Einbau und Prüfung von Abwasser- testing, operation – Formstücke und Armaturen
leitungen und -kanälen Complementary provisions aus duktilem Gusseisen –
[DWA worksheet A 139 concerning OENORM EN 476, EN 752 Verpackung von Form-
Installation and testing and EN 1610] stücken und Armaturen
of drains and sewers] 2012-08-01 [Ductile iron fittings and valves –
2010-01 Packaging of ductile iron
[19.12] SIA 190; SN 533190 fittings and valves]
[19.10] OENORM B 2538 Kanalisationen – 2013-06
Transport-, Versorgungs- und Leitungen, Normal- und
Anschlussleitungen von Sonderbauwerke
Wasserversorgungsanlagen – [Sewage systems –
Ergänzende Bestimmungen Pipelines, standard and
zu OENORM EN 805 special constructions]
2000-07
10.2015
[19.15] EN 12351 [19.18] EADIPS®/FGR®-Norm 75 [19.20] DVGW-Merkblatt W 332

Industrial valves – Rohre aus duktilem Gusseisen – Auswahl, Einbau und Betrieb von
Protective caps for valves Kennzeichnung des zulässigen metallischen Absperrarmaturen in
with flanged connections Bauteilbetriebsdrucks (PFA) Wasserverteilungsanlagen
[Industriearmaturen – längskraftschlüssiger beweglicher [DVGW technical information sheet
Schutzkappen für Arma- Steckmuffen-Verbindungen W 332
turen mit Flanschanschluss] von Rohren – Selection, installation and operation
2010 Ergänzung zur EN 545:2010 of metallic shut-off valves in water
[Ductile iron pipes – distribution systems]
[19.16] ISO 2230 Marking of the allowable operating 2006-11
Rubber products – pressure PFA of restrained flexible
Guidelines for storage push-in socket joints of pipes – [19.21] DVGW-Arbeitsblatt GW 310
[Produkte aus Gummi – Supplement to EN 545:2010] Widerlager aus Beton –
Leitlinie für die Lagerung] 2013-06 Bemessungsgrundlagen
2002-04 [DVGW worksheet GW 310
[19.19] EADIPS®/FGR®-Norm 30 Concret thrust blocks –
[19.17] DVGW-Arbeitsblatt W 346 Rohre, Formstücke und Armaturen Principles of sizing]
Guss- und Stahlrohrleitungs- aus duktilem Gusseisen – 2008-01
teile mit ZM-Auskleidung – Schraubenlängen für
Handhabung Flansch-Verbindungen [19.22] SVGW-Richtlinie W4-2
[DVGW worksheet W 346 [Ductile iron pipes, Richtlinie für Wasserverteilung –
Cast iron and steel pipes fittings and valves – Planung, Projektierung,
and components with Length of bolts for flanged joints] Bau, Prüfung sowie
internal mortar lining – 2013-06 Betrieb und Instandhaltung
Handling] der Trinkwasserverteilung
2000-08 außerhalb von Gebäuden –
Teil 2: Planung und Projektierung
10.2015
[Guideline for water distribution – [19.24] DVGW-Arbeitsblatt W 392 [19.27] EN 545

Planning, project development, Rohrnetzinspektion und Ductile iron pipes, fittings,
construction, testing as well as Wasserverluste – accessories and their joints
operation and maintenance Maßnahmen, Verfahren for water pipelines –
of drinking water distribution und Bewertungen Requirements and test methods
systems outside buildings – [DVGW worksheet W 392 [Rohre, Formstücke, Zubehörteile
Part 2: Planning and project Piping network inspec- aus duktilem Gusseisen und ihre
development] tion and water losses – Verbindungen für Wasserleitungen –
2013-3 Activities, procedures Anforderungen und Prüfverfahren]
and assessments] 2010
[19.23] SVGW-Richtlinie W4-5 2003-05
Richtlinie für Wasserverteilung – [19.28] EN 598
Planung, Projektierung, Bau, [19.25] DIN 4124 Ductile iron pipes, fittings,
Prüfung sowie Betrieb und Instand- Baugruben und Gräben – accessories and their joints for
haltung der Trinkwasserverteilung Böschungen, Verbau, sewerage applications –
außerhalb von Gebäuden – Arbeitsraumbreiten Requirements and test methods
Teil 5: Praxisunterlagen, Themen- [Excavations and trenches – [Rohre, Formstücke, Zubehör-
blatt Nr. 7: Rohrnetzspülung Slopes, trench shoring, teile aus duktilem Gusseisen
[Guideline for water distribution – breadth of working space] und ihre Verbindungen für
Planning, project development, 2012-01 die Abwasser-Entsorgung –
construction, testing as well as Anforderungen und Prüfverfahren]
operation and maintenance [19.26] ZTV A-StB 12 2007+A1:2009
of drinking water distribution Zusätzlichen Technischen Vertrags-
systems outside buildings – bedingungen und Richtlinien für [19.29] ATV-DVWK-A 127
Part 5: Practical data sheet, data Aufgrabungen in Verkehrsflächen Statische Berechnung von Abwasser-
sheet No. 7: Network flushing] [Additional technical contract condi- kanälen und -leitungen
2013-3 tions and guidelines for excavations (korrigierter Nachdruck 2008-04)
in traffic areas] [Structural design of drains and
2012 sewers (corrected reprint 2008-04)]
2000-08
10.2015
[19.30] OENORM B 5012 [Corrosion of metals – [19.34] DVGW-Arbeitsblatt GW 9

Statische Berechnung erd- Probability of corrosion of Beurteilung der Korrosionsbe-
verlegter Rohrleitungen für metallic materials when subject lastungen von erdüberdeckten
die Wasserversorgung to corrosion from the outside – Rohrleitungen und Behältern aus
und die Abwasser-Entsorgung Buried and underwater pipelines unlegierten und niedrig legier-
[Structural design of buried and structural components] ten Eisenwerkstoffen in Böden
water and sewerage pipelines] 1985-09 [DVGW worksheet GW 9
2008-10-01 Assessment of the corrosion
[19.33] DIN 50929-3 Beiblatt 1 level of buried pipes and tanks
[19.31] OENORM B 5012/A Korrosion der Metalle – in unalloyed and low-alloyed
Statische Berechnung erdverlegter Korrosionswahrscheinlichkeit ferrous materials in soils]
Rohrleitungen für die Wasserver- metallischer Werkstoffe bei 2011-05
sorgung und die Abwasser- äußerer Korrosionsbelastung –
Entsorgung (Änderung) Teil 3: Rohrleitungen und Bau- [19.35] OENORM B 5013-1
[Structural design of buried teile in Böden und Wässern – Oberflächenschutz mit orga-
water and sewerage pipe- Beiblatt 1: Korrosionsraten nischen Schutzmaterialien
lines (Amendment)] von Bauteilen in Gewässern im Siedlungswasserbau –
2014-09-01 [Corrosion of metals – Teil 1: Abschätzung der Korrosions-
Probability of corrosion of metallic wahrscheinlichkeit und Schutz
[19.32] DIN 50929-3 materials when subject to corrosion von unlegierten und niedrig-
Korrosion der Metalle – from the outside – legierten Eisenwerkstoffen
Korrosionswahrscheinlichkeit Part 3: Buried and underwater pipe- [Corrosion protection by organic
metallischer Werkstoffe bei lines and structural components – coatings for water and wastewater
äußerer Korrosionsbelastung – Supplement 1: Corrosion rates of engineering in residential areas –
Rohrleitungen und Bauteile structural components in water] Part 1: Assessment of corrosion
in Böden und Wässern 2014-11 probability and protection of
unalloyed and low-alloyed ferrous
materials]
2013-12-15
10.2015
[19.36] DIN 30675-2

Äußerer Korrosionsschutz von
erdverlegten Rohrleitungen –
Schutzmaßnahmen und Einsatz-
bereiche bei Rohrleitungen
aus duktilem Gusseisen
[External corrosion protection
of buried pipes –
Corrosion protection systems
for ductile iron pipes]
1993-04
10.2015
E-Book – Ductile iron pipe systems Chapter 20: Pressure tests 20/1
20 Pressure tests
10.2010
E-Book – Ductile iron pipe systems Chapter 20: Pressure tests 20/2
20 Pressure tests
10.2010
E-Book – Ductile iron pipe systems Chapter 21: Commissioning of ductile iron pipelines for drinking water 21/1
21 Commissioning of
ductile iron pipelines
for drinking water
21.1 Preliminary comment
21.2 Preventive measures
21.3 Cleaning measures
21.5 Flushing with water and air
21.7 Other cleaning techniques
21.8 Disinfection process
21.9 Disinfection agent
21.10 Handling and disposal
21.11 Inspection and release of the pipeline
21.12 Measures for existing cast iron pipelines
21.13 Summary
21.14 Closing comments, additional information and prospects
21.15 References
10.2015
21 Commissioning of ductile iron pipelines for drinking water pipelines”, SVGW guideline W1000
[21.3]; in Austria in ÖVGW guideline
Drinking water legislation lays down requirements for our most important W 55 “Hygiene in reservoirs and pipe-
food – drinking water. Water supply companies are obliged to supply hygienically line networks” [21.4].
impeccable water and it is for this reason that comprehensive standards and
regulations specifying requirements, test methods and practices are available It is important that no substances
both for extraction and storage equipment and for distribution networks. should be found in the pipeline which
can serve as nutrient substrates for
microorganisms. Basically these sub-
strates can originate from inappropriate
pipe materials and assembly agents or
21.1 Preliminary comment Hence the title of DVGW worksheet they can be introduced via impurities.
W 291 “Disinfection of water supply
equipment” which appeared in 1986. The first possibility can be avoided if
Apart from their fittings and valves, However experience has taught us that components with DVGW certification,
ductile iron pipelines consist mainly disinfection alone rarely produces the for example, are envisaged right from
of pipes with cement mortar linings. desired result. Preventive measures and the planning stage. This requirement
DVGW worksheet W 346 [21.1] describes cleaning play an important role. The is included in e.g. DIN 2000 [21.5]
the handling of pipes and fittings with revised edition of DVGW worksheet (Section 6.6: Materials, Section 6.6.1:
this tried and tested lining and provides W 291 [21.2] bears the title “Cleaning Microbiological and sanitary require-
advice on commissioning pipelines and and disinfection of water distribution ments, Section 6.6.3: Testing and
putting them into operation in its two equipment” in order to indicate the certification). Basically, only materials
annexes, Annex 1: Changes in the pH importance of careful preliminary with valid sanitary certificates should
value, Annex 2: Flushing and disinfecting. cleaning. The worksheet places the be used. Components with e.g. DVGW
emphasis on cleaning, while disinfection certification guarantee that the corre-
Formerly, disinfection was the general is seen as an additional safety measure. sponding qualifications have been
term usually used for measures for get- In Switzerland this issue is dealt with in met. Also Section 17 of the latest
ting the equipment into a hygienically the “Recommendations for the cleaning version of the German drinking
impeccable condition. and disinfection of drinking water. water ordinance dated 2 August 2013
[21.6] specifies requirements for the
10.2015
extraction, processing and distribution The second possible means of ingress When installing a new pipeline it
of drinking water. These components for impurities arises during the should also be borne in mind that,
are to be planned, constructed and manufacturing of pipeline compo- for example, only assembly agents
operated at least in accordance with nents, during their handling – includ- certified according to DVGW test
the generally accepted technical rules ing storage and transport – and during specification VP 641 [21.15] should
and standards. The entrepreneur and their installation. By means of be used. These are only used for
other owners of equipment of this appropriate packaging, for example the assembly process itself and must
kind must make sure that only suitable protective caps for pipes, fittings be able to be flushed out. For check-
materials and substances are used for and valves, the contamination of ing the characteristics of assembly
new constructions or during servicing surfaces in contact with water can agents in terms of rinsing/flushing
and maintenance. The German Federal be avoided. Instructions for this can them out of valves, DVGW test
Environment Agency (UBA) determines be found in EN 805 [21.11] and also specification W 363 [21.16], standard
assessment criteria so that the require- in DVGW worksheet W 400-2 [21.12] Annex A “Checking the rinsing/flush-
ments can be met in practice [21.7]. For (Section 5: Incoming goods inspection, ing capability of assembly agents” and
the area of drinking water, accredited transport and storage of parts for pipe- [21.17] are applied in Germany. Thread
certification bodies issue certificates to lines, Section 7.2: Cleaning parts for cutting agents must meet the require-
confirm that these requirements have pipelines) for all pipeline parts during ments of DVGW worksheet W 521 [21.18]
been met. Similarly in Switzerland, transport and storage, DVGW work- in Germany.
according to SVGW guideline W4-1 sheet W 346 [21.1] for cast iron pipes
[21.8] (Planning, project organisation, and fittings and EN 1074-1 [21.13] Appropriate cleaning mobilises and
construction, testing, operation and (Section 8: Packaging) for valves. For removes the unavoidable substances
maintenance of drinking water net- fittings and valves, EADIPS®/FGR® which could adversely affect the
works outside buildings) products with standard 74 [21.14] should also be quality of the drinking water. Finally,
SVGW certification are considered to be observed. disinfection has the aim of killing
suitable for the construction of drink- or damaging microorganisms which,
ing water supply equipment. In Austria despite careful cleaning, still remain
this subject is regulated in Austrian in the equipment.
standards B 5014-1 [21.9] and B 5014-2
[21.10].
10.2015
For the successful commissioning of a drinking water pipelines are basically 21.3 Cleaning measures
drinking water pipeline there are three fitted with pipe caps when they leave
terms to be found in DVGW worksheet the production line. The same applies
W 291 [21.2] and similarly in SVGW for valves, where foil often protects the The cleaning of pipelines is aimed at
guideline W1000 [21.3], SVGW guide- packaging units. The caps are there getting rid of impurities, deposits and
line W4-3 [21.19] and ÖVGW guideline to prevent impurities and even small other undesirable substances. Such
W 55 [21.4]: animals from getting inside the substances can lead in the long term
components during storage and trans- to the proliferation of micro-organisms
■ preventive measures, port. Obviously these caps must stay on surfaces in contact with water and
■ cleaning, in place until the joints are assembled hence to a multiplication of the colony
■ disinfection. with the components. count in the water or to contamination
of the water. The first stage involves
These terms serve as guidelines and Impurities introduced by personnel, mobilising these substances. After that
are explained below. by working materials such as dirty they must be completely flushed out of
rags for wiping off the sockets and the system. In no case should they be
pipe brushes as well as pollutants allowed to be deposited again elsewhere,
21.2 Preventive measures introduced from the air (the oily mist thereby resulting in further detrimen-
of exhaust gas given off by 2-stroke tal effects to the water. For cleaning
pipe cutters!) must be excluded. purposes a basic distinction needs to be
A condition for the problem-free com- During breaks in work and overnight made between newly installed pipelines
missioning of newly installed drink- the ends of the pipeline need to be and existing ones.
ing water pipelines is compliance with sealed to be watertight. There is often
sanitary requirements right from a risk that heavy rain or groundwater Newly installed pipelines contain
the planning stage and throughout will inundate the pipe trenches. Soil agents to assist with assembly as well
installation. Hence the preventive getting into the pipeline is the main as impurities occurring unintentionally.
measures properly begin with the cause of persistent recontamination. In all cases these are to be mobilised
correct choice of pipeline parts along The ends of pipelines must be closed and flushed away. In the event of
with their storage, transport and off sufficiently tightly so that nei- “incidents” such as unforeseen and
installation. Pipes and fittings in ther groundwater and dirty water nor unplanned events like the ingress
ductile cast iron for the production of animals can penetrate. of mud in bad weather during the
10.2015
Table 21.1: all cases the sections of pipeline to be

Flushing process for pipelines cleaned must be shut off from the rest
of the network before cleaning in order
Flushing process Description to prevent the flushing water from
Flushing water A simple, conventional process contaminating the drinking water. In
pipelines it is predominantly the flush-
Flushing with water and air Flushing with an air/water mix ing techniques described in Table 21.1
Pulsed flushing technique that are used.
Combined flushing and pigging Flushing with water and sponge rubber balls
Flushing with water and plastic pigs
Special cleaning techniques High-pressure cleaning
Cleaning with scrapers
The simplest cleaning process is flush-
ing with drinking water. For the flush-
ing to be successful it is important that
assembly phase, intensive flushing is flushing of pipelines in Swiss SVGW the water in the pipeline achieves a
indicated. The aim is to remove micro- guideline W4-5 [21.20] also describes sufficient speed of flow of between 2 m/s
organisms and above all the nutrient the measures necessary for this. The and 3 m/s, which is normally possible
substrates for micro-organisms from type of cleaning technique to be used in pipelines up to DN 150. With larger
the pipeline. The more thorough the will depend on the nominal size of nominal sizes both the amount of drink-
cleaning, the more effective and likely the pipeline and the level of its ing water required and the resulting
to succeed the subsequent disinfection contamination. Basically, mechanical amount of flushing water are increased.
measures will be. cleaning is to be preferred over clean- Figure 21.1 provides information on
ing with chemicals here. With pipelines the water required for flushing pipe-
The cleaning of water distribution it is practically only mechanical tech- lines according to the nominal size.
systems (pipelines and reservoirs) is niques which are used. A distinction is
described in DVGW worksheet W 291 made between accessible pipelines with
[21.2]. ÖVGW guideline W 55 applies in nominal sizes greater than DN 600 and
Austria [21.4]. Data sheet no. 7 on the pipelines which are not accessible. In
10.2015
cess the capacity of these fixtures needs

to be taken into account. With con-
ventional hydrants this is around
110 m³/h and with free-flow hydrants
it is around 150 m³/h. Above DN 150
their capacity is no longer sufficient.
There are modern techniques avail-
able for this, particularly for DN > 150.
Figure 21.1 provides information on
the water volume required for flushing
with water, with air and water and with
the pulsed flushing technique as well as
flow limiting by flushing hydrants.
21.5 Flushing with water and air

Fig. 21.1:
Water requirement for flushing pipelines where the flow is limited by underground
hydrants (source: Hammann GmbH) As compared with flushing with water,
the work according to this technique
sets high process and safety technol-
Depending on the cross-section of adjacent pipelines should not be subject ogy requirements and should only
the pipeline, at least three to five times to any pressure drop during flushing. be carried out by experienced experts.
the capacity of the pipeline should Also the mobilisation of deposits in Only purified air should be used. It
be envisaged as the volume of water pipelines upstream caused by a high must be oil-free with a low particle
required. In principle, gravity flow pipe- flow speed should not cause turbidity and germ count. The flushing water/
lines should be flushed from the top of the drinking water. When draining flushing air ratio is between 1 : 1 and 1 : 3.
downwards. Effects on the adjacent off the flushing water local regulations
pipeline network must be taken into and legislation must be observed. If
account. This means that the supply in hydrants are used in the flushing pro-
10.2015
The inclusion of air improves the

performance of the cleaning process.
However, if air bubbles collect in the
crown of the pipe, this effect may be
limited to the bottom of the pipe only.
Uncontrolled pressure surges can cause
pipe bursts.

Fig. 21.2:
Cleaning a defined section of pipeline using the impulse-flushing method
An alternative to flushing with water (source: Hammann GmbH)
and air is the impulse-flushing method.
Purified compressed air is delivered
in pulses into a defined section to be This means that negative effects in The advantages of the impulse-flushing
flushed, without exceeding the dead adjacent networks and pipelines method as compared with conventional
pressure of the network (Figure 21.2). upstream can largely be avoided. processes can be summarised as follows:
This produces high-speed blocks of air
and water in the section to be flushed. Research projects have enabled the ■ more intensive cleaning,
The turbulent flow covers a broad area effectiveness of cleaning to be increased ■ up to 90 % less water required,
and produces locally high forces to while using less water. The blocks ■ no turbidity and pressure drops
mobilise the deposits. of water produced in partially filled in networks upstream,
pipelines reach flow speeds of more ■ water supply can be maintained
This drastically reduces the amount than 15 m/s. A lower water requirement outside the section being flushed,
of water required as compared with also means less flushing water to be ■ improvement in the functioning
flushing with water only (Table 21.2). disposed of, which is of particular of valves.
significance with pipelines of higher
nominal sizes.
10.2015
Table 21.2: The pulsed flushing technique is used

Water required for flushing with water and for the impulse-flushing method first and foremost for cleaning drink-
ing water distribution systems. New
Water requirement in m³/h process techniques in recent years mean
that even large transport pipelines with
Flushing with water Impulse-flushing method
Nominal size nominal sizes of up to DN 1200 can now
at flow speed of indicative value
be cleaned. In these pipelines, because of
2 m/s 3 m/s Low High the water requirement, cleaning is often
80 36 54 5 15 only possible using the impulse-flushing
method [21.21].
100 57 85 8 25
125 88 133 10 30 Reducing the amount of water required
150 127 191 20 38 has gained in importance over recent
years. In contrast to drinking water
175 173 260 23 50 pipelines, in times of low consumption
200 226 339 35 70 well galleries and raw water pipelines
could be cleaned without interrupting
225 286 429 40 80
their operation and the flushing water
250 353 530 42 85 purified at the waterworks [21.22].
300 509 763 50 100
1039 Persistent impurities can not only form
350 693 70 110
in old pipelines; they can also come
400 905 1357 90 150 about after “incidents”, for example in
450 1145 1718 110 190 case of unforeseen and unplanned events
during the installation phase of new
500 1414 2121 140 230
pipeline sections. The performance of
550 1711 2566 180 280 the cleaning process can be increased
600 2036 3054 220 330 in such cases with the addition of solids,
e.g. pieces of ice.
10.2015
21.7 Other cleaning techniques example, pig diameters are too small, Cleaning with scrapers is predominantly
water for carrying away the mobilised carried out before the renovation of old
deposits can get into the section of cast iron pipelines with cement mortar.
With particularly persistent contami- pipeline to be cleaned.
nations, combined flushing and pigging
or special cleaning techniques can be In special cases, high-pressure cleaning 21.8 Disinfection process
used. For pigging, sponge rubber balls and cleaning with scrapers are methods
or plastic pigs come into use. In both which are used. High-pressure clean-
cases equipment needs to be provided ing can be used regardless of surface The simplest process for disinfecting
for the insertion and removal of the quality. However, the cleaning nozzles, pipelines which is still widely used
pigs. Hydrants, and preferably free-flow pressure and distance from the wall today is the standing technique. The
hydrants, are suitable for the sponge must be adapted to the type of surface disinfecting agent is left to stand in the
rubber balls. With pipelines which need in order to avoid damage. Hot water completely filled section of pipeline for
to be cleaned frequently, e.g. for raw or can improve the cleaning. In addition at least 12 hours.
process water, pigging fittings are to be a disinfecting agent can be used spar-
recommended. ingly in a targeted manner. Particu- With the standing technique, the disin-
larly in this case measures should fecting agent gets into the pipeline
Sponge rubber balls are normally used be taken to dispose of or process the by adding the solution to be applied
for cleaning pipelines up to DN 150. flushing water appropriately. to the water by means of metering
While more loosely adhering deposits pumps or injectors providing a constant
and sediments can be mobilised and For pipelines which are not accessible, ratio via a connection piece, an air valve
flushed out using sponge rubber balls, jetting lances are used with the jet or a hydrant. During the standing time
special pigs can also remove persistent directed backwards and a free outflow fittings in the section of pipeline being
deposits. Attention must be paid to of the flushing water. In accessible treated, such as valves or hydrants,
cleanliness during the handling and pipelines short sections can be cleaned should be operated so that the disin-
storage of pigs for drinking water manually. In this case it is possible to fectant can also get into areas where the
pipelines. During the cleaning process, concentrate the cleaning on particularly flow is poor.
precautions are to be taken to ensure heavily soiled areas. Safety specifications
that the pig does not become stuck in are to be observed in all cases.
the section being cleaned. And if, for
10.2015
At the end of the standing time a resid- Table 21.3:

ual concentration of the disinfecting Dynamic disinfection process
agent should still be able to be detected
in the water. Effective use
Process Application
of the agent
The standing technique is a static dis- Small nominal sizes,
infection process. The disinfecting solu- Run-through method short pipe sections, poor
tion stands in the pipeline. Only part of Flushing with disinfecting solution
it works on the surface of the pipeline.
Double line or ring line, recircula-
This means that the concentration of Closed loop method good
tion of the disinfecting solution
active substance decreases there, while
it remains unused on the inside of Large nominal sizes,
the pipeline and then has to be dis- Plug method long pipe sections, plugging good
posed of. This disadvantage is ironed out with disinfecting solution
by the dynamic disinfecting process.
Here the disinfecting solution moves
through the pipeline. In this way no Ingress of the disinfecting solution 21.9 Disinfection agent
differences in the concentration of into the piping network still in opera-
active agent occur. With the dynamic tion is to be prevented by disconnecting
disinfecting process, however, par- the pipeline or by watertight shut-off A distinction is to be made between the
ticular conditions are required, which devices. The shut-off devices must be following disinfection agents:
are described in Table 21.3. With checked for tightness and identified to ■ commercial form,
the plug method it is recommended prevent them being activated by mis- ■ application form or dosage solution
that the disinfecting solution is moved take. The positive operating pressure in (stock solution),
slowly through the pipeline between the section of pipeline to be disinfected ■ disinfection solution.
two pigs. must be considerably lower than that in
the adjacent drinking water piping net-
work.
10.2015
Chlorine and hydrogen peroxide are In recent years the use of disinfecting disinfection agents for pipelines are:
available as ready-to-use dosage solu- agents based on chlorine and hypo-
tions. Commercial chlorine bleaching chlorite has been decreasing. Reasons ■ chlorine/hypochlorite 50 mg/L
agent has a chlorine content of 130 g/L for this are, among other things, the ■ hydrogen peroxide 150 mg/L
to 150 g/L. Solutions of hydrogen restricted area of application, the pro- ■ chlorine dioxide 6 mg/L
peroxide often have a content of 30 % duction of undesirable by-products and
or 50 %. Chlorine bleaching agent and the expense of disposal. Modern disin- The efficacy of the disinfection agent
hydrogen peroxide solutions are to be fecting agents are based on hydrogen depends essentially on the pH value.
stored in the dark, cool and tightly peroxide or chlorine dioxide. Calcium With pH values < 8 the disinfection
sealed. Light, heat and impurities hypochlorite and potassium perman- solutions with the concentrations
accelerate deco position. Hydrogen ganate do not play any significant role recommended in DVGW worksheet
peroxide solutions often contain in pipeline disinfection. W 291 [21.2] work well. However at
stabilisers. higher pH values the effectiveness
DVGW worksheet W 291 [21.2] dedi- of chlorine/hypochlorite and hydro-
Chlorine dioxide solution can easily be cates a special section to disinfection gen peroxide quickly subsides. Such
produced on site with two components agents. Advice on the choice of dis- conditions can arise with construction
with good storage stability. The ready- infection agent and safe working components in cementitious materials
to-use dosage solution usually has a practices can also be found there. The and/or soft water. DVGW worksheet
chlorine dioxide content of 3 g/L. It relevant table provides information W 346 [21.1] provides information in its
is stable for weeks if stored correctly. on chemicals for disinfecting equip- Annex 2 on the efficacy of disinfection
Meanwhile single-component products ment and gives a summary of the agents with pipelines lined with cement
are also available for producing chlorine commercial form, storage and appli- mortar depending on the type of water.
dioxide solutions. Calcium hypochlorite cation concentrations. Special sections In pipelines with untreated cement
and potassium permanganate are sol- deal with the individual disinfection mortar lining the pH value can increase
ids from which dosage solutions can be agents including their chemical prop- considerably with soft water of water
produced before use. erties and fields of application. The types WKSI and WKSII and hence the
application concentrations recom- efficacy of chlorine/hypochlorite and
mended in DVGW worksheet W 291
[21.2] for the major.
10.2015
hydrogen peroxide decreases. Table 21.4 Table 21.4:

provides information on essential con- Efficacy of different disinfection agents with pipelines lined with cement
tent in a simplified form. mortar based on DVGW worksheet W 346 [21.1], Annex 2
The redox voltage or oxidation-reduc- Cement mortar without pre-treatment with pre-treatment 1)
tion potential (ORP) is often used for
Water typw WKSI WKSII WKSIII WKSI WKSII WKSIII
estimating efficacy. The ORP is the
mixed potential of all oxidation and KS 4,3 in mmol/L < 0,5 0,5 bis 2 >2 < 0,5 0,5 bis 2 >2
reduction reactions (redox reactions) Chlorine/hypochlorite – 0 2) + 0 2) 0 +
occurring in the water, where the
substances contained in the water Hydrogen peroxide – 2), 3) 0 2) + 0 2), 3) 0 +
and in the material as well as their Chlorine dioxide + + + + + +
possible chemical reactions are not 1)
known. Therefore the redox potential + good If applicable water treatment with WKSI and with WKSII
2)
cannot be calculated from the con- 0 adequate High disinfection agent concentration and long working time
3)
centration of disinfection agent – poor Improves efficacy with addition of 1 % phosphoric acid
alone. Added to this is the fact that
many redox reactions are dependent
on the pH value. Figure 21.3 shows the untreated cement mortar lining then, To be recommended in these cases are
correlation between redox potential as a consequence of the increase in the disinfection agents with an ORP which
and pH value for the major disinfection pH value, the ORP required for disin- has a zero or low dependency on the
agents. fection of EH > 800 mV cannot be pH value, such as chlorine dioxide for
achieved with many disinfection agents, example.
In order to achieve a germicidal effect or can only be achieved with high con-
there should be an ORP of EH > 800 mV. centrations and long reaction times. If a cement mortar lined pipeline is put
These conditions apply not only to the Among these disinfection agents are, into operation with sufficiently hard
water but they must also be ensured for example, the frequently used water, then surface layers are formed
at the water/material phase interface. chlorine/hypochlorite which, at pH on the surface of the mortar.
If soft, slightly buffered water is used values above 8, increasingly causes
for filling a pipeline which has a fresh, difficulties with disinfection.
10.2015
and safety data sheets. DVGW work-

sheet W 346 [21.1], Annex 2 offers advice
here.
Redox potential EH in mV
HClO/ClO-
All disinfection agents have a tendency
ClO2 to decay, light and dust as well as heavy
metal compounds and organic materials
have an accelerating effect. Therefore
H2O 2 disinfection agents, and above all their
dosage solutions, must always be stored
in cool and dark conditions. Only the
equipment recommended by the manu-
EH = 800 mV facturer is to be used for handling them.
If too much dosage solution is taken out
of the storage container it must not be
put back.
pH value
Dosage solutions should not be stored
Fig. 21.3: for too long. The manufacturer’s in-
ORP of the disinfection agents chlorine (hypochlorous acid)/hypochlorite (HClO/ClO-), structions must be followed. The free
hydrogen peroxide (H2O2) and chlorine dioxide (ClO2) depending on pH value [21.23] chlorine content of commercially avail-
able chlorine bleaching agents dimin-
ishes constantly depending on tempera-
Good buffering of harder water alle- 21.10 Handling and disposal ture. DVGW worksheet W 229 [21.24]
viates the increase in the pH value. provides information on this correla-
Accordingly, surface layers and good tion. This disintegration also produces
buffering of the water favour the Information on the storage, handling and undesirable by-products. Therefore it is
achievement of the necessary redox disposal of disinfection agents can be essential that the content of free chlorine
potential. found in the manufacturer’s data sheets is checked after longer storage times.
10.2015
In contrast to hydrogen peroxide and cation there are e.g. pump sprays with also on partial sections. It is essential
chlorine dioxide solutions, sodium hydrogen peroxide concentrations of that the measures stated in e.g. standard
hypochlorite solution is alkaline around 3 %. These allow parts or joints ISO 5667-5 [21.25] – also included in the
(chlorine bleaching agent) with pH to be disinfected on site. German standard method for the analy-
values between 11.5 and 12.5. After it sis of water, wastewater and sludge; gen-
has been added, the pH value of the DVGW worksheets W 291 [21.2] and eral information (Group A); (A 14) – are
treated water inevitably rises. With soft W 346 [21.1], Annex 2, ÖVGW guide- taken into account when taking the
water this affects the efficacy of the line W 55 [21.4] and SVGW guideline samples. This includes run-out, clean-
disinfecting solution and with very hard W 1000 [21.3] all provide information ing and flaming of the extraction valves.
water it can lead to the precipitation of on the disposal of water containing
calcium carbonate. Reducing the pH disinfection agents. The success of cleaning and disinfec-
value by mixing the solution with acids tion measures is to be checked by micro-
is to be discouraged because chlorine biological examinations. Basically, pipe-
gas can escape and this may trigger an 21.11 Inspection and release lines should only be put into operation
incident. of the pipeline once corresponding test results produce
evidence of complete microbiological
Disinfection solutions containing safety and the limit values specified
chlorine should basically be treated After disinfection, the disinfection for chemical substances are respected.
before they are introduced into the solution is flushed out of the pipeline Inspections with limit values and tests
sewage system or into bodies of water. and it is filled with the water to be trans- are based on the drinking water regula-
The possibilities here are dilution, ported subsequently. No more disin- tions. If the result is not satisfactory the
chemical neutralisation with e.g. fection agent should be able to be measures must be repeated.
sodium thiosulphate or filtration detected in the last filling of water.
through activated carbon filters. Approximately two to three times the It should be mentioned that, on the
pipeline capacity is necessary for the basis of microbiological examinations
Disinfection agents based on hydrogen flushing. At the end of the flushing after thorough cleaning, e.g. using the
peroxide are available under various process water samples are to be taken impulse-flushing method, there may be
trade names. As an dosage solution they from the pipeline for microbiological no need for disinfection [21.21]. This is
have hydrogen peroxide concentrations examination. This is done at the end of of particular interest if there is not
of around 35 % or 50 %. For spray appli- the pipeline or, with longer pipelines, enough water available or there are
10.2015
large flushing volumes to be disposed of. speed. By adding disinfecting agents, dis- Raw water pipelines have a tendency
The impulse-flushing method reduces infection can be achieved if necessary to incrustation, particularly with high
the amount of water required for clean- during the flushing process. In all cases iron and manganese contents. Depend-
ing and can save the need for subsequent the instructions of DVGW worksheet ing on the operating method and type
disinfection and rinsing of the pipeline. W 291 [21.2] are to be observed. of raw water it can happen that, because
of traces of dissolved oxygen, oxidation
It happens time and again that water and precipitation already occur before
21.12 Measures for existing quality is adversely affected by malfunc- treatment of the water. It is currently
cast iron pipelines tions, exceptional events or emergencies. being investigated whether and to what
Examples are failures in water purifi- extent microbial iron ochre formation
cation, the ingress of impurities into the is a cause of the negative impacts [21.27].
After repairs and other work on a pipe- drinking water pipeline via leaks, or an
line, the sections of the pipeline need to unintentional connection with pipelines In order to safeguard the performance
be put back into operation as quickly as which do not carry drinking water. The capability of these pipelines, regular
possible. Therefore there is no time left Federal environmental agency gives maintenance is necessary, for example
for standard disinfection and sampling recommendations on provisions for by flushing with rubber balls or pigging.
with the issuing of a release. In this case a sufficient disinfection capacity in By contrast, compressed air “pigs” fit
it must be ensured by other means that such cases [21.26]. After disinfection every pipe cross-section and reliably
the drinking water pipeline is in perfect of the specific area of drinking water carry the mobilised deposits away. The
condition from the hygiene viewpoint using mobile equipment, it is above all causes of deposits in raw water pipe-
after completion of the work. Particu- essential to understand the cause of lines as well as measures for avoiding
lar attention is to be paid here to clean the problem. After remedial measures, and removing them, above all using the
practices when carrying out the work. the drinking water supply system in impulse-flushing method, are described
It is recommended that the com- question must be thoroughly cleaned. in [21.28].
ponents are checked for cleanli- As this normally involves impurities
ness and disinfected with spray which are difficult to remove, highly
solution before their installation. effective cleaning measures are indi-
After the end of the work the section cated. The impulse-flushing method
of pipeline is to be thoroughly flushed has proved itself here. Its efficacy can
through with water, if possible at high be increased by the injection of solids.
10.2015
21.13 Summary 21.14 Closing comments, papers [21.35], [21.36]. There is now
additional information some important new knowledge avail-
and prospects able about biofilms in systems carrying
When planning, constructing and com- drinking water, in particular regarding
missioning new pipelines, attention the VBNC state of bacteria. VBNC means
needs to be paid to aspects of hygiene. 21.14.1 European rules viable but not culturable. The disin-
Table 21.5 provides information on work and standards fectant influences the transitions bet-
before, during and after cleaning and ween the culturable and VBNC stages of
disinfection. Preventive measures take In contrast to DVGW rules and standards, certain bacteria. It can alter the popu-
account of sanitary aspects during the to date European rules and standards do lations and favour fast-growing bacteria.
planning and construction of pipelines. not contain any particular standard for Cleaning does not mean the same thing
After disinfection, arrangements need the commissioning or the cleaning and as disinfection. Effective cleaning is a
to be made for the proper elimination disinfection of pipelines. precondition for the success of disin-
of the water containing disinfecting EN 805 [21.11] only provides informa- fecting measures.
agent and for putting the pipeline into tion on disinfection in Section 12. Here,
operational condition by flushing it with flushing with drinking water without any In the explanations it is clearly described
drinking water. Microbiological testing disinfection agent with or without the what cleaning means – namely removing
provides information on whether the addition of air is considered as part of impurities, deposits and other undesir-
measure was completed successfully. The disinfection. Annex A.28 together with able substances from the pipelines. In this
pipeline may only be put into operation Table A.3 offers advice on the selection process all loose deposits are to be
once the release has been given. of the disinfection agent. mobilised and carried away. In no case
should they be deposited again else-
21.14.2 Research projects where, thereby leading to further
detriment to the drinking water. The
In recent years a number of research removal of deposits reduces the possi-
projects have helped with a better bility of the implantation of micro-
understanding of connections in terms organisms and optimises the operating
of cleaning and disinfection. The results condition of the drinking water system.
are published in the form of thesis
10.2015
Table 21.5:
Sanitary aspects when planning, constructing and commissioning pipelines
Measure Work Standard work/reference

Selection of materials according to generally Guideline 98/83/EC [21.29], Deutsche TrinkwV § 17 [21.6],
accepted technical rules and standards DIN 2000 [21.5], Section 6.6
Use of tested materials Federal environment agency guidelines [21.7],
DVGW worksheets W 270 [21.30], W 347 [21.31]
and W 348 [21.32]
SVGW guideline W4-1 [21.8]
OENORM B 5014-1 [21.9] and OENORM B 5014-2 [21.10]
Use of tested aids; flushing-out capability DVGW test specifications VP 641 [21.15]
and W 363 [21.16], Annex A, plus [21.17],
DVGW worksheet W 521 [21.18]
Preventive
Use of certified products when available DVGW index of products for the water industry [21.33]
measures
Avoidance of impurities during production, EN 805 [21.11], Section 10.1.3,
storage and transport; closure with caps, DVGW worksheets W 400-2 [21.12],
packaging Section 5, and W 346 [21.1],
EN 1074-1 [21.13], Section 8
SVGW guideline W4-3 [21.19],
ÖVGW guideline W 55 [21.4]
Cleanliness during installation; DVGW worksheets W 346 [21.1] and
avoidance of impurities W 400-2 [21.12], Section 7.2
e.g. mud, dirty rags SVGW guideline W4-3 [21.19]
Continued on page 21/18
10.2015
Measure Work Standard work/reference

DVGW-worksheets W 291 [21.2] and
Removal of unintentional foreign matters; W 346 [21.1], Annex 2
Cleaning
removal of assembly agents SVGW guideline W4-3 [21.19]
DVGW-worksheets W 291 [21.2]
Killing/damaging micro-organisms; and W 346 [21.1], Annex 2
Disinfection
compliance with fields of application SVGW guideline W4-3 [21.19]
DVGW worksheets W 291 [21.2]
Measures after Flushing, taking water samples; and W 346 [21.1], Annex 2
disinfection disposal of water containing disinfection agents SVGW guideline W4-3 [21.19]
EN 16412 [21.34]
Inspection of Microbiological testing; Deutsche TrinkwV [21.6]
measures measuring the pH value SVGW guideline W4-3 [21.19]
10.2015
Simulated calculations show areas where Based on DVGW worksheet W 291 The first step in eliminating impurities
there is insufficient flow. Such areas in [21.2] and as a supplement to EN 806-4 is always cleaning. This also applies
joints and components can result in [21.38], DVGW worksheet W 557 [21.37] for microbial contaminations. Micro-
an increased biofilm formation during was produced. In fact pipes and fittings organisms embedded in particles or
operation and must be constructively in ductile cast iron according to EN 545 corrosion products are not really killed
minimised. Also the length of little-used [21.39] are normally only used out- with the help of disinfection agents
outlets should be limited to a maximum side buildings, but this worksheet as these do not reach the micro-
of three times the internal diameter. In nevertheless contains information on organisms. Therefore the particles or
the event of contamination, areas of the operation of distribution networks corrosion products have to be removed
low flow can only be reached by means of such outstanding importance that it by flushing or other cleaning measures.
of intensive cleaning processes such is worth mentioning here. System disinfection may be necessary
as the pulsed impulse-flushing method. as an additional safety measure. De-
Simulated calculations have already DVGW worksheet W 557 [21.37] was posits favour the growth of micro-
helped with the optimisation of com- published in October 2012 with the organisms, which can then result in
ponents with the aim of reducing prob- knowledge available at that time but it adverse microbial effects. In order to
lems with increased biofilm formation did not yet take account of the results of prevent this, cleaning is necessary when-
during operation, as well as improving the latest research project [21.36]. In its ever there is a presence of deposits.
cleaning and disinfection. structure it reflects the three themes of Where the quality of the drinking water
DVGW worksheet W 291 [21.2]: has been adversely affected by micro-
21.14.3 DVGW worksheet ■ preventive measures, bial action, cleaning must be carried
W 557 [21.37] ■ cleaning, out as the first measure. In these cases,
■ disinfection. additional disinfection of the system
While DVGW worksheet W 291 [21.2] may be necessary after cleaning.
concerns water distribution systems, DVGW worksheet W 557 [21.37] em-
rules were needed for drinking water phasises the importance of cleaning The worksheet refers to the stress on
installations inside buildings as a before disinfection. This advice applies materials due to disinfection. Each
result of different operating conditions, equally for water distribution, in par- system disinfection places stress on
nominal sizes, materials, components and ticular for impurities and contamination. the materials and components of the
apparatus.
10.2015
drinking water installation, meaning The new DWA rules take account of the 21.15 References
that damage may occur to the drinking maintenance of wastewater pressure
water installation. Repeating system pipes. Here cleaning is possible by means
disinfection at regular intervals in order of pigging, flushing with compressed air [21.1] DVGW-Arbeitsblatt W 346
to prevent contaminations is not to be or the impulse-flushing method. The Guss- und Stahlrohrleitungsteile mit
recommended for this reason. corresponding insertion equipment ZM-Auskleidung –
or pigging traps need to be envisaged Handhabung
21.14.4 Revision of DVGW during planning and construction. Static [DVGW worksheet W 346
worksheet W 291 [21.2] compressed air flushing should pre- Cast iron and steel pipes and com-
vent deposits while the impulse-flush- ponents with cement mortar lining –
After more than 15 years the revision of ing method can target the cleaning to Handling]
DVGW worksheet W 291 [21.2] is pend- sections of the pipeline where it is 2000-08
ing. Work begins in 2015. needed. Both processes normally work
online and use accumulated water for [21.2] DVGW-Arbeitsblatt W 291
21.14.5 Cleaning and maintenance cleaning. Reinigung und Desinfektion von
Wasserverteilungsanlagen
Cleaning is not only necessary at the [DVGW worksheet W 291
time of commissioning in order to expel Cleaning and disinfection of
impurities and assembly agents but also water distribution systems]
plays a major role in the maintenance 2000-03
of pipelines. It ensures a hygienically
impeccable condition and security of [21.3] SVGW-Richtlinie W1000
supply. Particularly with raw water Empfehlungen für die Reinigung
pipelines, regular cleaning is necessary und Desinfektion von Trink-
if, for example, the pipeline is affected wasserleitungen
by iron ochre formation [21.23]. [SVGW guideline W1000
Recommendations for cleaning
and disinfection of drinking
water pipelines]
2000-03
10.2015
[21.4] ÖVGW-Richtlinie W 55 [21.7] Leitlinien des Umweltbundes- [21.10] OENORM B 5014-2

Behälter- und Rohrnetzhygiene amtes (Übersicht) Sensorische und chemische Anforde-
[ÖVGW guideline W 55 http://www.umweltbundesamt.de/ rungen und Prüfung von Werk-
Hygiene in reservoirs and themen/wasser/trinkwasser/trink- stoffen im Trinkwasserbereich –
pipeline networks] wasser-verteilen/bewertungs- Teil 2: Zementgebundene
2012-05-01 grundlagen-leitlinien Werkstoffe
[Organoleptic and chemical require-
[21.5] DIN 2000 [21.8] SVGW-Richtlinie W4-1 ments and testing of materials in
Zentrale Trinkwasserversorgung – Richtlinie für Wasserverteilung – contact with drinking water –
Leitsätze für Anforderungen an Teil 1: Allgemeines Part 2: Cementitious materials]
Trinkwasser, Planung, Bau, Betrieb [SVGW guideline W4-1 2011-12-15
und Instandhaltung der Guideline for water distribution –
Versorgungsanlagen Part 1: General] [21.11] EN 805
[Central drinking water supply – 2013-03 Water supply –
Guide lines regarding requirements Requirements for systems and
for drinking water, planning, [21.9] OENORM B 5014-1 components outside buildings
construction, operation and Sensorische und chemische Anforde- [Wasserversorgung –
maintenance of plants] rungen und Prüfung von Werk- Anforderungen an Wasserversor-
2000-10 stoffen im Trinkwasserbereich – gungssysteme und deren Bau-
Teil 1: Organische Werkstoffe teile außerhalb von Gebäuden]
[21.6] Deutsche Trinkwasserver- [Organoleptic and chemical require- 2000
ordnung in der Fassung der ments and testing of materials in
Bekanntmachung vom contact with drinking water –
2. August 2013 Part 1: Organic materials]
http://www.gesetze-im-internet.de/ 2000-11-01
trinkwv_2001/BJNR095910001.html
10.2015
[21.12] DVGW-Arbeitsblatt W 400-2 [21.14] EADIPS®/FGR®-Norm 74 [DVGW test specification W 363

Technische Regeln Wasserver- Formstücke und Armaturen Isolation valves, check valves, air
teilungsanlagen (TRWV) – aus duktilem Gusseisen – valves and control valves made
Teil 2: Bau und Prüfung Verpackung von Formstücken of metallic materials for drinking
[DVGW worksheet W 400-2 und Armaturen water distribution systems –
Technical rules for water [Ductile iron fittings and valves – Requirements and testing]
distribution systems – Packaging of ductile iron 2010-06
Part 2: Construction and testing] fittings and valves]
2004-09 2013-06 [21.17] DVGW-Prüfgrundlage W 363-B1:
1. Beiblatt zu DVGW-Prüf-
[21.13] EN 1074-1 [21.15] DVGW-Prüfgrundlage VP 641 grundlage W 363 –
Valves for water supply – Gleitmittel für Steckmuffen- Absperrarmaturen, Rückfluss-
Fitness for purpose requirements Verbindungen in der Wasser- verhinderer, Be-/Entlüftungsven-
and appropriate verification tests – versorgung – tile und Regelarmaturen aus
Part 1: General requirements Anforderungen und Prüfungen metallenen Werkstoffen für Trink-
[Armaturen für die Wasserver- [DVGW test specification VP 641 wasserversorgungsanlagen –
sorgung – Lubricants for push-in Anforderungen und Prüfungen
Anforderungen an die Gebrauchs- joints in water supply – [DVGW test specification W 363-B1:
tauglichkeit und deren Prüfung – Requirements and testing] Supplement 1 to DVGW test
Teil 1: Allgemeine Anforderungen] 2009-06 specification W 363 –
2000 Isolation valves, check valves, air
[21.16] DVGW-Prüfgrundlage W 363 valves and control valves made
Absperrarmaturen, Rückfluss- of metallic materials for drinking
verhinderer, Be-/Entlüftungsventile water distribution systems –
und Regelarmaturen aus Requirements and testing]
metallenen Werkstoffen für Trink- 2014-09
wasserversorgungsanlagen –
Anforderungen und Prüfungen
10.2015
[21.18] DVGW-Arbeitsblatt W 521 [21.20] SVGW-Richtlinie W4-5 [21.22] Immel, S., Schimmelpfennig, S.,
Gewindeschneidstoffe für die Richtlinie für Wasserverteilung – Klein, N., Utke, C., und Gnirss, R.:
Trinkwasser-Installation – Planung, Projektierung, Brunnengalerien und Rohwas-
Anforderungen und Prüfung Bau, Prüfung sowie serleitungen online reinigen
[DVGW worksheet W 521 Betrieb und Instandhaltung [Inline cleaning of well galleries
Thread cutting agents for der Trinkwasserverteilung and raw water pipelines]
drinking water installation – außerhalb von Gebäuden – wwt – Wasserwirtschaft
Requirements and testing] Teil 5: Praxisunterlagen, Themen- Wassertechnik,
1995-12 blatt Nr. 7: Rohrnetzspülung Heft 1–2,
[SVGW guideline W4-5 2014, S. 15 ff.
[21.19] SVGW-Richtlinie W4-3 Guideline for water distribution –
Richtlinie für Wasserverteilung – Planning, project development, [21.23] Klein, N. und Rammelsberg, J.:
Planung, Projektierung, construction, testing as well as Inbetriebnahme von Rohrleitungen
Bau, Prüfung sowie operation and maintenance mit Zementmörtel-Auskleidung
Betrieb und Instandhaltung of drinking water distribution [Commissioning of cement
der Trinkwasserverteilung systems outside buildings – mortar lined pipelines]
außerhalb von Gebäuden – Part 5: Practical data sheet, data 3R international (48),
Teil 3: Bau und Prüfung sheet No. 7: Network flushing] Heft 3-4,
[SVGW guideline W4-3 2013-3 2009, S. 144 ff.
Guideline for water distribution –
Planning, project development, [21.21] Bernemann, M. und Farke, O.: [21.24] DVGW-Arbeitsblatt W 229
construction, testing as well as Bau einer Trinkwassertransport- Verfahren zur Desinfektion
operation and maintenance leitung DN 700 in Paderborn von Trinkwasser mit Chlor
of drinking water distribution [Construction of a drinking water- und Hypochloriten
systems outside buildings – main DN 700 in Paderborn] [DVGW worksheet W 229
Part 3: Construction and testing] bbr – Fachmagazin für Leitungs- Disinfection procedures
2013-3 bau, Brunnenbau und Geothermie of drinking water with
2007-02, S. 16 ff. chlorine and hypochlorite’s]
2008-05
10.2015
[21.25] ISO 5667-5 [21.27] Mikrobielle Verockerung in [DVGW worksheet W 270

Water quality – technischen Systemen Microbial enhancement on
Sampling – http://www.anti-ocker.de/ materials to come into contact
Part 5: Guidance on sampling with drinking water –
of drinking water from treat- [21.28] Klein, N. und Hammann, H.-G.: Testing and assessment]
ment works and piped Reinigen der Rohwasserleitungen 2007-11
distribution systems sichert die Trinkwasserversorgung
[Wasserbeschaffenheit – [Cleaning of raw water pipelines [21.31] DVGW-Arbeitsblatt W 347
Probenahme – secures drinking water supply] Hygienische Anforderungen
Teil 5: Anleitung zur Probenahme Energie | wasser-praxis, an zementgebundene Werk-
von Trinkwasser aus Aufbereitungs- Ausgabe 06 stoffe im Trinkwasserbereich –
anlagen und Rohrnetzsystemen] 2008, S. 24 ff. Prüfung und Bewertung
2006 [DVGW worksheet W 347
[21.29] Richtlinie 98/83/EG Hygiene requirements for cemen-
[21.26] Bundesgesundheitsblatt – Richtlinie 98/83/EG des Rates titious materials intended for use
Gesundheitsforschung – vom 03.11.1998 über die in drinking water supply systems –
Gesundheitsschutz Qualität von Wasser für Testing and evaluation]
Empfehlung des Umwelt- den menschlichen Gebrauch 2006-05
bundesamtes [Directive 98/83/EC
Vorhalten einer hinreichenden Council Directive 98/83/EC [21.32] DVGW-Arbeitsblatt W 348
Desinfektionskapazität nach of 3 November 1998 on the Anforderungen an Bitumen-
§ 5 Abs. 4 TrinkwV 2001 für quality of water intended beschichtungen von Formstücken
außergewöhnliche Vorkomm- for human consumption] aus duktilem Gusseisen und im
nisse oder Notfälle 1998-11-03 Verbindungsbereich von Rohren
2004-11 aus duktilem Gusseisen, unlegier-
https://www.umweltbundesamt. [21.30] DVGW-Arbeitsblatt W 270 tem und niedrig legiertem Stahl
de/sites/default/files/medien/374/ Vermehrung von Mikroorga-
dokumente/desinfektions- nismen auf Werkstoffen für
kapazitaet_2004_11.pdf den Trinkwasserbereich –
Prüfung und Bewertung
10.2015
[DVGW worksheet W 348 [21.35] Erkenntnisse aus dem BMBF [21.38] EN 806-4
Requirements of bituminous (Deutsches Bundesministerium Specifications for installations
coatings of ductile iron fittings für Bildung und Forschung) – inside buildings conveying water
and in the jointing area of Verbundprojekt for human consumption –
ductile iron pipes and unalloyed „Biofilme in der Trinkwasser- Part 4: Installation
and low-alloyed steel pipes] Installation“ [Technische Regeln für
2004-09 http://www.biofilm-hausin- Trinkwasser-Installationen –
stallation.de/dokumente/ Teil 4: Installation]
[21.33] DVGW-Verzeichnis wasser- Thesenpapie_2_0.PDF 2010
fachlicher Produkte
http://www.dvgw-cert.com/?id=34 [21.36] Erkenntnisse aus dem Projekt [21.39] EN 545
http://mycert.dvgw-cert. „Biofilm-Management“ Ductile iron pipes, fittings,
com/verzeichnisse/index/ Erkennung und Bekämpfung accessories and their joints
von vorübergehend unkul- for water pipelines –
[21.34] EN 16421 tivierbaren Pathogenen Requirements and test methods
Influence of materials on water in der Trinkwasser-Installation [Rohre, Formstücke, Zubehör-
for human consumption – http://www.biofilm-management. teile aus duktilem Gusseisen
Enhancement of microbial de/sites/default/files/Projektmeet- und ihre Verbindungen
growth (EMG) ings/Bonn_2014/Thesenpapier/ für Wasserleitungen –
[Einfluss von Materialien auf Wasser Thesenpapier%201.1.pdf Anforderungen und Prüfverfahren]
für den menschlichen Gebrauch – 2010
Vermehrung von Mikroorganismen] [21.37] DVGW-Arbeitsblatt W 557
2014 Reinigung und Desinfektion von
Trinkwasser-Installationen
Cleaning and disinfection of
drinking water installations]
2012-10
10.2015
10.2015
E-Book – Ductile iron pipe systems Chapter 22: Use of ductile iron pipes for trenchless installation techniques 22/1
22 Use of ductile iron pipes

for trenchless installation
techniques
22.1 General
22.2 Coatings of ductile iron pipes for trenchless pipe installation
22.3 Joint technology
22.4 Trenchless installation techniques
22.5 References
04.2015
22 Use of ductile iron pipes for trenchless

installation techniques
22.1 General In parallel with this method of replac- As time went on, further techniques were
ing pipes along the same route, addi- developed which are more or less widely
22.1.1 Historical development tional techniques were developed for used. A few examples of these processes
the trenchless installation of ductile iron are cutting or ploughing in or the pulling
The roots of the construction method pipes. First and foremost here is the hori- (relining) of ductile iron pipelines.
known as the trenchless installation tech- zontal directional drilling (HDD) tech-
nique lie in soil displacement hammers. nique. The first successful example of Ductile cast iron is a tough iron-carbon
The burst lining technique was developed directional drilling was the roughly 180 m material in which the carbon element is
from this at the beginning of the 1980s. long crossing under the Pajaro River predominantly present as graphite in free
British Gas was already using modified in the vicinity of the Watsonville (Cali- form. Pipes and fittings in ductile cast
soil displacement rockets for the trench- fornia) in 1972. The essential details of iron are structurally treated as flexible
less replacement of pipelines on a large this technique were taken from the deep pipes. Pipes produced in rigid materials
scale in the early eighties. Burst lining was drilling process for oil, for example, and were scarcely able to safely cope with the
developed further over the years. Then, in then further refined. In the years which mechanical tensile and bending loads
1990, Berliner Wasserbetriebe in collabo- followed, up to 1980, the controlled hori- produced during trenchless installation.
ration with the Karl Weiss company intro- zontal directional drilling technique
duced the press/pull or Hydros technique. progressed rapidly. At this time the first So the development of trenchless pipe
This in turn was later developed into the projects using the HDD technique were installation techniques is inseparably
auxiliary pipe technique. Since then both also being carried out in Europe. linked with ductile iron pipes, their
techniques have been applied by Berliner push-in joints and their external pro-
Wasserbetriebe with ductile iron pipes. In In addition to this classic trenchless tech- tection techniques. Soon the potential
Berlin alone, around 10,000 m of pipelines nique, another possibility had been estab- of restrained push-in joints developed
in nominal sizes of DN 80 to DN 500 are lished for the trenchless replacement of as a substitute for concrete thrust blocks
replaced in this way each year. old pipelines – so-called pipe relining. was recognised for the first trenchless
This method consists of pulling a smaller installation techniques. Since then ductile
04.2015
iron pipe systems have come to represent without prospect of compensation. In this Nevertheless experience is gradually
the benchmark in terms of reliability and respect it is hardly possible to make a fair showing that trenchless installation and
efficiency in trenchless installation tech- financial comparison between trench- replacement techniques can generally
niques. less and open techniques because the be more cost effective than conventional
“social” costs borne by the public at large, open technique. For example, a regional
In 2012 a summary of current installation although perfectly capable of being esti- gas and water supply company has pub-
techniques was published in ISO 13470 mated, are not taken into account when lished a comparison between open and
[22.1]. contracts are awarded. closed construction methods as shown
in Table 22.1.
22.1.2 Efficiency aspects of
trenchless installation
These days it is generally understood that

a process for installing pipes is usually Table 22.1:
considered efficient if it means that the Overall comparison of the open and closed construction techniques [22.2]
pipeline constructed in this way can be
quoted and completed at the lowest price.
Conventional technique Closed technique
This approach seldom considers the oper-
ating and maintenance costs of the pipe- Line length 100 % 100 %
line, let alone the costs of replacement Civil engineering on
once its normal working life has come to 100 % 15 %
surface restoration
an end.
Construction time 100 % 30 %
Until now no account has generally been Costs 100 % 50 – 70 %
taken of the costs incurred by the con-
struction of the pipeline in its surround- Working life 100 % 70 – 100 %
ings and factors concerning the general Conserving resources 20 % 80 %
public in the form of traffic hold-ups,
Noise, damage to the
noise nuisance and pollution of the envi- 100 % Ideal gain
environment
ronment have been tacitly put up with
04.2015
Table 22.2:
Rough cost comparison of construction techniques [22.2]
Open technique Closed technique

Soil displace- Press/pull
Bursting Relining
ment hammer technique
with annular gap without annular gap flexible pipe
100 % 70 % 70 % 80 %
60 % 70 % 60 %
An estimated comparison of the costs W 400-1 [22.9] emphasises the predomi- 22.1.3 Ecological aspects of trench-
of closed replacement techniques with nant influence which the choice of piping less installation techniques
those using the open method also shows system has in connection with the choice
clear potentials for savings with the closed of construction technique. In the development of trenchless instal-
technique (Table 22.2). lation techniques, first of all it was eco-
The key areas for the choice of piping nomic considerations which were in the
In order to safeguard the workmanship system are given as the following [22.9]: forefront in order to emphasise advan-
of drinking water pipelines installed 1. Bedding and conditions of use tages as compared with conventional
or replaced using the trenchless (e.g. diffusion characteristics, capacity techniques using open trenches, mak-
technique, over recent years the DVGW reserves), ing their use possible with most public
in Germany, for example, has produced 2. Features of the corrosion protection pipeline projects. Once the trenchless
a comprehensive set of rules (series system and joint technology, technique had become established
commencing GW 320-1) which takes 3. Positive experiences found with par- and was being widely used, its posi-
account of precisely this requirement ticular systems, tive influence on ecological considera-
[22.3 to 22.8]. This describes the quality 4. Appropriate availability (delivery tions became clear. It is to the credit of
parameters for current trenchless instal- times, stocks, system continuity). the GSTT (German Society of Trench-
lation and replacement techniques and less Technologies) that the beneficial
determines limit values and measurement effects of trenchless techniques on the
specifications for them. DVGW worksheet reduction of CO2 and fine particulate
04.2015
matter emissions in the construction, Economic sustainability criteria:

renovation and replacement of pipe-
lines was investigated and published –– hohe
push-in joints make for highly
Einbauproduktivität durchproductive X reduziert
X reduces Arbeitskosten
labour costs
(www.gstt.de). installation
Steckmuffen-Verbindungen
–– kein
no welding needed
Schweißen erforderlich X reduces
X reduziert
labour costs
Arbeitskosten
22.1.4 Sustainability with ductile iron –– witterungsunabhängiger
installation in all weathers
Einbau X reduces
X reduziert
labour costs
Arbeitskosten
pipe systems using trenchless –– häufig
sand bedding often not required
keine Sandbettung erforderlich X reduces
X senkt
materials andund
Material- logistics costs
Logistikkosten
techniques –– keine
concrete thrust blocks not
Betonwiderlager needed
erforderlich X reduces
X senkt
materials andund
Material- logistics costs
Logistikkosten
when
bei joints are restrained
schubgesicherten Verbindungen
–– Abwinkelbarkeit
joints can be deflected angularly
der Verbindungen X saves
X spart
on fittings
Formstücke
The sustainability criteria of ductile iron
–– großes
wide range of fittings
Formstück- undand valves available
Armaturen - X reduces
X reduziert
materials and labour
Material- und costs
Arbeitskosten
pipe systems in combination with trench-
so no needvermeidet
programm for specialsSonderanfertigungen
less installation techniques are summa-
–– niedrigste
extremely Schadensraten
low damage rates X reduces
X senkt
operating, energy,
Betriebs-, repair
Energie-, Reparatur- und
rised below. and maintenance costs
Wartungskosten
–– Nutzungsdauer
operating life of100
upüber
bis to 100
years oryears
100 Jahreor more
more X keeps
X minimiert
renovationSanierungsbudgets
budgets to a minimum
Ecological sustainability criteria:
– impermeability to diffusion X
X
safeguard
safeguards drinking water in all soil and
installatio
installation conditions, protects against
environme
environmentally harmful hydrocarbons,
protects
protectsg groundwater in sewage transport
– linings approved to food hygiene X Xensure hyhygienic and environmentally safe
ensure
standards transport
transport of drinking water
– scrap as the raw material X Xminimises
minimises the consumption of primary and
fossil raw
fossil raw materials and reduces CO2 emissions
– ductile iron can be recycled X Xsaves reso
saves resources for present and future
generatio
generations
– low expenditure on maintenance and X Xavoids wa
avoids waste, minimises the consumption
repair expenses with long operating ofof
resourc
resources and reduces CO2 emissions
working life
04.2015
Technical sustainability criteria: 15 542 [22.12] (Figure 22.1) and poly-

urethane coating (PUR) to EN 15189
– material strength X allows operating pressures up to 100 bars [22.13] (Figure 22.2). They have thor-
– effective external protection X shields against mechanical and chemical attack oughly proved their credentials for the
– static load-bearing capacity X allows very high loads in the transverse and trenchless installation technique.
longitudinal directions
– joints X allow operating pressures up to 100 bars;
are resistant to root penetration 22.3 Joint technology
– ductile iron X is non-combustible
– installation X is possible with no special equipment
– restrained joints X allow very high tractive forces and are therefore With push-in joints for ductile iron pipes
ideal for trenchless installation
a distinction is basically made between
– the material has superior properties X which allow special applications in mountainous
regions and for fire-fighting pipelines, snow-making
non-restrained and restrained construc-
systems and hydroelectric power stations tions.
22.3.1 Non-restrained push-in joints

22.2 Coatings of ductile iron pipes to relevant soil parameters in Annex D
for trenchless pipe installation (EN 545 [22.10]) and Annex B (EN 598 Among the non-restrained push-in joints
[22.11]). there is for example the TYTON® push-in
joint (Chapter 8) to DIN 28 603 [22.14].
Dctile iron pipes are basically supplied With the trenchless installation of pipes This kind of joint is only suitable for
with factory coatings. Coatings need the coatings of ductile iron pipes are trenchless installation techniques to a
to be selected so that the durability of exposed to a variety of external mechani- limited extent. The only method which
the pipeline is guaranteed. For this it is cal loads. In order to avoid damage to the comes into question here is the push-in
important to know in what types of soil coatings applied in the factory during technique in pipe relining. As the pipe
the pipelines are to be installed. The lim- trenchless installation, the use of coat- is pushed in the axial force is transmit-
its for the use of different coating sys- ings which can resist high mechanical ted from the spigot end across the root of
tems for pipes, fittings and accessories loads is recommended. Two important the socket to the next pipe (Figure 22.3).
are stated in product standards EN 545 examples of such heavy-duty iron pipe Permissible pushing-in forces are stated
[22.10] and EN 598 [22.11] with reference coatings are cement mortar coating to EN further on in this chapter.
04.2015
Further details and conditions of use for

this process can be requested from the
manufacturers.
22.3.2 Restrained push-in joints
Restrained push-in joints are divided

into friction locking and positive locking
push-in joints (Chapter 9).
22.3.2.1 Friction locking

push-in joints
Figure 22.1: Figure 22.3:
Cement mortar coating Pipe relining – With friction locking constructions the
to EN 15542 [22.12] pushing in ductile iron pipes traction forces are transmitted via the
contact surface, e.g. toothed elements
which grip onto the surface of the spigot
end (Figure 22.4).

Polyurethane coating Friction locking push-in joint
to EN 15189 [22.13] Fig. 2807A
04.2015
22.3.2.2 Positive locking 22.3.3 Fields of use for restrained tile iron pipes, it is predominantly posi-
push-in joints push-in joints tive locking restrained push-in joints
that are recommended. For burst lining,
With positive locking push-in joints the Opinions differ in the individual according to DVGW technical informa-
forces are transmitted across shaped el- countries of Europe as to which type tion sheet GW 323 [22.7], only positive
ements (e.g. welding beads) to the spigot of restrained push-in joint should locking joints are permissible.
ends in combination with force transmit- be used or is best recommended for
ting elements (e.g. locks or segments) and which installation technique. So for In other European countries friction
cast-on or pre-fixed thrust resistance example in Germany, according to the locking restrained push-in joints are
chambers (Figures 22.5 and 22.6). DVGW worksheets GW 320-1 [22.3], also permitted. They should be used in
GW 321 [22.4], GW 322-1 [22.5], GW consultation with the pipe manufacturer.
322-2 [22.6] and GW 324 [22.7] on the
subject of trenchless installation of duc- Technical data on positive locking
restrained push-in joints (traction forces,
curve radiuses etc.) according to DVGW
Worksheet GW 320-1 [22.3] are given in
Table 22.3.

HYDROTIGHT positive locking push-in joint BLS®/VRS®-T positive locking push-in joint
04.2015
Table 22.3:
Technical data on positive locking restrained push-in joints according to Table A.6 – Allowable traction forces, angular deflection
and curve radiuses for pipes in ductile cast iron with BLS® 1) joints (incl. VRS®-T for DN 80 – DN 500 and TKF for DN 600 – DN 1000)
and TIS-K (type pressure testing Ptyp = PFA x 1.5 + 5 bar, reduced by the safety factor S = 1.1 for construction condition) [22.2]
Allowable Angular deflection /

Nominal size Allowable traction force 2), 3)
Wall thickness class operating pressure 2) minimum curve radius
DN Fzul [kN]
PFA [bar] [°/m]
80 10 64 70 3/115
100 10 64 100 3/115
125 9 60 140 3/115
150 9 50 165 3/115
200 9 40 230 3/115
250 9 35 308 3/115
300 9 30 380 3/115
400 9 25 558 3/115
500 9 25 860 2/172
600 9 25 1200 2/172
700 9 25 1400 1.5/230
800 9 16 1350 1.5/230
900 9 16 1700 1.5/230
1000 9 10 1440 1.5/230
1)
From DN 80 to DN 250 BLS® - joints with high pressure lock must be used.
2)
Higher pressures and traction forces are to be agreed with the pipe manufacturer where necessary.
3)
Where the route of the pipeline is in a straight line (max. 0.5° deflection per joint) allowable traction forces may be increased by 50 kN
04.2015
Individual manufacturers and utility com- ■ Relining technique:

panies allow higher allowable traction Relining is understood to be the pull-
forces and smaller curve radiuses in their ing or pushing of a new pipe into an
own works standards. old, larger carrier pipe. This produces
a reduction of the cross-section of the
new carrier pipe.
22.4 Trenchless installation Figure 22.7:
techniques Bursting head with ribs,
22.4.1 Burst lining technique upsizing element and traction head
With trenchless installation techniques 22.4.1.1 General

we will now be making a basic distinc-
tion between: Burst lining is used for the trenchless Video 22.01:
replacement of pipelines along the same Burst lining, DN 200, Vienna
■ Processes for replacing existing pipe- route. To do this the existing old pipe-
lines along the same route: line is destroyed by means of a bursting Burst lining is particularly well suited
This includes the burst lining head while simultaneously being pushed to old pipes in brittle materials such as
technique, the press/pull technique into the surrounding soil by an upsizing asbestos cement, vitrified clay or grey
and the auxiliary pipe technique. element (Figure 22.7) and the new pipe cast iron. But pipes made of steel or duc-
With these techniques the existing string is drawn in ( Video 22.01). The tile cast iron can also be “burst” using the
route of the pipe is used for installing old pipe material remains in the ground. static technique with the help of special
a new pipe of the same or a different Depending on the material this offers cutting heads. The newly inserted pipe
dimension. advantages as regards disposal, but also can be in the same nominal size as the
■ Trenchless laying of new pipelines: disadvantages as regards the point load- old pipe or, depending on the size of the
The usual techniques for ductile iron ing of the new pipes. When ductile iron upsizing head used, in larger dimensions
pipes are horizontal directional drill- pipes with mechanically resistant coat- [22.15].
ing (HDD), cutting in, ploughing in ings are used, however, it can be assumed
and guided pilot jacking. that the body of the pipe and the coating
will not be sensitive to the loads produced
(e.g. by fragments of old rigid pipes).
04.2015
Enlarging the nominal size by up to lines replacement using the open trench
three stages is possible. If the new pipe- technique may be more cost effective
line can be smaller than the old pipe- [22.16].
line, pipe relining is an available alter-
native. Of equal importance is the accuracy of the
documentation on the existing old pipe-
With ductile iron pipes, an upsizing line. Among other things the following
dimension (Figure 22.8) which is larger points are to be documented:
than the diameter of the socket is to be
selected. Based on DVGW technical infor- ■ Diameter and material of the old pipe,
mation sheet GW 323 [22.7], the required ■ Change of nominal sizes and materials,
distance to adjacent supply carriers and ■ Cover depth,
the depth of cover are to be determined Figure 22.8: ■ Changes of direction,
according to the upsizing dimension (UD). Definition of the upsizing dimension UD ■ Horizontal and vertical offset sections,
The following minimum distances are ■ Branch pipes or connections,
to be observed: ■ Condensate drains,
is difficult from a work safety point of ■ Valves,
■ parallel line: > 3 x UD, min. 40 cm, view when replacing pipes in open ■ Concrete thrust blocks,
■ parallel fragile lines < DN 200: trenches does not apply here. ■ Fittings, clamps, etc.,
> 5 x UD, min. 40 cm, ■ Parallel and crossing line equipment.
■ parallel fragile lines from DN 200: In the area of distribution networks the
> 5 x AM, min. 100 cm, use of burst lining (or any trenchless
■ crossing lines at critical distance open replacement) is above all dependent on
wherever possible, the number of intermediate installation
■ pipe cover: > 10 UD. pits necessary. Intermediate installation
pits have to be created for house connec-
Another advantage of burst lining old tions, valves, changes of direction and
pipes in asbestos cement can be seen in cross-section and branch pipes. Bends
the fact that the problematic process- up to 11° can usually go through. With a
ing and disposal of the old pipes, which tighter series of house connection pipe-
04.2015
22.4.1.2 Description of technique Dynamic burst lining Static burst lining
With burst lining a distinction is made The force needed for bursting is intro- With this technique the force is intro-
between dynamic and static processes. duced in the longitudinal direction of the duced through a traction rod in the
With both techniques forces are intro- pipe by a kind of soil displacement ham- bursting head which is run from the
duced into the old pipeline to destroy mer. This is driven by compressed air from target pit through the old pipeline from
it when the bursting head is used. a compressor. In order to guide the burst- the traction unit to the bursting head
Brittle materials are burst into frag- ing head it is winched from the target pit (Figures 22.11 and 22.12).
ments (Figure 22.9), all others are cut by a traction cable pulled through the old
open (Figure 22.10). The fragments or pipe. The dynamic technique is above all During the pulling process the traction
cut pipes are pushed into the surround- suitable for highly compacted and stony unit is supported against the wall of the
ing earth. soils and brittle old pipes. It is not suitable target pit. The traction rod is successively
for laying new ductile iron pipes. dismantled. The static technique is suit-
able for easily displaceable, homogeneous
soils and is suitable for laying new ductile
iron pipes.
22.4.1.3 Advice for users
The largest nominal size of ductile iron

pipes inserted to date using the burst
lining technique is DN 600. But in
principle any nominal size, including
DN 1000, is possible. The tractive power
of the machine used is to be designed
according to the nominal size to be burst
and the upsizing expected.

Grey cast iron fragments Steel pipe cut open
04.2015

Diagram of static burst lining-technique Traction rod with bursting head
As a rough classification, the following However, the traction forces to be The usual pipe lengths are between 50 m
tractive power levels can be assumed expected are also still dependent on a and 200 m. Longer lengths are also pos-
depending on the diameter of the old pipe; few other factors, such as e.g. the upsizing sible theoretically as in fact only a small
refer to [22.17]: dimension, the type of soil to be found and part of the tensile force is due to the pipe
pipe lengths. The major part of the tensile material and its length and consequently
■ d DN 250 ➝ 400 kN, forces is produced by the breaking of the to surface friction. But pipe lengths are
■ > DN 250 d DN 400 ➝ 770 kN, old pipe and the upsizing. Added to this is usually limited by local circumstances
■ > DN 400 d DN 600 ➝ 1250 kN, a relatively small proportion from surface such as changes in direction or other
■ > DN 600 d DN 1000 ➝ 2500 kN. friction with the new pipe. components.
04.2015
The lengths which are actually possible Video 22.02: Berlin street regulations. All unused
and practicable are to be determined indi- Burst lining, demo site in Lennestadt construction materials have to be
vidually for each project. completely removed.
Meanwhile there are also practical ex- 22.4.2 Press/pull technique Hence the development of two spe-
periences with the replacement of ductile cial pipe replacement techniques –
pipe materials (spheroidal graphite cast 22.4.2.1 General the press/pull technique and the
iron and steel) with ductile iron pipes. auxiliary pipe technique – was almost
Here the old pipes are cut open with The greatest innovative boost in the inevitable. With both techniques pipelines
special perforating and cutting wheels domain of trenchless replacement came can be replaced along the same route
(Figure 22.13) and then bent open with from Berlin. The oldest grey cast iron net- without digging trenches with new
the upsizing head until the new pipe work of water pipes in Germany, dating pipelines of the same or larger nominal
can be drawn through. Use up to nomi- back more than 120 years, is in opera- sizes, e.g. new DN 125/150 for old DN 100
nal size DN 400 has been tried and tested tion here and in urgent need of replace- (Table 22.4), where the pipes of the old
[22.18] ( Video 22.02). ment. The ambient conditions in Berlin pipeline are salvaged, either in frag-
make replacement more difficult, mainly ments or in whole pipes. This offers the
because of the following two require- following advantages:
ments:
■ Valuable raw materials are put back
1. The pipelines lie in the area of the into the cycle,
roots of trees lining the street pave- ■ Surfaces and nature are only affected
ments. The trees are under strict pro- to a minimum extent,
tection and the roots may in no case ■ the underground space is not
be damaged. The use of pipe trenches obstructed by additional pipelines.
and conventional installation is not
permitted.
2. Replacement techniques in which
the old pipes, either whole or in
Figure 22.13: fragments, remain in the trench,
Cutting whell for old pipes in steel cannot be used because of the
04.2015
Table 22.4: ■ Depending on the machine technol- The distance between the intermediate
Maximum nominal size enlargement ogy used, with a max. noise emission pits depends on the nominal size of the
with trenchless replacement of < 54.5 dB(A) a particularly “quiet” old pipes and its condition, the nominal
and dust-free site is possible. In fact in size of the new pipe, the machine technol-
Maximum residential areas it is possible to work ogy, the type of soil, the status of trees and
Nominal size without night-time interruptions. roots and, naturally, traffic conditions and
nominal size
of old pipe the presence of utility lines. Depending
of new pipe
Above all in inner-city construction pro- on technique and location, the distance
DN 80 DN 150 jects with extremely densely laid piping between the intermediate pits should
DN 100 DN 200 networks, lines running parallel or cross- not exceed 25 m to 50 m. In normal cases,
ing lines are at high risk when heavy civil where the route runs in a straight line
DN 150 DN 200 engineering equipment is used in open or there is a minimum curve radius of
DN 200 DN 300 trenches. This risk is minimised with the 170 m, there is a distance of 100 m to
use of trenchless replacement techniques. 180 m between launch and target pits.
DN 300 DN 400
Before the replacement process, the old
DN 400 DN 400 Both techniques (press/pull and aux- pipeline is taken out of operation. Resi-
iliary pipe techniques) are used with dents continue to be supplied by tempo-
supply pipelines in the nominal size range rary water pipelines, where the water is
Additional plus points of the two tech- DN 80 to DN 400. fed into the disconnected house connec-
niques are: tion pipelines in the house connection
■ There is no need to move bus stops or Requirements: pits.
reroute bus services. ■ a machine pit to take the machine
■ Delivery traffic in shopping streets is technology, 22.4.2.2 Description of technique
hardly affected at all. ■ an assembly pit for the new pipes
■ Other utility lines are not put at risk (about 7 m long), In the press/pull technique ( Video
by excavations. ■ intermediate pits for house connec- 22.03) the old pipe is pushed onto a
tions and branch pipes. splitting cone, broken up and removed
in fragments from the machine or inter-
mediate pit (Figure 22.14). The new
04.2015
pipes with restrained joints are attached

to the end of the traction rod via the pull/
push head and drawn into the space as it
is freed. Both stages take place simulta-
neously. In this way, as already described,
there is still a stage for upsizing behind
the traction head, allowing for widening
of up to three nominal sizes (Table 22.4).
Once the necessary launch, target and

intermediate pits have been created and
installed, the old sections of pipeline are
removed and dismantled. When doing
this, the old pipe must not be removed
from the ground all at once along its
whole length but only between the
individual pits. This means a lower trac-
tion force. Specially prepared assembly/
launch pits make pipe assembly easier
and avoid the ingress of contamination
(Figures 22.15 and 22.16). Because of the
overall length of ductile cast iron pipes, Figure 22.14:
they should not be less than 7 m to 8 m Diagram of the press/pull technique for the trenchless replacement of grey cast iron pipelines
long.
Video 22.03:
Presentation of the press/pull technique – Example in Switzerland
04.2015
Firstly a coupling traction rod is inserted As the socket acts much like an upsiz-
into the old pipeline and anchored onto ing element, in general only forces from
a transition adapter at the end of the surface friction are produced here, while
old pipeline (Figure 22.14) so that the the 6 m long barrel of the pipe, which is
old pipe is pushed out of the ground in smaller in diameter, makes no contribu-
the replacement process. No fragments tion to the production of surface friction
remain in the bedding zone of the new forces.
pipeline. The new pipe is also attached
to the transition adapter and simulta- At the back wall of the target pit, the
neously drawn along afterwards as the hydraulic press/pull equipment (traction
pipe is removed. unit) is supported e.g. by a steel construc-
tion as a thrust bearing (Figure 22.17).
Figure 22.15: The traction forces are introduced across
Launch and assembly pit the traction rod at the transition adapter The thrust bearing is calculated according
as axial compressive forces in the end of to the reaction forces and the nominal
the old pipeline. In some cases it can hap- size and only allows for a small overlap
pen that the old pipe is already so weak with the pipe so that as far as possible no
that it cannot take up the axial forces earth is pushed into the pit. The hydraulic
occurring and thus cannot be pushed piston of the press/pull equipment allows
out of the ground. In such cases the old the old pipe to be pushed out without
pipe must be reinforced in advance. This vibrations and jolting. In the intermediate
can be done for example by pulling in an construction pits the old pipe is pushed
empty pipe and then filling the empty gap across a splitting cone or shattered with
between the old pipe and the empty pipe an automatic pipe cracker (Figure 22.18).
with concrete.
It is only the traction forces of its own

weight and surface friction which act on
Figure 22.16: the new pipe string to be pulled in.
Assembly accessories
04.2015
Just as with burst lining (Chapter 22.4.1)

here again an upsizing dimension is to
be selected which is greater than the
diameter of the socket. On top of the
upsizing dimension UD (Figure 22.8)
the necessary distance from adjacent
utility carriers and the cover depth are
to be determined.
Figure 22.18: The following minimum distances are to

Hydraulic pipe cracker be observed according to [22.7]:
■ parallel line: > 3 x UD, min. 40 cm,

In this way it is always only the old sec- ■ parallel fragile lines < DN 200:
tion of pipe which is pushed out in front > 5 x UD, min. 40 cm,
of the splitting cone, which results in a ■ parallel fragile lines from DN 200:
not inconsiderable reduction in the trac- > 5 x UD, min. 100 cm,
tion forces required. The position and size ■ crossing lines at critical distance open
of the intermediate pits is determined in wherever possible,
situ on the basis of e.g. house connections, ■ pipe cover: > 10 UD.
branch pipes and components. Usually
the distance between them is 20 m to 22.4.2.3 Latest developments
50 m. The fragments in the intermediate
and target pits are taken to the surface in During the Baustellentag der Wasser
containers. With the last section drawn, Berlin 2011, a further development of
the old pipe drawn into the target pit is the press/pull technique was presented
generally crushed by the return stroke as a world premiere. Together with the
of the piston. Tracto Technik company from Lenne-
Figure 22.17: stadt, the Berlin branch of the Josef
Traction unit and thrust bearing Pfaffinger company developed the pos-
04.2015
sibility of also replacing larger nominal Video 22.04:

size differences based on the press/pull Press/pull technique with soil removal
technique, even with shallow depths of
cover ( Video 22.04). 22.4.3 Auxiliary pipe technique
This is made possible by removing soil 22.4.3.1 General

between the press/pull head and the
new pipe. The soil removed is carried The auxiliary pipe technique has been
away by means of a feed auger (Figure developed out of the burst lining and
22.19) through a steel pipe running inside press/pull processes. Basically, the same
the utility pipe (Figure 22.20) into the principles apply as already described in
launch pit. At the same time the old pipe Figure 22.19: Chapter 22.4.1 and Chapter 22.4.2.
is pushed into the target pit where it is Traction head with internal feed auger
burst. In this way, with a pipe cover of In contrast to the press/pull technique
only 1.5 m, an old DN 300 grey cast iron the auxiliary pipe technique is used for
pipe can be replaced with a new ductile replacing pipes in ductile materials – i.e.
sewage pipe of nominal size DN 500. The those which cannot be burst in target
lengths tested here were around 50 m. or intermediate construction pits (e.g.
Ductile sewage pipes to EN 598 [22.11] steel pipes) along the same route. If such
with positive locking restrained BLS®/ materials are to be removed from the
VRS®-T push-in joints and ZM-U-Plus ground, without excavation and without
cement mortar coating were used. The leaving residues, and replaced by a new
cement mortar coating and the very low pipe along the same route, the auxiliary
overcut of approximately 15 mm meant pipe technique can be used. Cross-sec-
that subsequent settlement was reduced tion enlargements of up to three nomi-
to a minimum [22.19]. nal size stages are also possible with this
Figure 22.20: technique (Table 22.4).
ZM-U-Plus cement mortar coated sewage
pipe fitted with feed tube and string of
auger sections
04.2015
As regards the upsizing dimension and

the minimum distances to adjacent util-
ity carriers and to the surface which are
closely related to this, the statements
made in Chapter 22.4.1.1 apply accord-
ingly.
22.4.3.2 Description of technique
With the auxiliary pipe technique the

replacement process is divided into
several working stages. Just as with the
press/pull technique described in Chap-
ter 22.4.2 here again a machine pit and
an assembly pit are needed as well as
the intermediate pits for house connec-
tions and branch pipelines. The distances
between the individual pits are also simi-
lar. In the first stage of the work the house
connections are disconnected and con-
nected up to the temporary supply pipe-
lines (Figure 22.21).
Parts of the old pipe which are missing

because of the removal of house con-
nections or other fittings are replaced by
transition pieces.
Figure 22.21:
Diagram of the auxiliary pipe technique for the trenchless replacement of
grey cast iron pipelines according to DVGW Worksheet GW 322-2 [22.6]
04.2015
After complete removal of the last of the 22.4.4 Horizontal directional drilling
old pipes the route is now occupied by the
reusable auxiliary pipes (Figure 22.21). 22.4.4.1 General
These now take up the loads of the cover
and the traffic and so secure the sewage In contrast to the techniques described
channel. in Chapters 22.4.1, 22.4.2 and 22.4.3
for replacing existing pipelines using the
In the last stage of the work, the new pipe same route, the following technique for
is connected up to the auxiliary pipes in the trenchless installation of a new pipe-
the pipe channel by means of a traction line of ductile iron pipes is now described.
head with an integrated tension force This includes horizontal directional drill-
gauge. The auxiliary pipes are drawn ing (HDD), cutting in, ploughing in and
Figure 22.22: back into the machine pit and with them guided pilot jacking. While the last-named
Steel pipes pushed out the new pipeline is pulled into the exist- techniques play a rather subordinate role,
ing pipe channel (Figure 22.21). As the the HHD technique practically represents
auxiliary pipes are being dismantled and an everyday form of trenchless installa-
Then the mechanical press pushes the old removed in the machine pit, the assem- tion of ductile iron pipes.
pipes out into the assembly pit by means bly of the new pipes is taking place in
of restrained auxiliary steel pipes until the pipe installation pit. If an upsizing Since the beginning of the nineties the
they have been completely removed (Fig- traction head is used, larger dimension development of this technique has been
ure 22.22). new pipes can also be pulled in. Usu- closely linked with ductile cast iron pipes.
ally a small overcut of 10 % to 15 % more As early as 1993, in experimental tests
If the old pipe cannot take the high press- than the external diameter of the socket Nöh [22.20] installed 60 m long DN 150
ing forces to be expected, it is cut in the is used. pipelines with positive locking push-in
intermediate pits and removed in shorter joints and extracted them from the pipe
pieces of pipe. channel again to assess the surface
stresses. The excellent results formed the
basis for a double culvert of 2 x DN 150
of around 200 m in length which
was installed in 1994 near Kinheim
04.2015
under the River Mosel, partly through

rocky ground.
The horizontal directional drilling tech-

nique is by far the most widespread
trenchless technique for the installation
of new pressure pipelines for water sup-
ply the [22.21]. Examples of execution can
be seen in Videos 22.05 and 22.06.
The process of the horizontal directional

drilling technique is divided into three
consecutive working stages as follows
(Figure 22.23):
■ Pilot boring,
■ Upsize boring,
■ Pulling in.
Figure 22.23:
Diagram of the horizontal directional drilling technique
Video 22.05:
HDD for a DN 500 culvert at Geel in Belgium
Video 22.06:
HDD for a DN 900 culvert at Alzira in Spain
04.2015
1. Pilot boring 2. Upsize boring
This is the first stage of producing a The purpose of upsize boring is, where
drilled channel from the starting point necessary, to enlarge the pilot bore to a
to the target pit into which the pipe string diameter sufficient for the insertion of
can be drawn. The pilot hole is driven in the utility pipe in a number of stages by
a controlled way using a drill head on the the use of appropriate tools. To do this
end of a drill pipe. In this process a watery an upsizing head is mounted on the pilot
bentonite suspension, the so-called drill- drill string, the size and design of which
ing fluid, escapes under high pressure at are based on the soil conditions in each
the drill head which is pumped through case and the dimension of the pipe to be
the drill pipe by the drilling machine to pulled through subsequently (Figures
the drill head. The drilling fluid serves the Figure 22.24: 22.25 and 22.26).
dual purpose of transporting the detached Drill head for pilot boring
material away and supporting the drill The upsizing head is drawn through the
hole. The drill head is designed dif- borehole under constant rotation and so
ferently for different soil types. With in the drill head above the route of the widens the pilot bore. The soil removed
sandy soils the outlet nozzles are gener- pipeline. Deviations from the target pipe- is carried away with the drilling mud,
ally sufficient for loosening and carrying line are corrected by steering movements. which simultaneously supports the chan-
away the drilling spoil. In rocky ground The precision of steering is so high these nel bored.
drill heads equipped with roller chisels days that it is possible to have pilot bores
can be used. arrive in a target area of only 1 m² after The upsizing process is repeated with ever
lengths of more than 1,000 m. larger drill heads until the desired inter-
The pilot boring is guided by controlled nal diameter of the channel is achieved.
rotation of the bevelled control surface of With ductile iron pipes the diameter of the
the drill head, the swerving movement of bore is based on the outside diameter of
which can be pushed by rotation in the the sockets. Usually an overcut of 20 % to
desired direction (Figure 22.24). The 30 % larger than the socket is necessary.
actual position of the drill head is located
by radio signals from a transmitter housed
04.2015

Examples of upsizing heads Reamer with swivel and traction head
3. Pulling in Depending on the space available, with

ductile iron pipes, the horizontal direc-
Once the drill hole has reached its final tional drilling technique can be carried
diameter, the pipe string can be pulled in. out with a completely pre-assembled
A reamer (Figures 22.26 and 22.27) is pipe string (Figures 22.29, 22.30 and
fitted to the drill pipe which is still inside 22.31) or for individual pipe assembly
the bored channel, followed by a swivel, (Figure 22.32).
which prevents the pipe string from rotat-
ing, and a traction head suitable for the
piping material to be pulled in (Figure
22.28). The traction head has a positive
locking to the pipe string. The maximum
possible length of the pipe string to be Figure 22.27:
pulled in depends on local circumstances. Positioning the swivel between
reamer and traction head
04.2015
Figure 22.28: Figure 22.30: Figure 22.32:

Traction head with sheet steel cone HDD – elevated pre-assembled pipe string HDD – individual pipe assembly
using an assembly ramp

HDD – pipe string pre-assembled HDD – pre-assembled pipe string
in the trench floating in the bentonite suspension
04.2015
22.4.5 Cutting in 22.4.5.2 Description of technique underground pressure pipelines for

public water supply in Germany.
22.4.5.1 General The cutting and installation unit cuts
the trench. The installation box is set up 22.4.6.2 Description of technique
According to GW 324 [22.8] the soil is and the ductile iron pipes are assembled
loosened, broken up and conveyed by a inside the box on the bottom of the trench. A hollow is produced by an upsiz-
cutting tool (chain, wheel). It is depos- The filling and compacting unit moves ing unit shaped like a rocket head on
ited beside the trench or carried away the backfilling material deposited on the the bottom of a ploughshare. In the
(Figure 22.33). A distinction is made side into the pipeline area in layers and same stage of the work, the pipe string
between cutting in without installa- compacts it. which is attached to the upsizing
tion box and cutting in with installation unit via a traction head is pulled into
box For the installation of ductile iron 22.4.6 Ploughing in this hollow space ( Video 22.07). Fig-
pipes, the cutting in process with instal- ure 22.34 shows the principle of the tech-
lation box (e.g. sliding formwork) is used 22.4.6.1 General nique.
(Figure 22.33).
For a long time cables and plastic So far the technique has been used with
pipelines have been ploughed in in nominal sizes DN 80 to DN 300.
rural areas and along routes without
pre-existing infrastructures or other The machine technology required consists
obstacles. This mainly happens along of a towing vehicle (Figure 22.35) and
service tracks at the edge of land used a plough (Figure 22.36) with a plough-
for agricultural purposes. In 2000 share. For vertical consistency of the
the technique was successfully trial- pipe route in an undulating topo-
led for the first time with pipes in graphic profile, the insertion depth of
ductile cast iron in the context of a the ploughshare can be controlled
research project and since then it hydraulically.
has been further developed to be-
Figure 22.33: come a standard technique. DVGW Work-
Cutting in – individual pipe assembly sheet GW 324 [22.8] is applicable
in sliding formwork for the planning and construction of
04.2015
Figure 22.35:
Towing vehicle
Figure 22.34:
Diagram of the ploughing-in technique
Video 22.07:
Ploughing in DN 150 ductile iron pipes
Figure 22.36:
Plough
04.2015
The plough is attached by a steel cable

(Figure 22.37) to the towing vehicle,
which can be supported by a plate on
the ground to transmit the traction
forces into ground.
The pipeline of ductile iron pipes

with positive locking restrained joints
is laid along the route. The pipe string
is then attached to the upsizing unit Figure 22.37: Figure 22.38:
(Figure 22.38) and ploughed into Steel cable to the towing vehicle Plough with upsizing unit
the soil via a launch pit with a sloping
ramp (Figures 22.39, 22.40 and 22.41).
The length of the launch pit depends on
the angular deflection capacity of the
restrained push-in joints.
Figure 22.39:
Launch pit with sloping ramp
04.2015
As the pipeline is pulled in, additional technique is so high that even the high
protection tubes, cables and warning tape requirements for gravity sewers can be
can be installed at the same time. In order met.
to fill the annular space or to reduce fric-
tion forces a bentonite suspension can be Basic conditions for guided pilot boring
introduced. Individual pipeline strings are displaceable soil, piping lengths
are connected one beneath the other with < 120 m, no stones > 80 mm in the route
collars. Any surface distortions existing and a groundwater level above the pipe
after the installation of the pipeline are of less than 3 m. The available machine
then evened out by running the excavator technology currently allows the instal-
over them. lation of pipes with a maximum outside
diameter of 1,000 mm. This approximately
Figure 22.40: 22.4.7 Guided pilot boring corresponds to a ductile iron pipe with
Launch pit positive locking restrained push-in joints
22.4.7.1 General of nominal size DN 800.
An interesting variation of the trench- The essential advantage of this technique

less installation of new pipelines in lies in the fact that even pipe materials
ductile cast iron is so-called guided pilot which are not normally available as
boring. Using a pipe boring machine jacking pipes can be very accurately
for micro-tunnelling, a guided pilot bore installed as new using a trenchless
is driven for about 70 m to the target technique.
pit. In a second stage, this bore is wid-
ened by removing soil using auxiliary
pipes with feed augers. The third stage
consists of withdrawing these aux-
iliary pipes while simultaneously pull-
ing in the individual ductile iron pipes
Figure 22.41: (Figure 22.42). The precision which
Pipeline ploughed in can be achieved with this version of the
04.2015
The first stage is the pilot boring. The pilot

pipe is pushed out from the launch shaft
into the target pit through the displace-
able soil. With the help of an optical path,
a control head, a theodolite with CCD
camera and monitor it is possible to guide
the equipment precisely to target with
constant control of direction and incli-
nation (Figure 22.42).
In the second state the pilot bore is wid-

ened by pushing through a restrained
steel casing (Figure 22.42). If necessary
the bore can now be widened to the final
dimension required. With the steel casing,
the pieces of pipe are pushed through the
pilot bore to the target shaft where they
are dismantled and salvaged. The exca-
vation material produced by widening the
borehole is conveyed back to the launch
shaft with a feed auger consisting of 1 m
Figure 22.42: long part sections. Here the soil is taken
Pulling in after guided pilot boring up in a container, lifted out with the site
lifting gear and collected in containers
for disposal.
04.2015
In the third stage of the work the ductile If necessary the bentonite mixture can
iron pipe with positive locking restrained be pushed through a feed pipeline which
push-in joint is released into the target runs through the new pipe in the area of
shaft and connected to the traction head the hole opener between pipe and soil.
of the foremost casing pipe. The fric-
tion-locked casing pipes are now drawn 22.4.7.3 Coatings
back to the launch shaft. Here they are
retrieved together with the feed auger Basically, for this technique, pipes with
(Figure 22.42). cement mortar coating to EN 15542 [22.12]
or polyurethane coating to EN 15189
All further product pipes are connected to Figure 22.43: [22.13] are used. The area of the joint
the pipe previously pulled in very quickly. Hole Opener is protected with a protective rubber
The traction head carries a tensile force sleeve and/or a sheet steel cone.
gauge with which the pulling forces work-
ing on the pipe string can be measured Many innovations are based on proven
and documented. products where skilful adaptation
and reorientation has developed them
As an alternative to the pulling head a further for new conditions of use and
so-called hole opener (Figure 22.43) can basic requirements. This is also the case
also be used with a connection for ductile with the ZM-U-Plus pipe which has
iron pipes (Figure 22.44) [22.22]. This been in use in Berlin for a number of
has the advantage that the utility pipe years.
to be laid can be installed to millimetre
precision, which is particularly important Initially developed and success-
when installing gravity sewers. The fric- fully because of the desire of Berliner
tional forces produced on the casing can Wasserbetriebe (BWB) for a trench-
be reduced by lubrication with bentonite. less pipe replacement technique in the
domain of drinking water which could
Figure 22.44: keep to the track in coarse-grained and
Coupling for ductile iron pipes loose soils containing gravel, the tech-
04.2015
nique of trenchless laying of new pipe- An advantage of guided pilot jacking is the
lines opened up an entirely new area of low overcut. Therefore there is no or only
use. a little amount of settlement as a result.
The technique is technically mature. It
With the ZM-U-Plus cement mortar combines the known technique of guided
coated pipe (Figure 22.45) ductile iron pipe jacking which has been tried and
pipes are so thickly coated with cement tested in the field of sewer construction
mortar up to the outside contour of the with the pull-in technique for restrained
socket that externally they have a cylin- ductile iron pipes. Traffic and environ-
drical contour without any recognisable ment are only affected to a slight extent.
socket. The cement mortar coating is
extremely mechanically robust. It resists 22.4.8 Relining technique
enormous friction forces over the entire Figure 22.45:
circumference of the pipe barrel. Once the ZM-U-Plus pipe 22.4.8.1 General
joints are assembled the gap between the
end face of the socket and the spigot end When replacing pipelines using the relin-
is closed with flexible material and then 22.4.7.5 Miscellaneous ing technique a new pipeline is drawn
sealed with special tape. or pushed into an existing pipeline. This
As a result the individual pipeline sec- always results in a reduction of the clear
22.4.7.4 Push-in joint tions can be conventionally assembled inside diameter. When relining with
in the installation pits (previously launch ductile iron pipes the reduction of the
As the utility pipe is pulled in by guided and pulling pits) with the help of standard cross-section of the pipeline depends on
pilot boring, here again the use of posi- fittings. For pipelines to be fully locked, the diameter of the sockets of the new
tive locking restrained push-in joints is restrained fittings are to be used. By using pipeline. As a rule this is two nominal size
necessary. Allowable traction forces and these fittings, with pressure pipelines the stages. The hydraulic efficiency of the
operating pressures for the positive lock- ends of the pipeline can also be closed for pipeline is reduced. However this is in
ing restrained push-in joints are given in pressure testing before connection. part compensated by the smoother inter-
Table 22.3. nal surface (lower wall roughness) of
Shoring of the ends of the pipeline is not the new pipeline. Old pipelines are often
necessary in this case. incrusted on the inside und therefore
04.2015
have a high wall roughness. The relining With sewage pipelines too, the speed of 22.4.8.2 Description of technique
technique can be used for drinking water flow increases with relining, which in
pipelines, industrial water pipelines and many cases means that sedimentation With the relining technique, pipes in
pressurised and gravity sewage pipelines. of the solids carried in the wastewater is ductile cast iron to EN 545 [22.10] or
Pipe relining is based on DVGW Work- avoided. It is because of the solids depos- EN 598 [20.11] are pulled or pushed
sheet GW 320-1 [22.3]. ited that wastewater pipelines often have into the old, existing pipeline sliding on
to be cleaned at relatively short intervals the socket and protected with a sheet
In Germany the consumption of drinking by high pressure flushing or pigging. In steel cone (Figure 22.46). Because of the
water by the public and by industry has some cases this may be unnecessary with high longitudinal bending resistance of
been declining for some years. Accord- the use of a smaller diameter. With all ductile iron pipes, only one support per
ing to information from the German pipelines where the distance is not too pipe (in this case the socket) is neces-
Federal Statistics Office the per capita short between changes of direction or side sary. Additional supports/skids are not
consumption in 1990 was still around connections, replacement using the relin- normally required. Figure 22.47 shows
145 L/(i · d); by 2007 it had dropped to ing technique is always more cost effec- a special relining measure in which the
around 120 L/(i · d). It has a very strong tive than laying a new pipeline in open new pipes have been provided with skids.
regional variation between 90 and pipe trenches. This applies in particular The very small annular gap has not been
135 L/(i · d). where pipelines run under hard surfaces filled.
(e.g. road surfaces) or in built-up areas.
Therefore reducing the hydraulic
cross-section of a pipeline often brings In the relining technique with ductile iron
advantages for the operator because the pipes, depending on the conditions locally,
speed of flow of the water is raised again section lengths of far more than 1,000 m
and the drinking water spends less time can be renovated in one process. All that
lying idle in the pipeline, which means is required for this is one launch pit and
that hygiene problems can often be one target pit. As regards the nominal size
avoided. of the new pipe, there are no limits.
04.2015
In the first stage, launch pits (Figure are also used (Figures 22.51 and 22.52).
22.48) and target pits (Figure 22.49) These have the additional advantage that,
are set up along the pipeline to be reno- compared with customary methods, the
vated. Their position depends above all trasction forces are considerably reduced.
on points of constraint such as changes Because of the high longitudinal bending
of direction and, of course, the beginning resistance of ductile iron pipes, only one
and end of the pipeline. The size of the bracket per pipe is necessary, just behind
pits depends on the machine technology each socket.
used and the new pipe material. For duc-
tile iron pipes, their length of about 6 m is With the simultaneous pulling/pushing of
crucial, entailing a construction pit size of a number of pipelines, at least one guide
Figure 22.46: around 8 m. the size of the assembly pit is rail should be provided in order to prevent
Sheet steel cone for protecting the socket based on the nominal size to be installed. the twisting of the pipe string.
The old pipeline is then cut off in the In almost all cases pipelines are put
construction pit. Good preparation of the together using the single pipe assembly
old pipeline will be important later. From technique. Even here, the short assembly
measures carried out in the past it has times (Table 22.5) allow for fast progress.
been shown that, with good preparation of
the old pipeline, removal of incrustations
(Figure 22.50), closing of joint gaps in the
pipe invert, application of a lubricant in
the invert of the pipe, etc. a friction coef-
ficient of μ d 1,0 can always be achieved.
This means that only part of the actual
pipe weight is pulled.
Figure 22.47: In particular cases, such as the simul-

Relining DN 200 (new) cast iron pipe taneous inclusion of additional empty
in an old DN 300 cast iron pipe pipes or supply carriers, rolling brackets
04.2015
Figure 22.48: Figure 22.49: Figure 22.50:

Launch pit Target pit Tool for removing incrustations
04.2015
As a rule, the remaining annular gap

between the old pipe and the new pipe
is filled with an alkaline insulator. How-
ever this is dependent on local conditions
such as the type of operation, the exterior
coating, the size of the annular gap and
the static load capacity of the old pipe.
The last stage consists of testing tightness,
connecting the individual renovation sec-
tions and backfilling the construction pits.
Figure 22.51: Figure 22.53: 22.4.8.3 Pushing in

Sewage pipeline – guided roller brackets Transmission of forces on pushing in
With the pushing in technique, duc-
tile iron pipes with the non-restrained
TYTON® push-in joints are pushed into
the old pipeline. Here the axial thrust
force is transmitted across the front of the
spigot end into the ground of the TYTON®
socket (Figure 22.53). As the spigot ends
of the pipes are bevelled (chamfered), not
the entire cross-section of the pipe wall is
available for the transmission of the axial
thrust force (Figure 22.54). In addition
the smallest possible outside diameter of
the pipes and the minimal wall thickness
according to EN 545 [22.10] and EN 598
Figure 22.52: Figure 22.54: [22.11] must be taken into consideration.
Sewage pipeline – Transmission of axial forces
assembling the roller brackets when pushing in the pipe
04.2015
Table 22.5:
Individual pipe assembly – Assembly times for pushing in /pulling
Nominal size Number of Assembly time with- Assembly time using a Assembly time using
DN installation out joint protection protective sleeve shrink-on sleeves
engineers [min] [min] [min]
80 1 5 6 15
100 1 5 6 15
125 1 5 6 15
150 1 5 6 15
200 1 6 7 17
250 1 7 8 19
300 2 8 9 21
400 2 10 12 25
500 2 12 14 28
600 2 15 18 30
700 2 16 – 31
800 2 17 – 32
900 2 18 – 33
1000 2 20 – 35
04.2015
Table 22.6:
Allowable pushing-in forces according to DVGW Worksheet GW 320-1, Table A.7 [22.3] for ductile cast iron pipes
(depending on joint, without safety factor – the safety factor must be adapted to local circumstances, i.e. in particular
curve radiuses and angular deflection, and correspond to the pipe manufacturer’s application technology)
Nominal size External diameter Wall thickness class Wall thickness Allowable com- Allowable
(DN/OD) pression strength pushing-in force
DN da smin ızul Fzul
[mm] [mm] [N/mm2] [kN]
80 98 10 4.7 550 138
100 118 10 4.7 550 168
125 144 9 4.7 550 206
150 170 9 4.7 550 244
200 222 9 4.8 550 339
250 274 9 5.2 550 513
300 326 9 5.6 550 723
350 378 9 6.0 550 968
400 429 9 6.4 550 1246
500 532 9 7.2 550 1912
600 635 9 8.0 550 1085
700 738 9 8.8 550 1767
800 842 9 9.6 550 2595
900 945 9 10.4 550 3561
1000 1048 9 11.2 550 4669
04.2015
The compressive strength of ductile cast When pushing in (Figure 22.55) the
iron is ıD = 550 N/mm2. Without taking spigot end is always first pushed into
account of a safety factor, therefore, a the socket of the last pipe installed.
pressing force of P = ıD x AWall is possible The spigot end of the first pipe installed
where Awall represents the cross-section is to be provided with a centering head
surface of the cast iron wall transmitting (Figure 22.56). This can be made
the force. available on loan by manufacturers.
The permissible pushing-in forces are As with the pulling process, at least two
given in DVGW Worksheet GW 320- construction pits are necessary. The size
1, Table A.7 [22.3] (Table 22.6). The of the pushing and assembly pit depends
values stated there do not include any on the pipe length (usually 6 m), the
safety factors. Before planning or start- pushing equipment used and the nomi- Figure 22.55:
ing construction, it is recommended that nal size of the pipes to be installed. The Pushing in a pipe
contact is made with the manufacturer’s size of the target pit depends on nominal
technical service department to determine size and any other components.
the relevant values. Depending on how
the route runs (gradient, radiuses) and the
condition of the old pipelines, different
safety factors are to be selected.
There is a report in [22.23] and [22.24]

on relining measures according to this
technique.
Figure 22.56:
Centering head
04.2015
22.4.8.4 Pulling in
A positive locking restrained push-in joint

is usually used for the pulling in tech-
nique. The permissible traction forces,
the maximum possible angular deflection
and the minimum possible radius can be
found in Table 22.3.
Pulling in the new pipe string with

tie rods has proved to be effective
(Figure 22.57). There is a report on
this in [22.25]. The use of a cable winch Figure 22.57:
and steel cable is not recommended Traction unit with rods
for pulling in and nor is the use of
friction locking restrained push-in joints.
22.4.8.5 Coating
A traction head is always required for
pulling in the new pipe string. This is If the annular gap remaining between the
produced from a positive locking old pipe and the new pipe is filled with an
restrained push-in socket (Figure 22.58). alkaline insulator, the pipes only require
Traction heads can be made available zinc or zinc aluminium coating. The socket
to firms carrying out the work by the pipe is protected with a sheet steel cone for the
manufacturer. pulling or pushing in process.
If the remaining annular gap is not filled,

ductile iron pipes with cement mor-
tar coating to EN 15 542 [22.12] or with
polyurethane coating to EN 15189 Figure 22.58:
[22.13] will be used. The push-in joints Pipe with traction head and sheet steel cone
04.2015
of cement mortar coated pipes are 22.5 References [22.3] DVGW-Arbeitsblatt GW 320-1
protected with rubber sleeves or PE Erneuerung von Gas- und Wasser-
shrink-on material to DIN 30 672 [22.26]. rohrleitungen durch Rohreinzug
[22.1] ISO 13470: oder Rohreinschub mit Ringraum
The socket joint protection will be given Trenchless applications of [DVGW worksheet GW 320-1
additional mechanical protection during ductile iron pipes systems – Replacement of gas and water
pulling and pushing in processes with a Product design and installation pipelines by pipe pulling or pipe
sheet steel cone (Figure 22.59). [Grabenlose Anwendungen von pushing with annular gap]
gusseisernen Rohrsystemen – 2009–02
Produktauslegung und -installation]
2012-07 [22.4] DVGW-Arbeitsblatt GW 321
Steuerbare horizontale
[22.2] Steinhauser, P.: Spülbohrverfahren für Gas-
Wirtschaftlichkeitsbetrachtungen, und Wasserrohrleitungen –
Betrachtungen bei der grabenlosen Anforderungen, Gütesicherung
Erneuerung – und Prüfung
Vortragsskript des Seminars NO DIG – [DVGW worksheet GW 321
Grabenlose Erneuerung bei alter, Horizontal directional drilling
schadhafter Kanalisation – technique for gas and water
Technische Akademie Hannover pipelines –
[Economic considerations for Requirements, quality
trenchless replacement – assurance and testing]
Presentation script for the “NO DIG – 2003-10
Trenchless replacement of old and
damaged pipelines”
Seminar at the Hannover
Technical Academy]
2007-01-18
Figure 22.59:
Fitting the sheet steel protective cone
04.2015
[22.5] DVGW-Arbeitsblatt GW 322-1 [22.7] DVGW-Merkblatt GW 323 [22.9] DVGW-Arbeitsblatt W 400-1

Grabenlose Auswechslung von Grabenlose Erneuerung von Technische Regeln Wasser-
Gas- und Wasserrohrleitungen – Gas- und Wasserversorgungs- verteilungsanlagen (TRWV) –
Teil 1: Press-/Ziehverfahren – leitungen durch Berstlining – Teil 1: Planung
Anforderungen, Gütesicherung Anforderungen, Gütesicherung [DVGW worksheet W 400-1
und Prüfung und Prüfung Technical rules for water
[DVGW worksheet GW 322-1 [DVGW technical information supply systems –
Trenchless replacement of sheet GW 323 Part 1: Design]
gas and water pipelines – Trenchless replacement of 2015-02
Part 1: Press/pull technique – gas and water pipelines by
Requirements, quality burst lining technique – [22.10] EN 545
assurance and testing] Requirements, quality Ductile iron pipes, fittings,
2003-10 assurance and testing] accessories and their joints
2004-07 for water pipelines –
[22.6] DVGW-Arbeitsblatt GW 322-2 Requirements and test methods
Grabenlose Auswechslung von [22.8] DVGW-Arbeitsblatt GW 324 [Rohre, Formteile, Zube-
Gas- und Wasserrohrleitungen – Fräs- und Pflugverfahren für hörteile aus duktilem Gussei-
Teil 2: Hilfsrohrverfahren – Gas- und Wasserrohrleitungen – sen und ihre Verbindungen
Anforderungen, Gütesicherung Anforderungen, Gütesicherung für Wasserleitungen –
und Prüfung und Prüfung Anforderungen und Prüfverfahren]
[DVGW worksheet GW 322-2 [DVGW worksheet GW 324 2010
Trenchless replacement of Trenching and ploughing in
gas and water pipelines – techniques for gas and
Part 2: Auxiliary pipe technique – water pipelines –
Requirements, quality Requirements, quality
assurance and testing] assurance and testing]
2007-03 2007-08
04.2015
[22.11] EN 598 [22.13] EN 15189 [22.15] Hobohm, S. und Bauer, A.:

Ductile iron pipes, fittings, Ductile iron pipes, fittings Grabenlose Erneuerung einer
accessories and their joints and accessories – Feuerlöschleitung mittels Berstlining
for sewerage applications – External polyurethane coating GUSS-ROHRSYSTEME,
Requirements and test methods for pipes – Heft 48 (2014), S. 69 ff
[Rohre, Formstücke, Zube- Requirements and test methods [Trenchless replacement
hörteile aus duktilem Gussei- [Rohre, Formstücke und Zubehör of a fire main using the
sen und ihre Verbindungen für aus duktilem Gusseisen – burst lining technique
die Abwasserentsorgung – Polyurethanumhüllung von Rohren – DUCTILE IRON PIPE SYSTEMS,
Anforderungen und Prüfverfahren] Anforderungen und Prüfverfahren] Issue 48, (2014), p. 66 ff]
2007+A1:2009 2006
[22.16] Emmerich, P. und Schmidt, R.:
[22.12] EN 15542 [22.14] DIN 28603 Erneuerung einer Ortsnetz-
Ductile iron pipes, fittings Rohre und Formstücke aus leitung im Berstlining-Verfahren
and accessories – duktilem Gusseisen – [Replacement of a local distribution
External cement mortar Steckmuffen-Verbindungen – pipeline using the burst
coating for pipes – Zusammenstellung, lining technique]
Requirements and test methods Muffen und Dichtungen GUSSROHR-TECHNIK,
[Rohre, Formstücke und Zubehör [Ductile iron pipes and fittings – Heft 39 (2005), S. 16 ff
aus duktilem Gusseisen – Push-in joints –
Zementmörtelumhüllung Survey, sockets and gaskets]
von Rohren – 2002-05
Anforderungen und Prüfverfahren]
2008
04.2015
[22.17] Rameil, M.: [22.19] Hobohm, S. und Schaffarczyk, F.: [22.21] Hobohm, S.:
Rohrleitungserneuerung mit Weltneuheit auf der Spülbohren mit
Berstverfahren – WASSER BERLIN duktilen Gussrohren –
Praxisleitfaden für Planer, Auftrag- INTERNATIONAL 2011 – Verfahrensbeschreibung, Vorteile,
geber und ausführende Press-/Zieh-Verfahren mit Einsatzgrenzen, Beispiele
Bauunternehmer – Bodenentnahme GUSSROHR-TECHNIK,
2. Auflage GUSS-ROHRSYSTEME, Heft 47 (2013), S. 50 ff
[Pipeline replacement with the Heft 46 (2012), S. 53 ff [Horizontal directional
bursting technique – [World premiere at drilling with ductile iron pipes –
Practical guide for planners, WASSER BERLIN process description, advantages,
clients and building contractors – INTERNATIONAL 2011 – fields of application, examples
2. edition] The press-pull technique DUCTILE IRON PIPE SYSTEMS,
2010 with soil removal Issue 47 (2013), p. 48 ff]
DUCTILE IRON PIPE SYSTEMS,
[22.18] Levacher, R.: Issue 46 (2012), p. 51 ff] [22.22] Brucki, O. und Rau, L.:
Erneuerung einer Verbindungs- Mit Spezialrohren aus
leitung DN 400 zwischen zwei [22.20] Nöh, H.: duktilem Gusseisen durch die
Wasserwerken im Berstlining- Moseldüker Kinheim – Berliner Müggelberge
und Spülbohrverfahren Grabenloser Einbau von GUSS-ROHRSYSTEME,
[Replacement of a DN 400 Gussrohrleitungen mit der Heft 45 (2011), S. 46 ff
connecting pipeline between FlowTex-Großbohrtechnik [With special ductile
two waterworks using the burst [Culvert at the river Mosel near iron pipes through
lining and directional drilling Kinheim – Berlin’s Müggel Hills
technique] Trenchless installation of DUCTILE IRON PIPE SYSTEMS,
GUSSROHR-TECHNIK, cast iron pipelines with the Issue 45 (2011), p. 42 ff]
Heft 40 (2006), S. 17 ff FlowTex large-scale
drill technique]
GUSSROHR-TECHNIK,
Heft 30 (1995), S. 25 ff
04.2015
[22.23] Schnitzer, G., Simon, H. [22.26] DIN 30672

und Rink, W.: Organische Umhüllungen für den
Langrohrrelining DN 900 Korrosionsschutz von in Böden
in Leipzig Mölkau und Wässern verlegten Rohr-
[Pipe relining DN 900 leitungen für Dauerbetriebs-
in Leipzig Mölkau] temperaturen bis 50 °C ohne
GUSSROHR-TECHNIK, kathodischen Korrosionsschutz –
Heft 39 (2005), S. 20 ff Bänder und schrumpfende
Materialien
[22.24] Bauer, A., Simon, H. und Rink, W.: [External organic coatings for the
Sanierung der Thallwitzer corrosion protection of buried and
Fernleitung DN 1100 mit immersed pipelines for continuous
Langrohrrelining DN 900 operating temperatures up to 50 °C
[Renovation of Thallwitz trunk line without cathodic protection –
DN 1100 with DN 900 pipe relining] Tapes and shrinkable materials]
GUSSROHR-TECHNIK, 2000-12
Heft 40 (2006), S. 28 ff
[22.25] Rink, W.:

Langrohrrelining mit
duktilen Gussrohren DN 800
[Pipe relining with DN 800
ductile iron pipes]
GUSSROHR-TECHNIK,
Heft 38 (2004), S. 17 ff
04.2015
04.2015
E-Book – Ductile iron pipe systems Chapter 23: Some new main applications for ductile iron pipes 23/1
23 Some new main applications

for ductile iron pipes
10.2010
E-Book – Ductile iron pipe systems Chapter 23: Some new main applications for ductile iron pipes 23/2
23 Some new main applications for ductile iron pipes

10.2010
E-Book – Ductile iron pipe systems Chapter 24: Standards, directives and technical rules 24/1
24 Standards, directives
and technical rules
24.1 General
24.2 The Standards Database
10.2010
E-Book – Ductile iron pipe systems Chapter 24: Standards, directives and technical rules 24/2
24 Standards, directives and technical rules 24.2 The Standards Database
The Standards Database linked to this chapter The Standards Database gives the
is constantly updated. numbers, titles and dates of issue (edi-
tions) of the standards, directives and
technical rules listed in it.
Given below are details of the types of standards, directives, technical rules
and other codes which are of significance to ductile iron water, wastewater On the search template, you can optimise
and sewage pipelines, i.e. to pipes, fittings and valves, and which are listed in a your search for a standard, directive or
Standards Database. technical rule, and can find the result of
the search quickly, by entering search
criteria. Some of these are preset. The
preset search criteria also include the
24.1 General For the field of ductile iron pipe systems, options of selecting the country in which
national rules are also included in the documents apply and their language.
listing to supplement the above.
The standards, directives, technical rules The listing of standards and other docu- The results of a search are shown in the
and other codes which are of signifi- ments contained in the Standards Data- form of a table and can be printed out.
cance to ductile iron pipelines, some of base does not claim to be complete. When Clicking on the „Details” button will show
which are referred to in this E-Book, are applying the standards, directives and you all the stored information on the stan-
covered by a Standards Database. The technical rules listed in the Standards dard or other document selected, source
standards and draft standards listed in the Database, it is essential to use the version of supply included.
Standards Database are not only national with the latest date of issue (the latest
standards such as German DIN standards, edition). Clicking on the link below will take you to
Austrian OENORM standards, Swiss SN the EADIPS®/FGR® Standards Database:
standards und Italian UNI standards, but eadips.org/normen/
above all European standards (EN) and
also international standards (ISO).
10.2010
E-Book – Ductile iron pipe systems Chapter 25: Index 25/1
25 Index
08.2013
E-Book – Ductile iron pipe systems Chapter 25: Index 25/2
25 Index
08.2013
E-Book – Ductile iron pipe systems Chapter 26: Imprint 26/1
26 Imprint
Full members
Sponsoring members
01.2017
Imprint Picture credits: Through this E-Book you are able to access
links to third-party websites which are not
European Association for Ductile under the control of the EADIPS® / FGR®.
Published by: Iron Pipe Systems · EADIPS®/ We have no control over the nature
and content of these third-party web-
Fachgemeinschaft
sites or over any changes made to them.
European Association for Ductile Guss-Rohrsysteme (FGR®) e. V.
We therefore accept no liability for the
Iron Pipe Systems · EADIPS®/ content of such third-party websites to
Fachgemeinschaft Disclaimer: which links are provided in our E-Book,
Guss-Rohrsysteme (FGR®) e. V. or for links to further websites which are
Doncaster-Platz 5 Whilst every care has been taken in the provided on such third-party websites.
45699 Herten compilation of the material, information
Germany and content contained in this E-Book, and Reproduction:
Phone: +49 (0)2366 9943905 every effort is made to ensure that it is both
Telefax: +49 (0)2366 9943906 accurate and up-to-date, the EADIPS® / FGR® Text, data, software and graphics appearing
makes no representations or warranties in this Annual Journal may be reprinted,
E-mail: info@eadips.org
of any kind, express or implied, about the reproduced, copied or used in other ways
www.eadips.org completeness, correctness, up-to-dateness for non-commercial, private, education
or technical accuracy of such material, or training-related purposes provided
Editor: information and content. Whilst all always that the text, data, software
reasonable steps have been taken to ensure and graphics are not modified and that
European Association for Ductile that this E-Book is free from computer an indication that the EADIPS® / FGR® is
Iron Pipe Systems · EADIPS®/ viruses, we accept no liability in respect of the copyright owner appears on every
Fachgemeinschaft any loss, cost, damage, inconvenience or copy. Prior written consent must be
Guss-Rohrsysteme (FGR®) e. V. expense suffered as a result of accessing obtained from us for any other use.
Christoph Bennerscheidt this E-Book. We also reserve the right
to make, at any time and without prior
notice, amendments or additions to or
Press date: Production:
deletions from the material, information
and content contained in this E-Book.
August 2014 Schneider Media GmbH,
Erfurt
01.2017
European Association for Ductile Iron Pipe Systems · EADIPS®/

Fachgemeinschaft Guss-Rohrsysteme (FGR®) e. V.
Full members
Düker GmbH
Hauptstrasse 39–41 · 63846 Laufach/Germany
Phone: +49 (0)6093 / 87-0 · Telefax: +49 (0)6093 / 87-246
E-mail: info@dueker.de
Website: www.dueker.de
Duktus Rohrsysteme Wetzlar GmbH

Sophienstrasse 52–54 · 35576 Wetzlar/Germany
Phone: +49 (0)644 / 49-2401 · Telefax: +49 (0)6441 / 49-1455
E-mail: info@duktus.com
Website: www.duktus.com
ERHARD GmbH & Co. KG

Meeboldstrasse 22 · 89522 Heidenheim/Germany
Phone: +49 (0)7321 / 320-0 · Telefax: +49 (0)7321 / 320-491
E-mail : info@talis-group.com
Website: www.talis-group.com
01.2017
Keulahütte GmbH
Geschwister-Scholl-Strasse 15 · 02957 Krauschwitz/Germany
Phone: +49 (0)35771 / 54-0 · Telefax: +49 (0)35771 / 54-220
E-mail: keulahuette@vem-group.de
Website: www.keulahuettekrauschwitz.de
Ludwig Frischhut GmbH & Co. KG

Franz-Stelzenberger-Strasse 9–17 · 84347 Pfarrkirchen/Germany
Phone: +49 (0)8561 / 3008-0 · Telefax: +49 (0)8561 / 3008-105
E-mail: frischhut@talis-group.com
Website: www.frischhut.de
TIROLER ROHRE GmbH

Innsbrucker Strasse 51 · 6060 Hall in Tirol/Austria
Phone: +43 (0)5223 / 503-0 · Telefax: +43 (0)5223 / 43619
E-mail: info@duktus.com
Website: www.duktus.com
01.2017
vonRoll hydro (deutschland) gmbh

Ferdinand-Lassalle-Strasse 16 · 72770 Reutlingen/Germany
Phone: +49 (0)7121 / 4347-49 · Telefax: +49 (0)7121 / 4704-33
E-mail: info@vonroll-hydro.de
Website: www.vonroll-hydro.de
vonRoll hydro (suisse) ag

von roll-strasse 24 · 4702 Oensingen/Switzerland
Phone: +41 (0)62 / 38811-11 · Telefax: +41 (0)62 / 38811-77
E-mail: info@vonroll-hydro.ch
Website: www.vonroll-hydro.ch
01.2017
European Association for Ductile Iron Pipe Systems · EADIPS®/

Fachgemeinschaft Guss-Rohrsysteme (FGR®) e. V.
Sponsoring members
Akzo Nobel Powder Coatings GmbH

Markwiesenstrasse 50 · 72770 Reutlingen/Germany
Phone: +49 (0)7121 / 519-197 · Telefax: +49 (0)7121 / 519-199
E-mail: resicoat@akzonobel.com
Website: www.resicoat.com
Friedrichshütte GmbH
Friedrichshütte 11–13 · 35321 Laubach/Germany
Phone: +49 (0)6405 / 826-0 · Telefax: +49 (0)6405 / 826-260
E-mail: info@friedrichshuette.com
Website: www.friedrichshuette.com
Rhein-Ruhr Collin KG
Geschäftsbereich HTI
Collinweg · 47059 Duisburg/Germany
Phone: +49 (0)203 / 28900-105 · Telefax: +49 (0)203 / 28900-103
E-mail: gsl.rrc@gc-gruppe.de
Website: www.hti-handel.de
01.2017
Saint-Gobain Building Distribution Germany GmbH

Hanauer Landstrasse 150 · 60314 Frankfurt/Germany
Phone: +49 (0)69 / 40505655 · Telefax: +49 (0)69 / 40505565
E-mail: mario.hinz@saint-gobain.com
Website: www.sgbd-Germany.de
SATTEC DBS GOMMA SRL

Via E. Mattei, 12 · 33080 Prata di Pordenone (PN)/Italy
Phone: +39 (0)434 / 620100 · Telefax: +39 (0)434 / 610055
E-mail: commerciale@sattecgomma.it
Website: www.sattecgomma.it
TMH Hagenbucher AG
Friesstrasse 19 · 8050 Zürich/Switzerland
Phone: +41 (0)44 / 3064748 · Telefax: +41 (0)44 / 3064757
E-mail: info@hagenbucher.ch
Website: www.hagenbucher.ch
01.2017
Tröger + Entenmann KG
In der Gabel 22 · 69123 Heidelberg/Germany
Phone: +49 (0)6221 / 825-0 · Telefax: +49 (0)6221 / 825-225
E-mail: info@tue-hd.de
Website: www.tue-hd.de
Vertriebsgesellschaft für Tiefbau und Umwelttechnik mbH + Co. KG

Wackerstrasse 7 · 85084 Reichertshofen/Germany
Phone: +49 (0)661 / 286-399 · Telefax: +49 (0)661 / 286-210
E-mail: martin.schulze@rf-tbu.de
Website: www.richter-frenzel.de
Woco IPS GmbH

Business Unit Pipe System Components
Hanauer Landstrasse 16 · 63628 Bad Soden-Salmünster/Germany
Phone: +49 (0)6056 / 78-7229 · Telefax: +49 (0)6056 / 78-57229
E-mail: ruwerner@de.wocogroup.com
Website: www.woco-psc.de
01.2017
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E-Book 10.

Ductile iron pipe systems

Contents 3.5 Application of coatings and linings

9 Restrained socket joints 11 Safeguarding with concrete thrust blocks

16 Structural design 21.8 Disinfection process

NEW 24 Standards, directives and technical rules

1 Introduction stresses. Firstly there is the internal

Pressure class (C classes) = PFA [bar] Table 1.1:

1.3.3 Screwed socket joints

The screwed socket joint has been used

The inside of the socket and the outside

– push-in joints make for highly productive X reduces labour costs

– impermeability to diffusion Xsafeguards drinking water in all soil and

– the material is strong X allows operating pressures up to 100 bars

1.6 Summary 1.7 References [Ductile iron pipes and fittings –

[1.6] EN ISO 4034 [1.9] DIN 28602

[1.8] DIN 28601 [1.10] Sustainably superior –

2 Ductile cast iron

2 Ductile cast iron as a material

Fig. 2.3: Fig. 2.4: Fig. 2.5:

Fig. 2.5 shows spheroidal graphite 2.3 Technological properties

Material Application Standard Minimum 0.2 % Minimum Hardness Notched Structure

Material Application Standard Minimum 0.2 % Minimum Hardness Notched Structure

With centrifugally cast pipes, in addition Table 2.2:

Because of the high bursting pressures

2.3.2 Material testing local grinding. After that a hardened

L0 Length of the machined cylindrical

Hardness is determined using the

2.4 References [2.3] EN 598 [2.5] ISO 6506-1

3 Production of pipes, fittings and valves

Heated air is blasted in from below

The cupola process has the advantage

The cupola furnace is omnivorous – even 3.1.2 The electric furnace

Because of their very low specific weight,

Despite extensive research, the mecha-

Various processes exist, e.g. pure or Fig. 3.5:

3.3 Casting process Essentially, two working methods are

3.3.1 Pipe production using the 1) Centrifuging in metal moulds (mould-

Fig. 3.7: Fig. 3.8:

Video 03.02: Centrifugal casting machine – animation

In the non-lined moulds of the de Lavaud

Fig. 3.12: Fig. 3.13: Fig. 3.14:

Also there is the vacuum moulding 3.4 Post-treatment

3.5 Application of coatings Cement mortar coating

With the spraying process the mortar

With the extrusion process, the cement

Fig. 3.23: Fig. 3.24:

Polyurethane coating The PUR coating has a uniform and even

This produces pore-free coatings with

The castings are often annealed before

After the annealing process the surface is

Fig. 3.33: Fig. 3.34:

3.6.2 Marking of valves in

The marking of valves (Figures 3.37,

Fig. 3.38: Fig. 3.39:

Fig. 3.37: Fig. 3.40:

3.8 References [3.3] EN 15542 [Vorbereitung von Stahloberflächen

[3.6] EN 14628 [3.8] EN 14901 [3.10] DIN 30677-1

[3.12] DIN 3476 [3.14] DIN 51178 [3.16] EADIPS®/FGR® 75