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WSAA Product Appraisal 1430 Issue 2 1

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vonRoll hydro (suisse) Ltd

PRODUCT APPRAISAL REPORT 1430 Issue 2 vonRoll Ductile Iron Pipes and Fittings for Water Supply and Sewerage

applications

BS EN 545:2010 Ductile iron pipes, fittings, accessories and their joints for water pipelines. Requirements and test methods

BS EN 598:2007 Ductile iron pipes, fittings, accessories and their joints for sewerage applications - Requirements and test methods Publication Date: 13 June 2017


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Document History

The following information indicates the changes made to this document.

Date Version File Location

15 July 2015 Peer Review

U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2014\PA 1430 VonRoll Hydro - Ductile Iron Pipes for Water Supply applications\vonRoll PA 14_30 VonRoll DI pipe 15-7-15.docx

15 July 2015 Peer Review

U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2014\PA 1430 VonRoll Hydro - Ductile Iron Pipes for Water Supply applications\vonRoll PA 14_30 VonRoll DI pipe 1772015.docx

12 October 2015 Peer Review final

U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2014\PA 1430 VonRoll Hydro - Ductile Iron Pipes for Water Supply applications\Peer Review Draft\vonRoll PA 1430 VonRoll DI pipe-Peer Review final.docx

15 December 2015 Publication

U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2014\PA 1430 VonRoll Hydro - Ductile Iron Pipes for Water Supply applications\Peer Review Draft\Final\vonRoll PA 1430 VonRoll DI pipe-Peer Review final2.docx

13 June 2017 Issue 2 Publication

U:\PP1 Industry Performance and Regulation\PP1-012 Product Appraisals\Civil Asset Infrastructure\2014\PA 1430 Issue 2 VonRoll Hydro - Ductile Iron Pipes for Water Supply applications\vonRoll PA 1430 Issue 2 VonRoll DI pipe.docx

Peer Reviewers

Name/Title Organisation Date

Product Appraisal Technical Advisory Group WSAA 11/11/2015

Carl Radford, Product Appraisal Manager WSAA 12/10/2015

Carl Radford, Product Appraisal Manager WSAA 13/6/2017


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Overview of WSAA

The Water Services Association of Australia (WSAA) is the peak industry body representing

the urban water industry. Our members provide water and sewerage services to over 20

million customers in Australia and New Zealand and many of Australia's largest industrial

and commercial enterprises.

Based around our vision of 'customer driven, enriching life', WSAA facilitates collaboration,

knowledge sharing, networking and cooperation within the urban water industry. We are

proud of the collegiate attitude of our members which has led to industry-wide approaches

to national water issues.

WSAA can demonstrate success in the standardisation of industry performance monitoring

and benchmarking, as well as many research outcomes of national significance. The WSAA

Executive retains strong links with policy makers and legislative bodies and their influencers,

to monitor emerging issues of importance to the urban water industry.

WSAA was formed in 1995 as a non-profit organisation to foster the exchange of information

between industry, government and the community, and to promote sustainable water

resource management.

The urban water industry is committed to anchoring its services to customers' values, and

to enrich communities where water services have broad economic, environmental and social

values. In line with this our main activities focus on four areas:

1. influencing national and state policies on the provision of urban water services and

sustainable water resource management

2. promoting debate on environmentally sustainable development and management of

water resources and the community health requirements of public water supplies

3. improving industry performance and establishing benchmarks and industry leading

practices for water service processes; and

4. fostering the exchange of information on education, training, research, water and

wastewater management and treatment and other matters of common interest.

Copyright

This document is copyrighted. Apart from any use as permitted under the Copyright Act

1968, no part of this document may be reproduced or transmitted in any form or by any

means, electronically or mechanical, for any purpose, without the express written permission

of Water Services Association of Australia Limited.

© Copyright 2017 by WATER SERVICES ASSOCIATION of Australia Limited All rights

reserved.


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CONTENTS

1 EXECUTIVE SUMMARY ........................................................................................................................................... 7

1.1 Recommendation ................................................................................................................................................ 8

2 THE DISTRIBUTOR AND MANUFACTURERS ......................................................................................................... 9

2.1 The Distributor ....................................................................................................................................................... 9

2.2 The Ductile Iron Pipe Manufacturer ..................................................................................................................... 9

2.3 The Ductile Iron Fitting Manufacturer .................................................................................................................. 9

2.3.1 ECOFIT ductile iron fittings ........................................................................................................................... 9

2.3.2 Derwent Industries ductile iron fittings ........................................................................................................ 10

3 THE PRODUCT ....................................................................................................................................................... 10

3.1 Polyurethane Internal Lining and External Coating ........................................................................................... 14

3.1.1 Polyurethane Internal Lining ....................................................................................................................... 14

3.1.2 Polyurethane External Coating ................................................................................................................... 14

3.2 Types of Joints and interconnection .................................................................................................................. 14

3.3 Elastomeric and Thrust-Resisting Joint Sealing Rings ...................................................................................... 21

3.3.1. Unrestrained Joint ........................................................................................................................................ 21

3.3.2 Restrained Joint ............................................................................................................................................ 21

3.4 vonRoll ISO sized ECOFIT DI fittings ................................................................................................................ 22

3.4.1 Types of Joints and Interconnections.......................................................................................................... 23

3.4.2 Restrained Joints for DI Fitting .................................................................................................................... 23

3.4.2.1 Internal Restrained Joint Single Chamber DN 80 – 700 ....................................................................... 23

3.4.2.2 External Restrained Joint Single Chamber DN 80 – 700 ...................................................................... 24

3.5 DI Fittings ISO sized – Configurations, Size and Class ................................................................................. 25

3.6 Elastomeric and Thrust-Resisting Joint Sealing Rings ISO sized .................................................................. 25

3.6.1 Unrestrained Joint ......................................................................................................................................... 25

3.6.2 Restrained Joint ............................................................................................................................................ 25

3.7 DI Socketed Fittings to AS/NZS 2280 ............................................................................................................ 25

4 SCOPE OF THE APPRAISAL ................................................................................................................................. 25

5 APPRAISAL CRITERIA ........................................................................................................................................... 26

5.1 Quality Assurance Requirements ...................................................................................................................... 26

5.2 Performance Requirements ............................................................................................................................... 26

5.2.1 Product Manufacturing Standards ................................................................................................................ 26

6 COMPLIANCE WITH APPRAISAL CRITERIA......................................................................................................... 27

6.1 Compliance with Quality Assurance Requirements ........................................................................................... 27

6.1.1 Distributor ................................................................................................................................................... 27

6.1.2 Manufacturers ............................................................................................................................................. 27

6.1.2.1 vonRoll DI pipes ................................................................................................................................... 27

6.1.2.2 ECOFIT DI fittings and DI components for external restrained joints ................................................... 28

6.1.2.3 TYTON® elastomeric seals ................................................................................................................... 28

6.1.2.4 Internal Restrained thrust-resisting rings .............................................................................................. 29

6.1.2.5 Jointing lubricant for vonRoll DI pipes and ECOFIT DI fittings ............................................................. 29

6.1.2.6 Bolts and Nuts for use with external restrained joints ........................................................................... 29

6.1.2.7 Elastomeric joint seals - ......................................................................................................................... 29

6.2 Compliance to the Appraisal Requirements ...................................................................................................... 29

6.2.1 Material properties ...................................................................................................................................... 29

6.2.1.1 Ductile iron tensile and hardness properties ........................................................................................ 29


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6.2.2 Wall thickness ............................................................................................................................................. 30

6.2.3 Performance test requirements to EN 545 and EN 598 .............................................................................. 30

6.2.3.1 Type tests and audit reports for vonRoll DI pipes ................................................................................. 31

6.2.4 Pressure ratings .......................................................................................................................................... 31

6.2.5 Pipe class designation ................................................................................................................................ 31

6.2.5.1 Pipe Classes for Water Supply Application .......................................................................................... 32

6.2.5.2 Pipe Classes for Sewerage Application ................................................................................................ 33

6.2.5.3 Flanged pipes for water supply and sewerage application ................................................................... 34

6.2.6 Joints .......................................................................................................................................................... 34

6.2.7 Elastomeric Seals for push-in socket joint connections .............................................................................. 35

6.2.7.1 Elastomeric seals for use on vonRoll hydro DI pipes and ECOFIT DI fittings ...................................... 35

6.2.7.2 Transition elastomeric seals – for use on DI pipe manufactured to EN 545 / EN 598 and AS/NZS 2280 manufactured Socketed DI fittings ..................................................................................................................... 36

6.2.8 Restrained joints ......................................................................................................................................... 39

6.2.9 Linings for DI pipes ..................................................................................................................................... 39

6.2.10 External Coatings...................................................................................................................................... 41

6.2.10.1 Polyurethane coating for ECOPUR® ductile iron pipes ....................................................................... 41

6.2.10.2 Zinc and finishing layer for DUCPUR® and GEOPUR® DI pipes ........................................................ 41

6.2.11 Polyethylene sleeving ............................................................................................................................... 41

6.2.12 Contact with drinking water ....................................................................................................................... 42

6.2.12.1 EPDM Elastomeric Seals ................................................................................................................... 42

6.2.12.2 Special Adaptor Elastomeric Seals .................................................................................................... 42

6.2.12.3 Jointing Lubricant ............................................................................................................................... 42

6.2.12.4 Internal coating of ECOFIT DI fittings ................................................................................................. 42

6.2.13 Flanged joints and flanged pipe ................................................................................................................ 42

6.2.14 Angular joint deflection of pipes and fittings .............................................................................................. 42

7 FITTING INSTRUCTIONS, TRAINING AND INSTALLATION ................................................................................. 43

7.1 Installation Instructions .................................................................................................................................. 43

7.2 Ductile iron fittings ......................................................................................................................................... 43

7.3 Tapped connections....................................................................................................................................... 43

8 MAINTENANCE ....................................................................................................................................................... 43

9 PIPE LAYING TRAINING AND DEVELOPMENT OF TECHNICAL LITERATURE .................................................. 43

10 PRODUCT MARKING ........................................................................................................................................... 43

10.1 vonRoll DI pipes for water supply and sewerage ............................................................................................. 43

10.2 ECOFIT DI fittings ........................................................................................................................................... 45

10.3 Polyethylene sleeving ...................................................................................................................................... 46

10.4 Elastomeric joint seals ..................................................................................................................................... 46

10.4.1 Elastomeric seals – supplied by WOCO for use on vonRoll DI pipe and ECOFIT DI fittings .................... 46

10.4.2 Special Transition Elastomeric seals – for use on vonRoll DI pipe and AS/NZS 2280 manufactured socketed fittings ..................................................................................................................................................... 46

11 TRACEABILITY ..................................................................................................................................................... 47

12 PACKAGING AND TRANSPORTATION ............................................................................................................... 47

13 PRODUCT WARRANTY ........................................................................................................................................ 48

14 WATER AGENCY EXPERIENCE WITH THE PRODUCT OR FIELD TESTING REPORT ................................... 48

14.1 Long Term ....................................................................................................................................................... 48

14.2 Short Term ...................................................................................................................................................... 49

15 AVAILABILITY OF PRODUCTS ............................................................................................................................ 49

16 REPAIRS TO POLYURETHANE COATING .......................................................................................................... 49


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17 DISCUSSION ......................................................................................................................................................... 49

18 OUTCOMES OF EXPERT PANEL PRODUCT REVIEW....................................................................................... 50

19 LIFE EXPECTANCY .............................................................................................................................................. 50

20 FUTURE WORKS .................................................................................................................................................. 51

21 DISCLAIMER ......................................................................................................................................................... 51

21.1 Issue of Report ................................................................................................................................................ 51

21.2 Limits on Reliance on Information and Recommendations.............................................................................. 51

21.2.1 Disclaimer of liability ................................................................................................................................. 51

21.2.2 Intellectual Property and other rights .......................................................................................................... 52

21.2.3 Need for independent assessment ........................................................................................................... 52

21.2.4 No Updating ................................................................................................................................................. 52

21.2.5 No Warranty ................................................................................................................................................. 52

APPENDIX A – GERMAN ACCREDITATION SYSTEM ............................................................................................... 53

APPENDIX B – QUALITY CERTIFICATIONS .............................................................................................................. 54

APPENDIX C – VONROLL DI PIPE ‘C’ CLASS AND ‘K’ CLASS ................................................................................. 58

APPENDIX D – UNRESTRAINED AND RESTRAINED JOINTS FOR VONROLL DI PIPES AND ECOFIT DI FITTINGS ....................................................................................................................................................... 59

APPENDIX E - WSAA PRODUCT SPECIFICATION .................................................................................................... 60

APPENDIX F - SUPPLIER CONTACTS ....................................................................................................................... 63

APPENDIX G – MPA NRW AUDIT OUTCOME AT VONROLL’S MANUFACTURING PLANT .................................... 64

APPENDIX H – SITE PHOTOGRAPHS ....................................................................................................................... 65


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1 EXECUTIVE SUMMARY

This Issue 2 is to address a previous outstanding work item and to update QA certification.

The supplier of TYTON gaskets is now WOCO, Germany. Details have been amended

accordingly.

Reece Australia Ltd (Reece) has been appointed as the Australian Agent and Distributor for

a range of vonRoll hydro ductile iron pipes and fittings, for use in water supply (drinking and

recycled) and sewerage (gravity and pressure) applications.

vonRoll hydro (Suisse) ltd is one of a number of independent business units of the vonRoll

Infratec Group. The vonRoll Group is primarily based in Switzerland with offices and

agencies in Europe, America, Asia and the Middle East. The vonRoll name has been

associated with the manufacturing industry in Switzerland and Europe for approximately 190

years.

The vonRoll hydro DUCPUR®, ECOPUR® and GEOPUR® range of ductile iron pipes and

ECOFIT ductile iron fittings are manufactured to EN 545:2010 and EN 598:2007 respectively

and also meet the requirements of ISO 2531:2009. Pipe outside diameters conform to ISO

dimensions and compatible fittings also incorporate flanges to ISO dimensions.

The DUCPUR®, ECOPUR® and GEOPUR® ductile iron pipes are manufactured using modern

fully automated centrifugal casting equipment at vonRoll in Choindez, Switzerland. The

vonRoll manufacturing facility at Choindez has an accredited Quality Management System

to ISO 9001 and DUCPUR®, ECOPUR® and GEOPUR® ductile iron pipes are included on the

product certification licences issued by MPA NRW for EN 545 and EN 598.

vonRoll hydro (Suisse) ltd holds ISO 9001:2008 certification for the manufacturer, system

vendor and provider of products and services for water and gas utilities, including piping and

fittings as well as manhole covers and drains for the road construction industry. The ISO

9001 Certificate of Registration No. 20430 was issued by Swiss Association for Quality and

Management System (SQS).

The manufacturing facility at Choindez produces up to 25,000 tons of ductile cast iron pipes

a year in diameters of DN 80 to DN 700 with a length of 6 metres.

DN 80 to DN 700 pipes are available in pressure classes PN 25 to PN 100 depending on the

DN. The standard thickness class is K9 for DN 80 up to DN 700. The comparison of ‘wall

thickness class K’ and ‘pressure class C’ is detailed in Appendix C.

Scope of appraisal also includes flanged pipe offered by vonRoll hydro as detailed in

Appendix A (Refer to A1).

A compatible range of ductile iron fittings is available in sizes DN 80 to DN 700 with various

combinations of socket and flange ends. Flanges comply with EN1092-2 PN 10, PN 16, PN

25, PN 40, PN 63 or PN 100. The available range of fittings is detailed in Appendix A (Refer

to A2).

The vonRoll range of DUCPUR® and ECOPUR® ductile iron pipes are suitable for the

transport of drinking water, soft and aggressive water as well as media with pH values

between 1 and 14. The vonRoll range of GEOPUR® ductile iron pipes is suitable for the

transport of sewage or aggressive waters with pH values of 1 to 14.

The vonRoll ductile iron pipes are available in nominal diameters from DN 80 to DN 700 and

manufactured as:

• DUCPUR® pipes with either spigot and socket flexible joints or screwed on flanges and

coated externally with zinc rich paint coating having a minimum mass of 220 g/m², and a

finishing layer of black colored bituminous paint and internally lined with polyurethane

(PUR).

• ECOPUR® pipes with either spigot and socket flexible joints or screwed on flanges and

supplied with internally lined and externally coated with polyurethane (PUR).


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• GEOPUR® pipes with spigot and socket flexible joints and supplied with polyurethane

(PUR) internal lining, outer side zinc rich paint coating having a minimum mass of 150

g/m², and a finishing layer of red brown colored bituminous paint

The pipe sizes ≤ DN 500 have a double chamber socket. The double chamber socket has

two grooves; one for the insertion of the TYTON® elastomeric seal which enables a flexible

joint and the other for a thrust resisting ring (if required).

The pipe sizes > DN 500 (i.e. DN 600 and DN 700) have a single chamber socket, supplied

with a TYTON® seal.

The vonRoll ECOFIT fittings are manufactured by Keulahütte GmbH in Krauschwitz,

Germany and are coated internally and externally with a thick film of Resicoat R4 Fusion

Bonded Epoxy to EN 14901 and GSK (Gemeinschaft für Schweren Korrosionsschutz)

standards in a powder coating plant.

Keulahütte GmbH manufacturing facility in Krauschwitz Germany has an accredited Quality

Management System to ISO 9001:2008 for the development, manufacture and sales of

fittings, hydrants, valves and castings for mechanical engineering and vehicle construction .

The ISO 9001 Certificate of Registration was issued by TÜV Reheinland Cert GmbH in

Germany.

The ECOFIT ductile iron fittings for water supply (drinking and recycled) and sewerage

(gravity and pressure) applications are included in the Product Certification Licence DV-

issued by DVGW CERT – DakkS Germany in compliance with EN 545 and EN 598.

Reece intends to supply AS/NZS 2280 DI socketed fittings, with special EPDM TYTON®

transition elastomeric seals, with delivery of DUCPUR®, ECOPUR® and GEOPUR® DI pipes

in sizes DN 100 to 300. Gulf Rubber supplies the special transition elastomeric seals to AS

1646.

AS/NZS 2280 allows fittings to be used with pressure pipe of alternative outside diameter by

the adoption of a compatible socket or utilisation of a transition elastomeric seals, provided

the joint meets the performance requirements of this Standard.

Tests have been carried out on the vonRoll hydro ductile iron pipe and Derwent Industries

DI socketed fittings (PA 1003 Issue 2) manufactured to AS/NZS 2280, using a transition

elastomeric seal to demonstrate compliance with the performance tests in AS/NZS 2280.

Such tests include pressure tests, vacuum tests and tests with deflection and applied shear

loading. According to the results of the performance testing the Allowable Operating

pressure (AOP) for the different diameter DN and transition elastomeric seal are as follows:

a) DN 100 - 250 Gulf Rubber TYTON® transition elastomeric seal with TYTON joint and

vonRoll hydro ductile iron pipe is 1600 kPa.

b) DN 300 Gulf Rubber TYTON® transition elastomeric seal with TYTON joint and


The product range as described by this appraisal report meets the requirements of

a) WSA PS-202- Ductile Iron Pipes and Fittings (ISO Sized) for Pressure Applications -

Water Supply.

b) WSA PS-202S - Ductile Iron Pipes and Fittings (ISO Sized) for Pressure and Non-

Pressure Applications – Sewerage.

1.1 Recommendation

It is recommended that WSAA members and associates, subject to any specific requirements

of the member or associate, accept or authorise the

(a) vonRoll ECOPUR®, DUCPUR® and GEOPUR® range of ductile iron pipes and

associated ECOFIT ductile iron fittings


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(b) vonRoll ECOPUR®, DUCPUR® and GEOPUR® range of ductile iron pipes, specified

AS/NZS 2280 complaint ductile iron socketed fittings, with special EPDM TYTON®

transition elastomeric seals.

as detailed in this report for use in the water supply (drinking and recycled) and sewerage

(gravity and pressure) applications provided design, installation, acceptance testing and

commissioning are in accordance with applicable WSAA Codes and the manufacturer’s

requirements, where specified.

2 THE DISTRIBUTOR AND MANUFACTURERS

2.1 The Distributor

Reece Australia Ltd (Reece) has been appointed as the Australian Agent and Distributor for

a range of vonRoll ductile iron pipes and fittings, for use in water supply (drinking and

recycled water) and sewerage (gravity and pressure) applications.

The above range of products was originally distributed by Wang Industries, before they were

acquired by Tyco Water in 2001. Tyco Water continued to import and distribute the vonRoll

ductile iron products between 2001 and 2008. From 2008 to 2014, Promains Pty Ltd was

importing, distributing and providing a full range of support services for the vonRoll

DUCPUR® and ECOPUR® ductile iron pipes for the Australian urban water industry.

Since February 2014, Reece has been acting as the exclusive distributor of vonRoll DI pipes

and fittings in Australia.

2.2 The Ductile Iron Pipe Manufacturer

vonRoll hydro (Suisse) ltd is one of a number of independent business units of the vonRoll

Infratec Group. The vonRoll Group is primarily based in Switzerland with offices and

agencies in Europe, America, Asia and the Middle East. The vonRoll name has been

associated with the manufacturing industry in Switzerland and Europe for approximately 190

years.

vonRoll hydro is the first Swiss supplier of products and services for water and gas supply.

vonRoll hydro deliver ductile cast iron pipes and valves systems, hydrants, road manhole

covers and systems for the water leak detection and water quality supervision.

The vonRoll ductile cast-iron pipe is manufactured at the Choindez facility in Switzerland

using fully automated centrifugal casting equipment. The manufacturing facility at Choindez

produces up to 25,000 tons of ductile cast iron pipes a year in diameters of DN 80 to DN 700

with a length of 6 metres. The ductile iron fittings are manufactured in Germany and are

coated with a thick film of epoxy resin to GSK (Gemeinschaft für Schweren

Korrosionsschutz) standards in a powder-coating plant.

vonRoll hydro has another manufacturing facility in Oensingen, Switzerland where up to

31,000 valves and 6000 hydrants are produced every year. The fittings are coated with a

thick film of epoxy resin to GSK (Gemeinschaft für Schweren Korrosionsschutz) standards

in a powder coating plant.

2.3 The Ductile Iron Fitting Manufacturer

2.3.1 ECOFIT ductile iron fittings

The ECOFIT ductile iron fittings are produced by Keulahütte in Krauschwitz, Germany.

Keulahütte is an iron foundry with production facilities for mechanical and hand-moulded

castings in the mass spectrum of 5 kg to 4500 kg. Much of the annual ductile and grey iron

production is used to run the integrated machining and epoxy powder coating process as

hydrants, valves and pressure pipe fittings. High quality industrial castings according to

customer specifications and architectural castings complete the production program.

For more information look at Keulahütte GmbH website as below:


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http://www.keulahuettekrauschwitz.de/en/

2.3.2 Derwent Industries ductile iron fittings

Reece intends to supply Derwent Industries AS/NZS 2280 DI socketed fittings, with special

EPDM TYTON® transition elastomeric seals, with DUCPUR®, ECOPUR® and GEOPUR® DI

pipes in sizes DN 100 to 300.

WSAA has successfully appraised the Derwent Industries range of DI fitting to AS/NZS 2280,

under WSAA Product Appraisal No 1003 Issue 2.

Additional testing has been performed by vonRoll hydro (suisse) Ltd to demonstrate that

Derwent Industries supplied DI socketed fittings with Gulf Rubber special EPDM TYTON®

transition elastomeric seals meet the performance requirements of AS/NZS 2280 when used

DUCPUR®, ECOPUR® and GEOPUR® DI pipes in sizes DN 100 to 300. Refer to Clause

6.2.7.2

3 THE PRODUCT

This appraisal applies to the vonRoll range of cast ductile iron pipes and ECOFIT ductile iron

fittings.

The vonRoll DUCPUR®, ECOPUR® and GEOPUR® range of centrifugally cast ductile iron

pipes produced in a manufacturing facility owned by vonRoll in Choindez, Switzerland.

FIGURE 1: VONROLL ECOPUR®, DUCPUR® AND GEOPUR® DUCTILE IRON PIPE

Among the three types of connection system shown in Figure 2, this appraisal applies only

for the following two types:

Push-in socket joint

Flange joint.

FIGURE 2: CONNECTION TYPES IN THE VONROLL DI PIPE SYSTEM

vonRoll range of valves and hydrants that are produced in a manufacturing facility owned by

vonRoll in Oensingen, Switzerland are not included in this appraisal.

The vonRoll DUCPUR®, ECOPUR® and GEOPUR® range of ductile iron pipes and ECOFIT

DI fittings are manufactured to:

http://www.keulahuettekrauschwitz.de/en/


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EN 545 Ductile iron pipes, fittings, accessories and their joints for water pipelines -

Requirements and test methods;

EN 598 Ductile iron pipes, fittings, accessories and their joints for sewerage applications

- Requirements and test methods; and

ISO 2531 Ductile iron pipes, fittings, accessories and their joints for water applications.

The product range submitted for appraisal consists of ductile iron pipe with ISO outside

diameters in sizes DN 80 to DN 700, with spigot and socket pipes as detailed in Tables 1 to

3, and flanged pipes in sizes DN 80 to DN 600 as detailed in Appendix A (vonRoll catalogue

pages from 4/1.1 to 4/1.12).

ECOFIT DI fittings include configurations with socket and/or flanged ends. Product Data

Sheets are provided in Appendix A (vonRoll catalogue pages from 2/3.1 to 2/7.3).

DUCPUR® and GEOPUR® ductile iron pipes are internally lined with polyurethane (PUR) and

coated externally with at least 220 g/m2 for DUCPUR® and at least 150 g/m2 for GEOPUR®

of zinc rich paint and a finishing layer of bituminous paint, at least 70 μm thick, applied in

accordance with ISO 8179. The socket is coated with bitumen for DUCPUR® and

polyurethane for GEOPUR®.

ECOPUR® ductile iron pipes are internally lined and externally coated with a Polyurethane

(PUR) coating. The polyurethane lining and coating are applied to all surfaces of the pipe

including the sockets to provide corrosion protection to the entire pipe. Refer to Table 4.

ECOPUR® and DUCPUR® ductile iron pipe and fittings are suitable for drinking water,

recycled water supply applications.

The GEOPUR® ductile iron pipes and fittings are suitable for most aggressive non-drinking

water supply and sewerage applications with pH values of 1 to 14.

For identification purposes GEOPUR® ductile iron pipes are supplied with a red brown

bituminous paint. A finishing layer of black bituminous paint is applied to the DUCPUR®

ductile iron pipes.

DUCPUR® and GEOPUR® ductile iron pipes may also be sleeved with blue, lilac or cream

polyethylene sleeve during installation of mains for potable water, recycled water and

pressure sewer applications respectively.

The new standard EN 545:2010 does not specify anymore the wall thickness “class K” but

the “pressure class C”.

ECOPUR®, DUCPUR® and GEOPUR® ductile iron pipes are available in C100 (PN 100), C64

(PN 64), C50 (PN 50), C40 (PN 40), C30 (PN 30), C25 (PN 25) pressure classes, depending

on size.

vonRoll hydro still produces K9 DI pipes as standard for size DN 80 up to DN 700.

In EN 545:2006 (previous standard) and ISO 2531:2009 Class “K9” is the standard

classification for water supply pipelines. Class “K12” has a thicker wall and is specified for

flanged (screwed) pipe or where additional structure strength is required.

The new standard EN 545:2010 does not specify pressure class for the vonRoll DI fittings.

Only the minimum wall thickness is mentioned which relates to the wall thickness class K12

for all fittings; i.e. socketed and flanged.

Standardised lengths of DI pipe are permitted in EN 545 / EN 598 and are a function of pipe

size and joint type. Reece are offering to supply standard DI pipe lengths of 6 m length for

spigot / socket pipes and maximum 5.9 m length for flanged pipes.

Reece only intend to import a small quantity of the Class K12 pipe (PN 16 rated) for

manufacture of flanged pipe (screwed on and bonded).


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FIGURE 3: DUCPUR® PRESSURE PIPE WITH PUSH-IN JOINT– FIGURES 2817 and

2815

TABLE 1: DUCPUR® PRESSURE PIPE WITH PUSH-IN JOINT - FIGURE 3

Nominal Dia DN (mm)

Pipe Class

Pressure Class

PN (bar)

Allowable Operating Pressure

MPa

Length (m)

DE Outside Dia (mm)

eG ePUR 1 DM T Weight Kg/m

801,2 C100 100 10 6.0 98 6 1.3 167 119 14.2

1001,2 C100 100 10 6.0 118 6 1.3 188 120 17.1

1251,2 C64 64 6.4 6.0 144 6 1.3 215 123 21.1

1501,2 C64 64 6.4 6.0 170 6 1.3 242 126 25.2

2001,2 C64 64 6.4 6.0 222 6.3 1.5 295 131 33.3

2501,2 C50 50 5.0 6.0 274 6.8 1.5 352 131 46.3

3001,2 C50 50 5.0 6.0 326 7.2 1.5 410 130 58.3

3501,2 C40 40 4.0 6.0 378 7.7 1.5 464 110 71.9

4001,2 C40 40 4.0 6.0 429 8.1 1.5 518 115 86.1

5001,2 K9 / C30 30 3.0 6.0 532 9 1.5 636 115 118.6

6003 K9 / C30 30 3 6.0 635 9.9 1.5 750 120 156.1

7003 K9 / C30 30 3 6.0 738 1.08 1.5 863 150 198.9

NOTES:

NOTE 1: DN 80 up to DN 500 with double-chamber; refer Figure 3 – figure 2817 NOTE 2: The double-chamber pipe can be fitted with internal thrust-resisting ring or external thrust-resisting ring. NOTE 3: DN 600 and DN 700 with single-chamber refer Figure 3 – figure 2815

FIGURE 4: ECOPUR® PRESSURE PIPE WITH PUSH-IN JOINT– FIGURES 2817 and

2815


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TABLE 2: ECOPUR® PRESSURE PIPE WITH PUSH-IN JOINT - FIGURE 4

Nominal Dia DN (mm)

Pipe Class

Pressure Class

PN (bar)

Allowable Operating Pressure

MPa

Length (m)

DE Outside Dia (mm)

eG ePUR 1 ePUR 2 DM T Weight Kg/m

801,2 C100 100 10 6.0 98 6 1.3 0.9 167 119 14.6

1001,2 C100 100 10 6.0 118 6 1.3 0.9 188 120 17.6

1251,2 C64 64 6.4 6.0 144 6 1.3 0.9 215 123 21.7

1501,2 C64 64 6.4 6.0 170 6 1.3 0.9 242 126 25.9

2001,2 C64 64 6.4 6.0 222 6.3 1.5 0.9 295 131 34.3

2501,2 C50 50 5.0 6.0 274 6.8 1.5 0.9 352 131 47.4

3001,2 C50 50 5.0 6.0 326 7.2 1.5 0.9 410 130 60.5

3501,2 C40 40 4.0 6.0 378 7.7 1.5 0.9 464 135 73.4

4001,2 C40 40 4.0 6.0 429 8.1 1.5 0.9 518 145 87.9

5001,2 K9 / C30 30 3.0 6.0 532 9 1.5 0.9 636 145 120.7

6003 K9 / C30 30 3 6.0 635 9.9 1.5 0.9 750 120 152.0

7003 K9 / C30 30 3 6.0 738 1.08 1.5 0.9 863 150 194.0

NOTES:

NOTE 1: DN 80 up to DN 500 with double-chamber refer Figure 4 – figure 2817 NOTE 2: The double-chamber pipe can be fitted with internal thrust-resisting ring or external thrust-resisting ring. NOTE 3: DN 600 and DN 700 with single-chamber refer Figure 4 – figure 2815

FIGURE 5: GEOPUR® PRESSURE PIPE WITH PUSH-IN JOINT– FIGURES 1817 and

1815

DN 100-500


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TABLE 3: GEOPUR® PRESSURE PIPE WITH PUSH-IN JONT – FIGURE 5

Nominal

Dia DN (mm)

Length

(m)

DE

Outside Dia (mm) eG ePUR 1 DM T

Weight Kg/m

Item No.

1001,2 6.0 118 4.8 1.3 188 120 14.2 260800

1251,2 6.0 144 4.8 1.3 215 123 17.5 260801

1501,2 6.0 170 4.8 1.3 242 126 20.9 260802

2001,2 6.0 222 4.9 1.5 295 131 27.8 260803

2501,2 6.0 274 5.3 1.5 352 131 37.6 260804

3001,2 6.0 326 5.6 1.5 410 130 47.2 260805

3501,2 6.0 378 6.0 1.5 464 135 58.1 260806

4001,2 6.0 429 6.3 1.5 518 145 69.5 260807

5001,2 6.0 532 7.0 1.5 630 145 95.7 260808

6003 6.0 635 7.7 1.5 750 120 125.9 260809

7003 6.0 738 9.6 1.5 863 150 179.6 260810

NOTES:

NOTE 1: DN 100 up to DN 500 with double-chamber, Refer to Figure 5, figure 1817.

NOTE 2: The double-chamber pipe can be fitted with internal thrust-resisting ring or external thrust-resisting ring.

NOTE 3: DN 600 and DN 700 with single-chamber, Refer to Figure 5, figure 1815.

3.1 Polyurethane Internal Lining and External Coating

3.1.1 Polyurethane Internal Lining

The vonRoll DUCPUR®, ECOPUR® and GEOPUR® range of ductile iron pipes are internally

lined with polyurethane in accordance with EN 15655. The thickness of the polyurethane is

shown in Table 4.

TABLE 4: POLYURETHANE LINING THICKNESS

DN (mm) Thickness (mm)

Mean Value Minimum Value

80 - 150 1.3 0.8

200 - 700 1.5 0.8

3.1.2 Polyurethane External Coating

The vonRoll ECOPUR® range of ductile iron pipes are externally protected with polyurethane

in accordance with EN 15189. The thickness of the polyurethane is a nominal 900 micron

with a minimum of 700 microns. The entire barrel including the spigot end is coated with

polyurethane.

The internal surface of the socket end is lined with polyurethane. The mean thickness is 150

microns and the minimum thickness is 100 microns.

3.2 Types of Joints and interconnection

vonRoll DI pipe sizes ≤ DN 500 have a double chamber socket. The double chamber socket

has two grooves; one for the insertion of the HYDROTIGHT seal which enables a flexible

joint and the other for an internal thrust-resisting ring (if required).

vonRoll DI pipe sizes > DN 500 (DN 600 and DN 700) have a single chamber socket, supplied

with a HYDROTIGHT seal, but without thrust-resisting ring.

The ‘Push-in socket joint’ includes the following jointing system:


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a) Pipe with double chamber socket (DN 80–500) unrestrained HYDROTIGHT seal

{TYTON® elastomeric seal manufactured from EPDM (water) Figure 2810 or NBR

(sewerage) Figure 2811. Refer to Figure 6.

b) Pipe with single chamber socket (DN 600 and 700) unrestrained HYDROTIGHT seal

{TYTON® elastomeric seal, manufactured from EPDM (water) Figure 2810 or NBR

(sewerage) Figure 2811. Refer to Figure 7.

c) Pipe with double chamber socket (DN 80–500) unrestrained HYDROTIGHT seal

{TYTON® elastomeric seal manufactured from EPDM (water) Figure 2810 or NBR

(sewerage) Figure 2811 with an additional:

i) HYDROTIGHT internal thrust-resisting ring Figure 2807B1 for DN 80 to DN 300.

Refer to Figures 8 & 9 or

ii) HYDROTIGHT internal thrust-resisting ring Figure 2807A2 for DN 80 to DN 500.

Refer to Figures 8 & 9 or

iii) External restrained joint Figure 2806 for DN 80 - 500. Refer to Figures 10 & 11

d) Pipe with double chamber socket (DN 80–500) fitted with Internal restrained joint

combined gasket with steel teeth TYTON®-SIT® Figure 2504 (DN 80 - 400) or TYTON®

SIT PLUS® Figure 2504-S (DN 80 – 500) exist. Refer to Figure 12.

NOTE: There is no unrestrained HYDROTIGHT TYTON® elastomeric seal (Fig. 2810 or 2811)

e) Pipe with single chamber socket (DN 600 and 700) fitted with:

i) External restrained joint Fig. 2805, DN 600 - 700 with welded bead as shown in

Figure 13; or

ii) Internal restrained joint combined gasket with steel teeth TYTON® SIT PLUS®

Figure 2504-S, DN 600 as shown in Figure 14.

For permissible pressure for the different thrust-resisting rings (both internal and external)

refer to Table 5.

Refer to Appendix D for unrestrained and restrained joints for vonRoll DI pipes of size range

DN 80 to DN 700.

Figure 6 shows an unrestrained joint for pipe with double chamber DN 80 – 500.

1 Hydrotight thrust-resisting ring (internal) for double chamber DN 80-300 (DN 80-200 is 25 bar; DN 250-300 is 16 bar), standard Fig. 2807B 2 Hydrotight thrust-resisting ring (internal) for double chamber DN 80-500 (for higher pressure: DN 80-200 is 40 bar; DN 250-300 is 25 bar), and pipes with DN 350-500 (16 bar). Fig. 2807A


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FIGURE 6: DOUBLE CHAMBER PIPE DN 80 – 500 WITH UNRESTRAINED JOINT

Figure 7 shows an unrestrained joint for single chamber DI fittings DN 80 – 700 and pipe

with double chamber DN 600 – 700.

FIGURE 7: SINGLE CHAMBER ECOFIT DI FITTING DN 80 – 700 AND SINGLE CHAMBER PIPE DN 600 – 700 WITH UNRESTRAINED JOINT

NOTE: “Unrestrained automatic joint” is the name for the completed assembly; “HYDROTIGHT TYTON®

elastomeric seal” is one element of the automatic joint.


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Figure 8 shows an internal restrained joint with double chambers for DN 80 to 500.

FIGURE 8: FIG 2807 - DOUBLE CHAMBER PIPE FITTED WITH INTERNAL RESTRAINED JOINT SYSTEMS - HYDROTIGHT THRUST RESISTING RING SHOWN

Figure 9 shows a cutaway section of an internal restrained joint for pipes with double

chamber of size DN 80 to 500.

FIGURE 9: FIG 2807 - CUTAWAY SECTION OF INTERNAL RESTRAINED JOINT WITH

DOUBLE CHAMBERS FOR DN 80 TO 500

The Rubberring with steel teeth (Fig. 2807A and Fig. 2807B) is a vonRoll product, which is

manufactured and supplied by Rex Articoli in Switzerland. Their function is only to restrain,

not provide leak tightness.

The Rubberring with steel teeth (Fig. 2807A and Fig. 2807B) is different to TYTON®-SIT®

and TYTON® SIT PLUS®, which have both functions in one ring, i.e. leak tightness and

restraint.

The Rubberring with steel teeth (Fig. 2807A or 2807B) internal restrained joint cannot be

used by the ECOFIT DI fittings supplied by Keulahütte as they have only a single chamber.

The groove of the single chamber is used for unrestrained HYDROTIGHT seal TYTON®

EPDM (water) Fig. 2810 NBR (sewer) Fig. 2811.

The single chamber ECOFIT DI fittings will be restrained in three ways (one internally and

two externally) as detailed in Section 3.4.2.

Rubberring with steel teeth Fig. 2807B or Fig. 2807A

HYROTIGHT seal TYTON EPDM (water) Fig. 2810 or NBR (sewer) Fig. 2811


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Figure 10 shows the exploded view of the combined internal and external restrained joint

system without welded bead (Fig. 2806) with double chambers for DN 80 to DN 500.

FIGURE 10: FIG 2806 - DOUBLE CHAMBER PIPE FITTED WITH INTERNAL AND EXTERNAL RESTRAINED JOINT SYSTEMS

Figure 11 shows the Cutaway section of a combined internal and external restrained joint

system without welded bead (Fig. 2806) with double chambers for DN 80 to DN 500.

The rubberring with steel teeth (without welded bead) belongs to the complete external

restrained joint Fig. 2806 which comprises the following:

Ductile Iron gland (Fig. 2806-1) – manufactured and supplied by Keulahütte, Germany;

The rubberring with steel teeth (Fig. 2806-2) – manufactured and supplied by Rex Articoli,

Switzerland; and

M20 Bolts and nuts galvanized or stainless steel 316 (Fig. 2806-3) – purchased by

vonRoll from third party

The whole external restraint joint (Fig. 2806) has a Product Certification in compliance with

EN 545. Individual EN 545 certificate for each component of the restraint assembly,

separately is not feasible, because only the function of the whole external restraint joint can

be tested as per the Standard.

FIGURE 11: CUTAWAY SECTION OF A COMBINED INTERNAL AND EXTERNAL RESTRAINED JOINT SYSTEM WITHOUT WELDED BEAD WITH DOUBLE CHAMBERS FOR

DN 80 TO DN 500

Bolts and nuts M20 Fig. 2806-3

Rubberring with steel Teeth Fig. 2806-2

Ductile iron gland Fig.2806-1

HYROTIGHT seal TYTON® EPDM (water) Fig. 2810 or NBR (sewer) Fig. 2811


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Figure 12 shows Internal Restrained Joint combined gasket with steel teeth TYTON®-SIT®

Figure 2504 (DN 80 - 400) or TYTON® SIT PLUS® Figure 2504S (DN 80 - 600).

FIGURE 12: RUBBERRING RESTRAINT TYTON® SIT® FIG. 2504 (DN 80-400) OR TYTON® SIT PLUS® FIG. 2504S (DN 80-500) FOR DOUBLE CHAMBER PIPES FIG. 2817

Figure 13 (Fig. 2805) external restrained joint with WELDED BEAD (DN 600-700) comprises

of the following:

a) DI gland (Fig. 2805-1) is made of ductile iron according to EN 545 - supplier is vonRoll

(produced in the foundry of the vonRoll group);

b) DI lock ring (Fig. 2805-2) is made of ductile iron according to EN 545 - supplier is vonRoll

(produced in the foundry of the vonRoll group);

c) M27 Bolts and Nuts (galvanised or stainless steel 316) are supplied by the same factory

as for the M20 bolts and nuts of Fig. 2806; and

d) Welded bead: The bead will be welded on the spigot end of the DI pipe after the

centrifugation and annealing. The material used is a special electrode of Fe/Ni for ductile

iron. The bead has the function to avoid the slipping of the lock ring.


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FIGURE 13: EXTERNAL RESTRAINED JOINT FIG. 2805 DN 600 - 700 WITH WELDED BEAD

Figure 14 shows internal restrained joint combined gasket with steel teeth TYTON®-SIT

PLUS® Fig. 2504-S DN 600.

FIGURE 14: RUBBERRING RESTRAINT TYTON® SIT PLUS® FIG. 2504S FOR SINGLE CHAMBER PIPES FIG. 2815 (DN 600)

Welded bead Ductile iron lock ring

Ductile iron gland

M27 Bolts and nuts

HYROTIGHT seal TYTON® EPDM (water) Fig. 2810 or NBR (sewer) Fig. 2811


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3.3 Elastomeric and Thrust-Resisting Joint Sealing Rings

The vonRoll hydro DUCPUR®, ECOPUR® and GEOPUR® range of DI pipes are supplied with

various accessories such as elastomeric seals, rubberring with steel teeth, thrust-resisting

rings, DI components and nuts and bolts to form unrestrained or restrained joints.

3.3.1. Unrestrained Joint

a) Double Chamber DN 80-500 - HYDROTIGHT standard elastomeric seal {TYTON® EPDM

(water) Fig. 2810 or NBR (sewerage) Fig. 2811} – supplied by WOCO.

b) Single Chamber DN 600-700 - HYDROTIGHT standard elastomeric seal {TYTON® EPDM

(water) Fig. 2810 or NBR (sewerage) Fig. 2811} – supplied by WOCO.

3.3.2 Restrained Joint

Pipe with double chamber socket (DN 80-500) fitted with unrestrained HYDROTIGHT seal

as mentioned in Item 3.3.1.1(a) above, with an additional:

a) Hydrotight internal thrust-resisting rings Fig. 2807B (DN 80-300) and Figure 2807A (DN

80-500) – vonRoll products supplied by Rex Articoli (Swiss)

b) Internal restrained joint combined gasket with steel teeth TYTON®-SIT® Fig. 2504 (DN

80-400) or TYTON®-SIT PLUS® Fig. 2504-S (DN 80-600) – supplied by WOCO.

c) HYDROTIGHT external thrust-resisting ring without a welded bead Figure 2806 (DN 80-

500) – suppliers are:

i) Rubberring with steel teeth – vonRoll product supplied by Rex Articoli (Swiss)

ii) DI gland – Keulahütte (Germany)

iii) M20 bolts & nuts galvanised / Stainless Steel 316 - purchased by vonRoll hydro

from third party

Pipe with single chamber socket (DN 600-700) fitted with:

a) Internal restrained joint combined gasket with steel teeth TYTON®-SIT PLUS® Fig. 2504-

S (DN 600) – supplied by WOCO

b) Unrestrained HYDROTIGHT standard elastomeric sea as mentioned in Item 3.3.1(b)

above, with an additional HYDROTIGHT external thrust-resisting ring with welded bead

Figure 2805 (DN 600-700) – suppliers:

i) unrestrained HYDROTIGHT seal TYTON® – WOCO

ii) DI gland & DI locking ring – Keulahütte (Germany)

iii) M27 nuts & bolts – purchased by vonRoll hydro from third party

vonRoll hydro has submitted copies of type tests and audit reports recognised by MPA NRW

to demonstrate that the elastomeric and thrust-resisting joint sealing rings used with vonRoll

DI pipes and ECOFIT DI fittings comply with the performance requirements specified in EN

545 and EN 598.

The above documents have been sighted by WSAA and saved in the folder.


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TABLE 5: PERMISSIBLE PRESSURES FOR THRUST RESISTING RINGS

DN Pressure class (C)

Allowable working pressure PFA (bar)

Internal restrained External restrained External restrained

Fig. 2807 A / B1 TYTON-SIT / TYTON-SIT PLUS Fig. 2806 Fig. 2805

80 K9 / C100 40 / 25 10 / 16 40

100 K9 / C100 40 / 25 10 / 16 40

125 K9 / C64 40 / 25 10 / 16 40

150 K9 / C64 40 / 25 10 / 16 40

200 K9 / C50 40 / 25 10 / 16 16/402

250 K9 / C50 25 / 16 10 / 16 16/402

300 K9 / C40 25 / 16 10 / 16 16/402

350 K9 / C40 16 10 / 16 16/252

400 K9 / C40 16 10 / 16 25

500 K9 / C30 16 - / 10 16

600 K9 / C30 - - / 10 - 25

700 K9 / C30 - - - 25

NOTE 1: Internal restrained joint with all teeth execution Fig. 2807 A or the half of the teeth execution Fig. 2807 B

NOTE 2: PFA with all bolts and nuts

3.4 vonRoll ISO sized ECOFIT DI fittings

FIGURE 15: VONROLL ECOFIT DI FITTINGS (BLACK OR BLUE - WATER SUPPLY;

RED BROWN OR BLACK - SEWERAGE)

Ductile iron fittings are sand cast in accordance with ISO 2531 and with EN 545 / EN 598.

All the fittings are in the class K12 and the thickness of the fittings is in accordance with the

European Standard EN 545 / 598. The fittings are subjected to a leak-tightness test carried

out with water in accordance with ISO 2531 and with EN 545 / EN 598.

The DI fittings are provided with an integral Resicoat R4 epoxy powder coating (internal and

external) at least 250 μm thick according to EN 14901 and GSK, perfectly suited to all types

of soil. GSK is a trade association (Gütezeichen) that has been registered in Germany for

over 20 years which acts as the global network for companies that coat valves and fittings

with an epoxy powder coating. For more information refer to http://www.gsk-

online.de/en/gsk.html

The coating made from epoxy resin powder (black epoxy pulver coating) provides proven

and pore-free corrosion protection for fittings used in water and gas supplies and for

wastewater disposal. The extremely smooth and pore-free epoxy internal coating offers

comprehensive protection for drinking water and meets all legal requirements on hygiene in

full. It prevents deposits from building up and is abrasion resistant. The epoxy coating is an

organic protective coating and its use has minimal environmental impact.

http://www.gsk-online.de/en/gsk.html

http://www.gsk-online.de/en/gsk.html


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3.4.1 Types of Joints and Interconnections

ECOFIT DI pipe fittings of size range DN 80 to DN 700 have a single chamber socket with a

single groove. The DI fittings are supplied with unrestrained HYDROTIGHT TYTON®

elastomeric seal which enables a flexible joint or with an internal thrust-resisting ring to form

a restrained joint system.

The material used for elastomeric seal is EPDM for water (Fig. 2810) and NBR for sewer

(Fig. 2811) in accordance with the European Standard EN 681-1. The International Standard

ISO 2230 provides a guide to the most suitable conditions for the storage of vulcan ized

rubber.

The single chamber ‘Push-in socket’ includes the following jointing system:

a) Unrestrained - DI fittings with single chamber socket (DN 80 and 700) unrestrained

HYDROTIGHT seal {TYTON® elastomeric seal, manufactured from EPDM (water) Figure

2810 or NBR (sewerage) Figure 2811. Refer to Figure 7.

b) Restrained

i) Internal restrained joint combined gasket with steel teeth TYTON®-SIT® Fig. 2504

(DN 80-400) or TYTON®-Sit PLUS® Fig. 2504S (DN 80-600). Refer to Figure 16.

ii) External restrained joint without welded bead Fig. 2806 (DN 80 – 500). Refer to

Figure 17.

iii) External restrained joint Fig. 2805 (DN 600 – 700) with welded bead. Refer to Figure

18.

For permissible pressure for the different thrust-resisting rings (both internal and external)

refer to Table 5.

Refer to Appendix D for unrestrained and restrained joints for ECOFIT DI fittings of size

range DN 80 to DN 700.

3.4.2 Restrained Joints for DI Fitting

3.4.2.1 Internal Restrained Joint Single Chamber DN 80 – 700

Internal restrained joint combined gasket with steel teeth TYTON®-SIT® Fig. 2504 (DN 80-

400) or TYTON®-SIT PLUS® Fig. 2504S (DN 80-600)

FIGURE 16: RUBBERRING RESTRAINT TYTON® SIT® FIG. 2504 (DN 80-400) OR TYTON® SIT PLUS® FIG. 2504S (DN 80-600) FOR SINGLE CHAMBER DI FITTING

Rubbering restraint TYTON®-SIT Fig. 2504-1 or TYTON®-SIT PLUS® Fig. 2504S-1

Marking ring Fig. 2504-2 / Fig. 2504S-2


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3.4.2.2 External Restrained Joint Single Chamber DN 80 – 700

External restrained joint without welded bead Fig. 2806 (DN 80 – 500)

FIGURE 17: EXTERNAL RESTRAINED JOINT FIG. 2806 (DN 80-500) WITHOUT WELDED BEAD

External restrained joint Fig. 2805 (DN 600 – 700) with welded bead

FIGURE 18: EXTERNAL RESTRAINED JOINT FIG. 2805 (DN 600-700 WITH WELDED BEAD

Gasket TYTON® Fig. 2810 / Fig. 2811

Rubberring with steel teeth

Bolts and nuts M20

Ductile iron gland

Gasket TYTON® Fig. 2810 EPDM water and Fig. 2811 SBR sewer

Welded bead Ductile iron lock ring

Ductile iron gland

Bolts and nuts M27


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Refer to vonRoll technical brochure for details of thrust-resisting rings and other information

about vonRoll DI Pipes and Fittings at the following link:

http://www.vonroll-hydro.ch/en/pipes.html

3.5 DI Fittings ISO sized – Configurations, Size and Class

The vonRoll ECOFIT ductile iron fittings range DN 80 to DN 700 consists of variety of fittings

complying with the requirements of EN 545 (Water) and EN 598 (Sewer). All fittings are lined

and coated with fusion bonded epoxy (FBE) resin.

3.6 Elastomeric and Thrust-Resisting Joint Sealing Rings ISO sized

The ECOFIT range of DI fittings with single chamber of size DN 80-700, is supplied with the

following elastomeric and thrust-resisting joint sealing rings:

3.6.1 Unrestrained Joint

Fittings with single chamber of size DN 80-700 - HYDROTIGHT standard elastomeric seal

{TYTON® EPDM (water) Fig. 2810 or NBR (sewerage) Fig. 2811}

3.6.2 Restrained Joint

Fittings with single chamber of size DN 80-700 have one internal and two external restrained

joints as follows:

(a) Internal restrained joint combined gasket with steel teeth TYTON®-SIT® Fig. 2504 (DN

80-400) or TYTON®-SIT PLUS® Fig. 2504-S (DN 80-600)

(b) HYDROTIGHT external thrust-resisting ring without a welded bead Figure 2806 (DN

80-500) - suppliers:

i) Rubberring with steel teeth – vonRoll product supplied by Rex Articoli (Swiss)

ii) DI gland – Keulahütte (Germany)

iii) M20 bolts & nuts galvanised / Stainless Steel 316 - purchased by vonRoll hydro

from third party

(c) HYDROTIGHT external thrust-resisting ring with welded bead Figure 2805 (DN 600-

700) - suppliers:

i) Unrestrained TYTON® seal – WOCO

ii) DI gland & DI locking ring – Keulahütte (Germany)

iii) M27 nuts & bolts – purchased by vonRoll hydro from third party

3.7 DI Socketed Fittings to AS/NZS 2280

WSAA has appraised the Derwent Industries range of DI fitting to AS/NZS 2280, under

WSAA Product Appraisal No 1003 Issue 2. A copy of this report can be downloaded from

the WSAA website.

Gulf Rubber supplies the special transition EPDM TYTON® elastomeric seals in compliance

with AS 1646:2007 ‐ Elastomeric seals for waterworks purposes.

Additional testing has been performed by vonRoll hydro (suisse) Ltd to demonstrate that

Derwent Industries supplied DI socketed fittings with Gulf Rubber special EPDM TYTON®

transition elastomeric seals meets the performance requirements of AS/NZS 2280 when

used with DUCPUR®, ECOPUR® and GEOPUR® DI pipes in sizes DN 100 to 300. (Refer to

Clause 6.2.7.2)

4 SCOPE OF THE APPRAISAL

The scope of this product appraisal application applies to:



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a) vonRoll DUCPUR®, ECOPUR® and GEOPUR® range of ductile iron pipes of two

connection types (push-in socket and flanged) with unrestrained and restrained joints as

specified in Section 3 and listed in Tables 1, 2, 3 and 5 for water supply (potable and

recycled) and sewerage (gravity, pressure and vacuum);

b) vonRoll ECOFIT ductile iron ISO sized fittings for use with vonRoll DI pipes as specified

in Section 3; and

c) Use of ductile iron socketed fittings manufactured to AS/NZS 2280 with vonRoll DI pipes

as specified in Section 3.

5 APPRAISAL CRITERIA

5.1 Quality Assurance Requirements

The WSAA product appraisal network accepts ductile iron pipes and fittings manufactured

under third party accredited quality assurance programs complying with AS/NZS ISO 9001

Quality Management System – Requirements and product certification by a Certification

Body at the manufacturing site of strategic products to appropriate Australian or

internationally recognised standards. The Certification Body shall have relevant

accreditation by the Joint Accreditation System of Australia and New Zealand (JAS-ANZ) or

by an equivalent international accreditation system recognised by JAS-ANZ.

5.2 Performance Requirements

5.2.1 Product Manufacturing Standards

The WSAA product appraisal network accepts ductile iron pipes and fittings manufactured

under cover of a third party certified management system complying with AS/NZS ISO 9001

and having ISO Type 5 product certification by a JAS-ANZ accredited Conformity

Assessment Body (CAB) or by a CAB accredited by international accreditation system

recognised by JAS-ANZ. The relevant product standards are:

EN 545: 2010 Ductile iron pipes, fittings, accessories and their joints for water pipelines -

Requirements and test methods and

EN 598: 2007 Ductile iron pipes, fittings, accessories and their joints for sewerage

applications - Requirements and test methods

The polyurethane internal lining and external coating has been assessed against the

following European Standards:

BS EN 15189:2006 - Ductile iron pipes, fittings, accessories – External polyurethane

coating for pipes– Requirements and test methods

BS EN 15655:2009 - Ductile iron pipes, fittings, accessories – Internal polyurethane lining

for pipes and fittings – Requirements and test methods

The following WSAA Product Specifications are also relevant to this application:

WSA PS 202 - Ductile Iron Pipes and Fittings (ISO Sized) for Pressure Applications –

Water Supply

WSA PS 202S - Ductile Iron Pipes and Fittings (ISO Sized) for Pressure and Non-

Pressure Applications – Sewerage

WSA PS – 312 Flange Gaskets and O-Rings

WSA PS – 320 Sleeving, Polyethylene (PE) for Ductile Iron Pipes and Fittings - Water

Supply and Sewerage

Refer to Appendix E for copies of the above specifications.


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6 COMPLIANCE WITH APPRAISAL CRITERIA

6.1 Compliance with Quality Assurance Requirements

6.1.1 Distributor

While Reece does not have a formal certified Quality Management System ISO 9001, they

have, over the past 95 years, been developing a significant management system, the Reece

Business Management System (RBMS) which underpins the delivery of Customer Projects

and consists of:

Reece R10 The Reece Way (Business Management Policy)

Reece Branch Procedures Manuals (includes Branch Audit reports)

Reece OH&S Management Systems Manual (includes OH&S Policy)

Reece Environmental Management Systems Manual

Reece Support Centre & Compliance Procedures Manual

Reece CIP Procedure Manual - (Continuous Improvement Program)

Reece After Sales & Customer Care

In addition to the above, Reece are the only Plumbing wholesaler in Australia to have its

own Test Laboratory and After Sales Facility for their branches and customers.

The facility is a fully operational laboratory with piping and pump facility to test flows and

pressures, a spectrometer to analyse and report on material make up of metals such as

brass, copper and steel, load testing cell and gauges to check thread engagement.

The quality team at the Reece Test Facility carry out regular inspection and checks of

products delivered to their National and Regional Distribution Centres to ensure quality and

standards criteria are met. Reece test and review current and potential products to ensure

they meet the relevant Australian and International Standards.

Refer to Appendix B for a copy of the above statement on a Reece letterhead.

6.1.2 Manufacturers

Quality Management System ISO 9001 and Product Certification to relevant Standards for

the manufacturers of DI pipes, DI fittings and associated components are as follows.

6.1.2.1 vonRoll DI pipes

The DUCPUR®, ECOPUR® and GEOPUR® range of ductile iron pipes are produced in

vonRoll manufacturing facilities located in Choindez, Switzerland. The manufacturing

facilities are owned by the vonRoll Infratec Group. vonRoll is a quality endorsed Company

and holds ISO 9001:2008 and ISO 14001:2004 certification for the development, production

and distribution of products and systems for the public water supply and sewage disposal ,

issued by Swiss Association for Quality and Management Systems (SQS).

SQS is a member of the International Certification Network (IQNet) which entitles SQS to

use IQNet logo and Certification Certificate. IQNet certificates are accepted globally

throughout 40 different Certification Accreditation Bodies (CAB) based on multilateral

recognition arrangement (MLA).

The SQS is a Certification Body (CB), accredited by the Swiss Accreditation Services (SAS)

which is a signatory to the Multilateral Recognition Arrangement (MLA) of the International

Accreditation Forum (IAF) which is recognised and accepted by JAS-ANZ.

vonRoll manufacturing facilities in Choindez, Switzerland have been issued with Certificates

of Conformity to EN 545 (water supply) and Certificate of Conformity to EN 598 (sewerage)

by Materialprufungsamt Nordrhein-Westfallen (MPA NRW) for their range of ductile iron

pipes.


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MPA NRW possesses accreditation and recognition from the German Accreditation system

audit GmbH (DAP). Refer to Appendix A for additional information on German Accreditation

system.

The MPA NRW Certificate of Conformity carries the Deutscher Akkreditierungs Rat (DAR)

logo and DAR registration and the International Accreditation Forum, Inc. (IAF) logo. Only

accredited bodies being signatories to the Multilateral Recognition Arrangement (MLA) of

the IAF and can use the IAF logo in connection with their own accreditation mark and the

registration number. The IAF logo is recognised and accepted by JAS-ANZ.

The MPA NRW has confirmed through their letter dated 04/09/2009 that the Certificates of

Conformity issued by the MPA NRW complies with the certification procedure which

corresponds to the product certification described in ISO/IEC Guide 67:2004. This is

sufficient to demonstrate compliance with ISO Type 5 product certification as specified in

WSA PS 202 - Ductile Iron Pipes and Fittings (ISO Sized) for Pressure Applications - Water

Supply and WSA PS 202S - Ductile Iron Pipes and Fittings (ISO Sized) for Pressure and

Non-Pressure Applications – Sewerage

6.1.2.2 ECOFIT DI fittings and DI components for external restrained joints

ECOFIT DI Fitting manufacturer Keulahütte GmbH manufacturing facility in Krauschwitz

Germany has an accredited Quality Management System to ISO 9001:2008 for the

development, manufacture and sales of fittings, hydrants, valves and castings for

mechanical engineering and vehicle construction. The ISO 9001 Certificate of Registration

was issued by TÜV Reheinland Cert GmbH. TUV Rheinland Group through its Australian

subsidiary TUV Rheinland Australia Pty Ltd is affiliated with JAS-ANZ.

Keulahütte GmbH’s facility in Krauschwitz, Germany has been issued with DVGW

Certificates of Registration by Deutsche Akkreditierungsstelle GmbH (DAkkS) for their range

of ductile iron fittings from DN 80 to DN 700 manufactured to EN 545 and EN 598. This

certification also includes potable water compliance to DVGW W 270 - Testing and

assessment of enhancement of microbial growth on non-metallic materials in contact with

drinking water.

DAkkS is Germany's government appointed National Accreditation Body to provide

accreditation of conformity to assessment bodies like DVGW Cert. DAkkS is a member of

EA (European Accreditation) and IAF (member of multilateral recognition arrangement).

IQNet certificates are accepted globally throughout 40 different Certification Accreditation

Bodies (CAB) based on multilateral recognition arrangement (MLA).

DAkkS is accredited by the Multilateral Recognition Arrangement (MLA) of the International

Accreditation Forum (IAF) which is recognised and accepted by JAS-ANZ.

6.1.2.3 TYTON® elastomeric seals

HYDROTIGHT TYTON® elastomeric seals for the vonRoll DI pipes and ECOFIT DI fittings

are supplied by WOCO GmbH. WOCO holds a quality management certificate to ISO/TS

16949:2009, which is equivalent to ISO 9001 with some additional requirements for the

automotive sector. TUV SUD Management Service GmbH in Germany issued the ISO 9001

certificate.


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A Type Examination Certificate issued by DVGW has been submitted to confirm that the

elastomeric compounds comply with EN 681.1. A copy of a Certificate issued by the Institute

of Environmental Hygiene and Toxicology has also been submitted to demonstrate

compliance in contact with potable water DVGW W 270.

6.1.2.4 Internal Restrained thrust-resisting rings

The Internal Restrained thrust-resisting ring manufacturer Rex Articoli’s manufacturing

facility in Mendrisio, Switzerland has an accredited Quality Management System to ISO

9001:2008 for the project, production and marketing of technical products from rubber,

rubber metal and thermoplastic. The ISO 9001 Certificate of Registration was issued by SQS

/ IQNet.

Rex Articoli and vonRoll hydro have been issued with a Product Certification for

manufacturing of internal restrained thrust-resisting joint system in compliance with EN

545:2007 MPA NRW – DakkS, Germany.

6.1.2.5 Jointing lubricant for vonRoll DI pipes and ECOFIT DI fittings

vonRoll hydro supplies the lubricant Fig. 240 with vonRoll DI pipes and ECOFIT DI fittings.

The Lubricant manufacturer van Baerle AG (Swiss), is an ISO 9001:2008 quality endorsed

company with Certificate Registration (available in German) for manufacture and supply of

Specialty Chemicals, issued by SQS / IQNet.

The lubricant has the hygienic compliance certification to SVGW W-UK7 / Liquid soap TN2

for use in contact with drinking water issued by the Swiss, German and French Accredited

Institutes for Water Quality; i.e. SVGW (Switzerland) / TZW (Germany) / CARSO (France)

The Certificate is available only in German.

6.1.2.6 Bolts and Nuts for use with external restrained joints

vonRoll hydro purchases M20 and M27 Bolts and Nuts (galvanised or stainless steel 316)

manufactured to relevant standards from third party, which are used with external restrained

joints Fig. 2806 and Fig. 2805 respectively.

Refer to Appendix B for copies of the above letters and certificates related to Quality

Management Certification and Product Certification. Certificates that are not attached in

Appendix B have been sighted by WSAA and saved in the folder as they are considered as

‘Commercial-in-Confidence’ documents.

6.1.2.7 Elastomeric joint seals -

Gulf Rubber supplies Reece with the EPDM TYTON transition elastomeric seals.

The special EPDM TYTON transition elastomeric seals are manufactured by Gulf Rubber

and comply with the requirements of AS 681.1:2008 (EN 681-1:1996).

Gulf Rubber holds a joint certification with Thong Nhat Rubber Company for StandardsMark

product certification (Licence SMK 20133) for the manufacturer transition elastomeric seals

in compliance with AS 1646:2007 and AS 681.1:2008 (EN 681-1:1996).

6.2 Compliance to the Appraisal Requirements

6.2.1 Material properties

6.2.1.1 Ductile iron tensile and hardness properties

EN 545 and EN 598 both require that DI pipe and fittings material conform to a minimum

tensile strength of 420 MPa. The minimum required elongation is 10% for pipe sizes DN 100

- 700 and 5% for fittings. The maximum hardness is specified as 230 HB for pipes and 250

HB for fittings.


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TABLE 6: MATERIAL PROPERTIES OF CENTRIFUGALLY CAST PIPES AND FITTINGS

Mechanical properties Symbol Unit Pipes Fittings

Minimum tensile strength Rm MPa 420 420

Yield strength Rp 0.2 MPa 270 270

Minimum elongation at break DN 100-700 A % 10 5

Minimum transverse compressive strength MPa 550 550

Bursting strength MPa 300 300

Longitudinal flexural strength MPa 420 420

Density ρ kg/dm3 7.05 7.05

Elastic modulus E MPa 1.7 x 105 1.7 x 105

Thermal expansion coefficient α 1/K 10 x 10-6 10 x 10-6

Hardness HB < 230 < 250

The compliance to these material test requirements is checked by:

vonRoll quality assurance department, daily; and

each audit of the independent body MPA NRW.

6.2.2 Wall thickness

The minimum wall thickness of the DUCPUR®, ECOPUR® and GEOPUR® range of C25 up

to C100 DI pipes and fittings comply with the minimum requirements specified in EN 545 and

EN 598.

6.2.3 Performance test requirements to EN 545 and EN 598

EN 545:2010 and EN 598:2009 incorporates a range of performance tests and acceptance

criteria aimed at setting minimum production performance levels as summarised below:

Quality control Type performance tests

a) dimensional checks

b) tensile property determinations

c) hydrostatic pressure tests

d) zinc coating mass determinations

e) paint coating thickness checks

f) polyurethane lining and coating

thickness checks

g) polyurethane lining and coating

adherence checks

a) leaktightness of flexible joints to positive

internal pressure under

• shear loading

• angular deflection

b) leaktightness of flexible joints to positive

external pressure shear loading

c) leaktightness of flexible joints to dynamic

internal pressure (water supply only)

d) mechanical strength and leaktightness of

flange-to-pipe attachment (for screwed-on

or welded-on flanges; water pipes only)

The manufacturing standards EN 545 and EN 598 used for the vonRoll DI pipes have similar

performance requirements to the DI pipe manufactured to AS/NZS 2280 where testing of

dimensions, mechanical properties, joint performance and pressure testing are all performed

on the pipes during manufacture. The ductile iron has equivalent mechanical properties to

AS/NZS 2280 i.e. minimum tensile strength of 420 MPa and minimum elongation of 10%.

As part of agreement no. 117455 dated 12.05.2011 between the client vonRoll hydro

(Suisse) ltd and the MPA NRW (Third party certification body) audits are conducted yearly

at their factory in line with Technical test specifications; DVGW GW 337-81, DIN EN

545:2010 and DIN EN 598:2007.


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vonRoll has submitted an English translation of MPA NRW annual audit report no. 11 7455

14-01 for DUCPUR® and ECOPUR® to EN 545 conducted on 16th and 17th of April 2014.

In addition, vonRoll has submitted MPA NRW ’s 2015 annual audit report no. 11 7455 15-01

for DUCPUR® and ECOPUR® to EN 545 and report no. 11 7417 15-01 for GEOPUR® to EN

598, in German. The audits were conducted on 15 th and 16th of April 2015 and reports were

issued on 28th April 2015 in German language. By the annual visit, MPA NRW looks at three

different executions of the pipes and associated fittings, simultaneously.

The certification from MPV NRW is accepted as sufficient conformance requirements for the

DI pipes and fittings. In addition an onsite review of the manufacturers testing data and the

process control also provide sufficient information to demonstrate compliance with both

standards EN 545 and EN 598.

WSAA has sighted the above MPA NRW annual audit reports and saved in the folder.

6.2.3.1 Type tests and audit reports for vonRoll DI pipes

vonRoll have a number of audit reports on DUCPUR®, ECOPUR® and GEOPUR® but the

content is almost the same. By the annual audit, MPA NRW checks the routine tests in the

production as wall thickness, lining, coating, mechanical characteristics of the material,

dimensions, etc. The type tests do not fall under the scrutiny of the annual audit because

they should be renewed only in case of a new development (i.e. new connection system,

change in material or design etc.). vonRoll did a comprehensive type tests in accordance

with EN 545 and EN 598 few years ago and the results are still valid.

The type tests for GEOPUR® DI pipe to EN 598 is similar to those of DUCPUR® and

ECOPUR® DI pipes to EN 545.

vonRoll has submitted full report on type tests conducted for GEOPUR® DI pipe which was

recognized by the MPA NRW for issuing the third party product certification to EN 598.

vonRoll has also submitted MPA NRW audit report for GEOPUR® DI pipe to EN 598 but it is

in German.

The type tests and audit reports associated with EN 598 have been sighted by WSAA and

saved in folder. As these documents are treated as “Commercial-in-Confidence”, anyone

need access should obtain the consent of the supplier Reece.

Complies with Performance type test requirements

6.2.4 Pressure ratings

The pressure rating of ductile iron pipes and fittings in EN 545 depends on:

a) Nominal size

b) Class designation (pipes) - see Section 6.2.2.1 below

c) Joint type

d) casting type (pipe / fittings)

6.2.5 Pipe class designation

The previous standard EN 545:2006 defined the classification of pipe and fittings, not related

to pressure rating but instead to coefficient “K" which when substituted in the following

formula specifies the minimum wall thickness for various nominal diameters with an absolute

minimum thickness of 6 mm for pipes and 7 mm for fittings.

e = K (0.5 + 0.001DN)

Where e is the nominal wall thickness, in millimetres:

DN is the coefficient used for the determination of the thickness. It is selected from a series

of whole numbers 8, 9, 10, 11, 12.


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The latest standard EN 545:2010 against which vonRoll DI pipes (DUCPUR® and ECOPUR®)

for water supply applications are manufactured, defined the pipe classification in Clause 3.21

as follows:

The pressure class of a component is defined by a combination of its structural performance

and the performance of its non-restrained flexible joint. Restrained joints may reduce the

PFA; in this case the PFA shall be declared by the manufacturer.

Pressure class (C) - alphanumerical designation of a family of components, including their

joints, relating to their operating pressures as verified by all the performance tests described

in this standard, which includes the letter C followed by a dimensionless number equal to

the maximum PFA in bars of the family of components.

As per Annex A of EN 545:2010, the maximum values of PFA, PMA and PEA are calculated

as follows:

a) PFA = (20 x emin x Rm) / (D x SF) Where

Emin is the minimum pipe wall thickness, in millimetres

D is the mean pipe diameter (DE – emin), in millimetres

DE is the nominal pipe external diameter, in millimetres

Rm is the minimum tensile strength of ductile iron, in MPa (Rm = 420 MPA)

SF is a safety factor of 3

The maximum PFA of a pipe is equal to its class number, e.g. PFA 40 for a class 40

pipe.

b) PMA: as PFA, but with SF = 2.5; therefore:

PMA = 1.2 x PFA

c) PEA = PMA + 5 bar

6.2.5.1 Pipe Classes for Water Supply Application

Pipe classes for water supplies is in accordance with EN 545:2010 and ISO 2531:2009

standards

a) Pipes with push-in sockets: Pressure Class C / Thickness Class K9

b) Pipes with flanges: K12 standard

The pressure performance capability of DI pipes and fittings for water supply to EN 545:2010

is shown in Table 2.

TABLE 7: MAXIMUM VALUES OF PFA, PMA AND PEA FOR VARIOUS PIPE CLASS

PUSH-IN JOINT PIPES AND ADAPTOR FITTINGS

Nominal Diameter DN (mm)

Pipe Class Pressure in Bar

PFA PMA PEA

80 C100 100 120 125

100 C100 100 120 125

125 C64 64 76.8 81.8

150 C64 64 76.8 81.8

200 C64 64 76.8 81.8

250 C50 50 60 65

300 C50 50 60 65


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Pipe Class Pressure in Bar

PFA PMA PEA

350 C40 40 48 53

400 C40 40 48 53

* 500 K9 / C30 38.4 46.1 51.1

* 600 K9 / C30 35.7 42.9 47.9

* 700 K9 / C30 33.8 40.6 45.6

* NOTE: vonRoll decided to put only the K9 thickness class for the DN 500 up to DN 700 in their catalogue but the marking on the pipes is as follows: DN 500 K9 / C30

DN 600 K9 / C30

DN 700 K9 / C30

PFA: Allowable Operating Pressure Maximum hydrostatic pressure that a component is capable of withstanding continuously in service PMA: Allowable Maximum Operating Pressure Maximum pressure occurring from time to time, including surge that a component is capable of withstanding in service PEA: Allowable Test Pressure Maximum hydrostatic pressure that a newly installed component is capable of withstanding for a relatively short duration, in order to insure the integrity and tightness of the pipeline

The allowable operating pressure for pipe classes C100, C64, C50, C40 and C30 of DI pipe (i.e. 10 MPa for 80-100; 6.4 MPa for 125-200; 5 MPa for 250-300; 4 MPa for 350-400; more than 3.38 MPa for 500-700) far exceeds the pressure needs of water supply systems which is usually 1.6 MPa.

Allowable operating pressures for DI pipelines will be dependent upon the rating of elastomeric seals, flanges and appurtenances.

NOTE: Applicable limits, which may not permit the full use of the pressure ranges as stated in Table 6 in an installed pipe, must be taken into consideration. For example:

- Operation at the PFA and PMA values given in Table 6 for socket pipes can be limited by the lower pressure range of other pipeline components, e.g. flange pieces (Table 8), certain types of Y-fittings and certain types of moveable connections.

- The water pressure test in pits with the high PEA values given in Table 6 can be limited due to the type and structure of the anchoring system of the pipe and/or the moveable connections.

6.2.5.2 Pipe Classes for Sewerage Application

vonRoll GEOPUR® DI pipe can be used for pressure (vacuum or pumping) and non-pressure

(gravity) applications.

Pipe class for pressure pipes for wastewater disposal is in accordance with the EN 598

standard as detailed in Table 8.

TABLE 8: MAXIMUM VALUES OF PFA, PMA AND PEA FOR PRESSURE PIPE CLASS

PUSH-IN-JOINT PIPES AND ADAPTOR FITTINGS USED FOR SEWERAGE TO EN 598


Pressure in Bar

PFA PMA PEA

80 40 48 53


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Pressure in Bar

PFA PMA PEA

100 40 48 53

125 40 48 53

150 40 48 53

200 40 48 53

250 38 46 51

300 35 42 47

350 32 39 44

400 30 36 41

500 28 33 38

600 26 31 36

700 29 35 40

6.2.5.3 Flanged pipes for water supply and sewerage application

TABLE 9: FLANGED PIPES AND FITTINGS FOR FLANGE JOINTS – HIGHEST PFA,

PMA AND PEA VALUES

DN PN 10 PN 16 PN 25 PN 40

PFA PMA PEA PFA PMA PEA PFA PMA PEA PFA PMA PEA

80 See PN 16 16 20 25 See PN 40 40 48 53

100 - 150 See PN 16 16 20 25 25 30 35 40 48 53

200 – 600 10 12 17 16 20 25 25 30 35 40 48 53

700 10 12 17 16 20 25 25 30 35

Result Complies

6.2.6 Joints

In accordance with EN 545 and EN 598, various types of joints and interconnections

(unrestrained and restrained) of:

a) vonRoll DI pipes (DUCPUR®, ECOPUR® and GEOPUR®) of size DN 80 to DN 700 as

detailed in Section 3.2, are performance tested and complied with the specified

requirements in the standard; and

b) ECOFIT DI fittings of size DN 80 to DN 700 as detailed in Sections 3.4.1 are performance

tested and complied with the specified requirements in the standard.

Unrestrained push-in socket joints for vonRoll DI pipes and ECOFIT DI fittings are formed

with the use HYDROTIGHT TYTON® elastomeric seal EPDM (water) and NBR (sewer).

Internal and External Restrained joints for vonRoll DI pipes and ECOFIT DI fittings are

formed by combining an additional HYDROTIGHT thrust-resisting rings (internal or external)

or an internal restrained joint combined gasket with steel teeth, as detailed in Appendix D.

The allowable working pressure for thrust-rings is shown in Table 10.

The HYDROTIGHT thrust-resisting ring reliably absorbs shear, tensile and pressure forces,

which can act on the pipe axially. It can be used with pipes, elbows, y-fittings or reducers

and is a space-saving, quick-to-fit, removable and mechanical connection.

vonRoll has submitted Product Certifications to EN 545 and EN 598 to demonstrate that

various types of joints and interconnections of vonRoll DI pipes and ECOFIT DI fittings

comply with relevant standards. Refer to Appendix B for copies of the certificates.


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TABLE 10: ALLOWABLE WORKING PRESSURES (PFA) FOR THRUST-RESISTING

RINGS

DN Thickness Class (K) Pressure Class (C)

Allowable working pressure PFA (bar)

Internal restrained External restrained

Fig. 2807 A / B 1) TYTON® SIT® / TYTON® SIT

PLUS® Fig. 2504 Fig. 2806 Fig. 2805

80 K9 / C100 40 / 25 10 / 16 40

100 K9 / C100 40 / 25 10 / 16 40

125 K9 / C64 40 / 25 10 / 16 40

150 K9 / C64 40 / 25 10 / 16 40

200 K9 / C50 40 / 25 10 / 16 16 / 40 2)

250 K9 / C50 25 / 16 10 / 16 16 / 40 2)

300 K9 / C40 25 /16 10 / 16 16 / 40 2)

350 K9 / C40 16 10 / 16 16 / 25 2)

400 K9 / C40 16 10 / 16 25

500 K9 / C30 16 - / 10 16

600 K9 / C30 - - / 10 - 25

700 K9 / C30 - - - 25

1) Internal restrained joint with all teeth execution A or the half of the teeth execution B 2) PFA with all bolts and nuts

Result Complies

6.2.7 Elastomeric Seals for push-in socket joint connections

6.2.7.1 Elastomeric seals for use on vonRoll hydro DI pipes and ECOFIT DI fittings

vonRoll hydro DUCPUR®, ECOPUR® and GEOPUR® range of DI pipes and ECOFIT DI

fittings are supplied with unrestrained HYDROTIGHT TYTON® elastomeric seal which is

manufactured from EPDM (water) or NBR (sewerage).

vonRoll hydro Standard” elastomeric joint (unrestrained) consists of a pipe socket profile

with a locking chamber, sealing chamber and spigot end chamber. The elastomeric seal

consists of a locking heel and a sealing body. The locking heel locates in the locking chamber

of the socket to restrain the seal from being dislodged during jointing. Sealing is achieved

by compression of the seal body between the socket sealing chamber and pipe spigot.

vonRoll hydro also supplies HYDROTIGHT thrust-resisting rings for internal or external

restraint joints of vonRoll DI pipes and ECOFIT DI fittings.

Manufacturer of the restraint joint components are:

a) Rex Articoli in Switzerland supplies Rubberring with steel teeth for internal restraint

system (Fig. 2807A and 2807B) and Rubberring with steel teeth for external restraint

system (Fig. 2806).

b) Keulahütte in Germany supplies the DI gland and DI locking ring for external restrained

system (Fig. 2805 and 2806).

c) vonRoll hydro buys M20 and M27 nuts and bolts (galvanised or stainless steel 316) from

third party, which are required to form the external restrained joints (Fig. 2806 and 2805

respectively).

Refer to Section 3.3 for details of elastomeric seals used to form various types of joints in

vonRoll DI pipes, and Section 3.6 for details of the same for ECOFIT DI fittings.

Copies of type test and audit reports recognised by MPA NRW have been submitted to

demonstrate that the elastomeric joints used with vonRoll DI pipes and ECOFIT DI fittings

comply with the performance requirements specified in EN 545 and EN 598.


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Result Complies

6.2.7.2 Transition elastomeric seals – for use on DI pipe manufactured to EN 545 / EN

598 and AS/NZS 2280 manufactured Socketed DI fittings

Reece intends to supply AS/NZS 2280 DI Socketed fittings, with special EPDM TYTON

transition elastomeric seals, with delivery of DUCPUR®, ECOPUR® and GEOPUR® DI pipes

in sizes DN 100 to 300.

AS/NZS 2280 allows fittings to be used with pressure pipe of alternative outside diameter by

the adoption of a compatible socket or utilisation of a transition elastomeric seals, provided

the joint meets the performance requirements of this Standard.

Tests have been carried out on the vonRoll hydro ductile iron pipe and Derwent Industries

DI socketed fittings (PA 1003 Issue 2) manufactured to AS/NZS 2280, using a transition

elastomeric seal to demonstrate compliance with the performance tests in AS/NZS 2280.

Such tests include pressure tests, vacuum tests and tests with deflection and applied shear

loading. According to the results of the performance testing the Allowable Operating

pressure (AOP) for the different diameter DN and transition elastomeric seal are as follows:

a) DN 100 - 250 Gulf Rubber TYTON® transition elastomeric seal with TYTON joint and


b) DN 300 Gulf Rubber TYTON® transition elastomeric seal with TYTON joint and


Gulf Rubber holds a joint certification with Thong Nhat Rubber Company for StandardsMark

product certification (Licence SMK 20133) for the manufacturer elastomeric seals in

compliance with AS 1646:2007 ‐ Elastomeric seals for waterworks purposes. The special

EPDM TYTON adaptor rubber jointing seal is manufactured by Gulf Rubber and complies

with the requirements of AS 1646.

Table 11 shows compatibility of vonRoll DI pipes with AS/NZS 2280 manufactured DI pipes


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TABLE 11: COMPATIBILITY OF VONROLL DI PIPES WITH AS/NZS 2280

MANUFACTURED DI PIPES

Nominal Diameter DN

(mm)

External Diameter (mm) *

vonRoll pipe to EN 545 and EN 598 DI pipe to AS/NZS 2280

Nominal Limit deviations Nominal Limit deviations

80 98 +1/-2.7 96

100 118 +1/-2.8 122 +1,-2

125 144 +1/-2.8 - -

150 170 +1/-2.9 177 +1,-2

200 222 +1/-3.0 232 +1,-2

225 - - 259 +1,-2

250 274 +1/-3.1 286 +1,-2

300 326 +1/-3.3 345 +1,-2

Length 6 m DI – 5.5 m; PVC – 6 m

* Excluding tolerances

vonRoll has submitted Performance Test Results for the ‘Leak-tightness of flexible joints’ to

demonstrate Socketed DI fittings manufactured to AS/NZS 2280 could be joined with DI pipe

manufactured to EN 545 / EN 598, using Gulf Rubber’s special adaptor elastomeric seals.

Two tests were conducted at vonRoll facility in Switzerland:

a) On 20/12/2012 for the size range 80, 100, 150, 200, 250 and 300mm as per Clause 7.2

of BS EN 545; and

b) On 18/06/2015 for the size range 250 and 300mm as per Clause 7.2 of BS EN 545 and

Clause 4.2.1 of AS/NZS 2280, Appendix F (Paragraph F2).

Conclusion of both tests is as follows:

a) Socketed DI fittings manufactured to AS/NZS 2280 could be joined with DI pipes

manufactured to EN 545 / EN 598 at 16 Bar for sizes 100, 150, 200 and 250 and at 10

Bar for size 300 mm.

b) The test results are valid for all three vonRoll DI pipes DUCPUR®, ECOPUR® and

GEOPUR® and the Australian made ductile iron socketed fittings.


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TABLE 12: TYPE TEST RESULTS FOR ISO SIZED VONROLL DI PIPES AND AS/NZS

2280 MANUFACTURED SOCKETED DI FITTINGS

Test Result Leak tightness of flexible joints

Sample used Outcome of the test

Certificate of Conformity (8 pages) for test conducted on 20/12/2012

Clause 7.2 of BS EN 545

(using special Gulf Rubber adaptor seal)

Double socketed collar to AS/NZS 2280 supplied by Derwent and ECOPUR® DI pipe.

Two samples were used:

150mm sample to represent 80 - 200mm size group; and

300mm sample to represent 250 - 300mm size group

Two tests were done:

DN 100, 150 and 200 passed the test at 16 Bar (test pressure 29 Bar = 1.5 x 16 plus 5).

DN 250 and 300 passed the test at 10 Bar (test pressure 20 Bar = 1.5 x 10 plus 5)

Certificate of Conformity (9 pages) for test conducted on 18/06/2015

Clause 7.2 of BS EN 545;

And

Clause 4.2.1 of AS/NZS 2280, Appendix F (Paragraph F2)

(using special Gulf Rubber adaptor seal)

Double socketed collar to AS/NZS 2280 supplied by Derwent and ECOPUR® DI pipe.

Two samples were used:

250 and 300 mm to represent 250 - 300mm size group

Three tests were done:

DN 250 passed the test at 16 Bar (test pressure 29 Bar as per BS EN 545)

DN 250 has also passed the test at 16 Bar (test pressure 20.8 Bar as per AS/NZS 2280;. 20.8 = 1.3 x 16)

DN 300 passed the test at 10 Bar (test pressure 13 Bar as per AS/NZS 2280; 13 = 1.3 x 10)

Note: DN 300 was not tested as per BS

EN 545 at 10 Bar because similar test was conducted on 20/12/2012

WSAA has sighted the type test results and saved in the folder. Anyone need access to

these documents should obtain the consent of Reece as they are considered as

“Commercial-in-Confidence”,

TABLE 13: RANGE OF ADAPTOR SEALS FOR ECOPUR®, DUCPUR® AND GEOPUR®

DI PIPES AND AS/NZS 2280 MANUFACTURED SOCKETED DI FITTINGS

Model Identification

Model Name

Brand Name

Product Description

Type Nominal

Size Elastomeric

Type

Nominal Elastomeric Hardness

4000.2 Gasket

ISO2531E Gulf

Rubber Gasket

ISO2531E Elastomeric

seals 100 EPDM 55/85

4001.2 Gasket

ISO2531E Gulf

Rubber Gasket



4002.2 Gasket

ISO2531E Gulf

Rubber Gasket



4003.2 Gasket

ISO2531E Gulf

Rubber Gasket



4004.2 Gasket

ISO2531E Gulf

Rubber Gasket



A copy of the Gulf Rubber / Thong Nhat Rubber Company StandardsMark Product Certification to AS 1646 can be found in Appendix B.

Result Complies


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Alternatively jointing between ISO sized vonRoll DI pipe (i.e. DUCPUR® / ECOPUR® /

GEOPUR®) and AS/NZS 2280 manufactured DI pipes at 16 Bar pressure rating is possible

with the use of DI Socket-Flange adaptors where flanges comply with AS/NZS 4087 Figure

B5, PN16. This system can be applied to 250 mm and 300 mm sizes only as shown in figure

19.

FIGURE 19: JOINTING ISO SIZED VONROLL DI PIPE TO AS/NZS 2280 MANUFACTURED DI PIPE USING SOCKET-FLANGE ADAPTOR

6.2.8 Restrained joints

All vonRoll’s internal and external restrained joints for DI pipes and fittings conform to EN

545 as they passed all relevant type tests according to EN 545. The type tests were carried

out at vonRoll’s Choindez facility under the supervision of an Independent body MPA

Dortmund.

vonRoll hydro has submitted certificates and reports (in Germany) as evidence which have

been sighted and saved in WSAA folder.

6.2.9 Linings for DI pipes

The internal lining of ECOPUR®, DUCPUR® and GEOPUR® pipes is a hard Polyurethane

formulation developed by vonRoll in 1972 and now incorporated into EN 15655 DI pipes,

fittings – Internal Polyurethane lining - requirements and test methods. This lining is applied

in the vonRoll factory.


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FIGURE 20: INTERNAL LINING OF ECOPUR®, DUCPUR® AND GEOPUR® PIPES

The polyurethane is composed of a two component resin. It’s three-dimensionally linked

molecular structure gives its mechanical stability. Polyurethane is a thermosetting plastic

with no solvents. Specific details of the polyurethane characteristics are shown in the vonRoll

Catalogue.

Each pipe is being grit, blasted twice and pre-heated before lining in order to obtain perfect

adhesion and curing. The smooth surface and the equal distribution of the polyurethane are

achieved by keeping the pipe in rotation during lining and coating.

The interior of the socket is fully protected with polyurethane for ECOPUR® and GEOPUR®

and with bitumen for DUCPUR®. The socket of the DUCPUR® pipes can be also lined by

polyurethane.

The thickness of the polyurethane lining shall be as follows:

TABLE 14: POLYURETHANE LINING THICKNESS

DN Thickness (mm)

Mean value Minimum value

80 - 150 1.3 0.8

200 - 700 1.5 0.8

Socket End: The internal surface of the socket end is lined with polyurethane. The mean

thickness is 150 microns and the minimum thickness 100 microns.

The polyurethane lining applied to vonRoll ductile iron pipe has been tested by the Australian

Water Quality Centre and they have certified it complies with AS/NZS 4020- Testing of

products for use in contact with drinking water for:

• Taste of Water Extract, Appendix C

• Appearance of Water Extract, Appendix D

• Growth of Aquatic Micro-organisms, Appendix E

• Cytotoxic Activity of Water Extract, Appendix F

• Mutagenic Activity of Water Extract, Appendix C

• Extraction of Metals, Appendix H

vonRoll has submitted Test Report No. 55651 dated 15/07/2009 (AWQC Ref 141020-2008-

CSR-2: Prod Test: Polyurethane Internal Coating) from the Australian Water Quality Centre

for DN 80 ECOPUR® pipe manufactured by VonRoll Hydro to demonstrate compliance with

AS/NZS 4020:2005.

The test results have demonstrated compliance of ECOPUR® and DUCPUR® to AS/NZS

4020 when tested at the 'in-the-product' exposure (50,000 mm2 per Litre). Product range –

DN 80 to DN 700 pipes.

Internal lining Socket end

External coating


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Based on the completion and evaluation of all test results Australian Water Quality Centre

has confirmed the products fully comply with the test requirements of AS/NZS 4020:2005.

Result Complies

6.2.10 External Coatings

6.2.10.1 Polyurethane coating for ECOPUR® ductile iron pipes

The coating of the pipes consists of a factory applied polyurethane coating. Each pipe is

being blasted and pre-heated before coating in order to obtain perfect adhesion and curing

in accordance with EN 15189 DI pipes – External Polyurethane coating – requirements and

test methods.

The thickness of the polyurethane is nominal 900 microns with a minimum of 700 microns.

The entire barrel included of the spigot end is coated with polyurethane. Minor coating

damage (during delivery etc.) can be repaired with an easy to use dual pack cartridge which

ensures the exact dosage of resin/hardener components. See vonRoll Products Manual.

6.2.10.2 Zinc and finishing layer for DUCPUR® and GEOPUR® DI pipes

The DUCPUR® and GEOPUR® DI pipes are internally lined with a Polyurethane (PUR) but

are externally protected with zinc coating in accordance with ISO 8179-2 Ductile iron pipes

- External zinc-based coating - Part 2 : Rich zinc paint with finishing layer. vonRoll hydro

applies the coating at a minimum of 220 g/m2 zinc layer as prescribed in EN 545 for

DUCPUR® and at a minimum of 150 g/m2 as prescribed in EN 598 for GEOPUR®. The zinc

coating is applied to the substrate of the ductile iron pipe by spraying of paint reach of zinc

(min. 90%).

DUCPUR® ductile iron pipes have a black bituminous paint applied as a finishing layer to a

minimum thickness of 70 μm.

GEOPUR® ductile iron pipes have a red brown bituminous paint applied as a finishing layer

to a minimum thickness of 70 μm.

The polyurethane lining is applied only in the pipe barrel for the DUCPUR®. The socket is

lined with bitumen. The socket of the GEOPUR® is lined with polyurethane.

The application of zinc coating enhances the external corrosion protection of the pipe and

fittings in buried applications. Zinc coating has not historically been widely utilised on ductile

iron pipes in Australia, however zinc based corrosion protection systems have been used in

Europe for more than 60 years. The application of this additional corrosion protection is

considered to be acceptable and beneficial to the performance of the pipe. In many soil

conditions it is possible to install zinc-coated pipes without polyethylene sleeving.

6.2.11 Polyethylene sleeving

Most Australian Water agencies specify polyethylene sleeving of ductile iron pipes as a

means of corrosion protection. Polyethylene sleeving provides corrosion protection in

aggressive soils by creating a passive uniform environment around the pipe and limiting

oxygen exposure.

Loose PE sleeving is installed on site on ductile iron pipelines in the form of a tubular film.

Cut lengths are slipped over the pipe, overlapped and wrapped up tight before securing in

place with bands and plastic adhesive tape. Polyethylene sleeving should be installed in

accordance with AS 3681:2008 - Guidelines for the application of polyethylene sleeving to

ductile iron pipeline. As the sleeving is the primary corrosion barrier, care needs to be

exercised during installation to prevent damage. Only accredited pipe layers trained in the

application of sleeving should be employed.

ECOPUR® DI pipe does not need the sleeving because of its polyurethane external coating

and DUCPUR® and GEOPUR® DI pipes with its zinc/bitumen coating only requires sleeving

where the soil conditions are known to be corrosive to ductile iron.


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6.2.12 Contact with drinking water

6.2.12.1 EPDM Elastomeric Seals

vonRoll has submitted a copy of a Certificate issued by the Institute of Environmental Hygiene

and Toxicology to demonstrate that the EPDM material is suitable for use in contact with potable

water to DVGW W270 Testing and assessment of enhancement of microbial growth on non-

metallic materials in contact with drinking water.

vonRoll has also submitted a letter of approval from WRAS (Water Regulations Advisory

Scheme) confirming WOCO EPDM black coloured rubber (51M5567) has met the

requirements of BS 6920 – Suitability of non-metallic products for use in contact with water

intended for human consumption with regard to their effect on the quality of the water .

Result Complies

6.2.12.2 Special Adaptor Elastomeric Seals

Gulf Rubber’s special adaptor elastomeric seals as listed in Table 13 are StandardsMark product certified to AS 1646, which also includes compliance with AS/NZS 4020.

Result Complies

6.2.12.3 Jointing Lubricant

vonRoll hydro has submitted copies of Certificates to confirm that the lubricant Fig. 240

which is manufactured by van Baerle AG (Swiss) has the hygienic compliance for use in

contact with drinking water from the Swiss, French and German Water Quality Institutes.

The hygienic certificates have been sighted by WSAA and saved in the folder.

Result Complies

6.2.12.4 Internal coating of ECOFIT DI fittings

vonRoll has submitted WRAS letter HL/M110333 dated 30/01/2014 confirming Resicoat R4 epoxy powder coating applied to the ECOFIT DI fittings internally and externally meet the requirements of BS 6920. WRAS approval Number to the coating manufacturer Akzo Nobel Coating GmbH is 112500.

6.2.13 Flanged joints and flanged pipe

Flanged pipe and fittings will be drilled to suit AS/NZS 4087:2011 - Flanges for water works

purposes prior to leaving Switzerland. On the limited occasions that lengths of flanged pipes

are required, they will be manufactured to the required length in Australia using K12 pipe

and pre-drilled screwed flanges supplied by vonRoll which will be transported to Australia

for the purpose. Other flange drillings configurations can be provided on request.

6.2.14 Angular joint deflection of pipes and fittings

The maximum allowable joint deflection for ECOPUR®, DUCPUR® and GEOPUR® spigot and

socket flexible push-in-joints is as follows:

TABLE 15: ELASTOMERIC SEAL JOINT DEFLECTION

DN Maximum Deflection

Max Deflection With Restraining Ring

80 - 300 5° 3°

350 - 400 4° 3°

500 - 700 3° 3°


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7 FITTING INSTRUCTIONS, TRAINING AND INSTALLATION

7.1 Installation Instructions

Installation methods for DI pipes are generally in accordance with AS/NZS 2566 Buried

flexible pipelines Part 2: ‘Installation’. The standard specifies the requirements for the

installation, field testing and commissioning of buried flexible pipelines with structural design

in accordance with AS/NZS 2566.1.

Installation, repair and maintenance of vonRoll DI pipe is the same as for all DI pipe systems

and should cause no problems for installers or maintenance personnel. When an ECOPUR®

pipe is cut, the exposed end can be coated with polyurethane which is supplied in a dual

cartridge applicator which ensures the components are mixed in the correct ratio. The same

cartridge applicators are used for minor repairs to the Polyurethane coating.

The vonRoll Product Catalogue show detailed installation instructions and ful l details on

carrying out minor repairs to the coating using the cartridge applicator. However, a range of

restrained and unrestrained mechanical couplings and flange adaptors are available to

enable end connections between CIOD to ISO pipe sizes, in order to maintain pipeline

systems.

7.2 Ductile iron fittings

A complete range of ECOFIT branded ISO sized ductile iron bends, tees, tapers and

connectors of size DN 80 to DN 700 are available from Keulahütte GmbH in Germany. Reece

also supplies AS/NZS 2280 manufactured socketed DI fittings for use with vonRoll DI pipes

using Gulf Rubber’s special adaptor seal for size DN 100, DN 150, DN 200, DN 250 and DN

300.

7.3 Tapped connections

ECOPUR® and DUCPUR® ductile iron pipes may be direct tapped with or without a suitable

tapping saddle. However it is suggested the practice of drilling holes in the pipe be minimised

where possible and that the use of Pre-Tap Connectors be utilised in new installations.

vonRoll DI pipes, ECOPUR® and DUCPUR® can be tapped for customer service connections with or without tapping saddle using a ferrule or ball valve. For more information on direct tapping of DI pipe refer to vonRoll hydro.

If the polyurethane coating or lining is damaged during this process please refer to 7.1 repair

lining and coating.

8 MAINTENANCE

A range of Mechanical Flexible Couplings and Flange Adaptors up to DN 700 and Stainless

Steel Repair Clamps up to DN 700 is available for use with vonRoll DI pipes.

9 PIPE LAYING TRAINING AND DEVELOPMENT OF TECHNICAL

LITERATURE

Reece do not intend to conduct training courses for the installation of vonRoll DI pipe, as

there is already Registered Training Organisations (RTO) conducting the training. Reece

will provide local advice and supervision for the first time users if required.

vonRoll have a comprehensive product brochure which lists all product range and has

comprehensive installation instructions, maintenance instructions, repair instructions and

design guidance.

10 PRODUCT MARKING

10.1 vonRoll DI pipes for water supply and sewerage

vonRoll DI pipes and fittings are branded with markings which clearly identify the

manufacturer’s mark, nominal size, classification, traceability using batch number and codes


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for manufacturing facility locations, and manufacturing standard. Additional markings have

been added to identify pipe class, internal linings and external coatings.

For example pipes are permanently and legibly labelled with the following markings

conforming to EN 545, EN 598 and ISO 2531 and proposed additions:

Manufacturer’s name - vonRoll

Year of manufacture – xx e.g. 14 cast into socket for 2014

Identification as ductile iron - cast into socket

Nominal size – DN xxxx cast into socket

The PN rating of the flange (when applicable) – PN 16 or PN 35

Reference to Standard – EN 545 or EN 598

Classification – Thickness class K9 and pressure class (C25, C30, C40, C64, C100)

Insertion marking line at spigot

FIGURE 21: EXAMPLES OF PIPE MARKING ON ECOPUR®

FIGURE 22: WITNESS MARKS ON ECOPUR®


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FIGURE 23: STORAGE OF ECOPUR® DI PIPE WITH CAPS

10.2 ECOFIT DI fittings

ECOFIT ductile iron fittings are marked in accordance with EN 545 and EN 598. All fittings

are permanently and legibly labelled with the following:

• Manufacturers name or mark

• Year of manufacturer

• The identification as ductile iron

• The DN

• The PN rating of the flange (when applicable)

• The reference to this standard

FIGURE 24: ECOFIT DUCTILE IRON FITTINGS


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10.3 Polyethylene sleeving

The Polyethylene sleeving supplied by Reece for use with DUCPUR® and GEOPUR® ductile

iron pipes is marked as follows and is in accordance with AS 3680 Polyethylene sleeving for

ductile iron pipelines:

• Manufacturer’s name.

• Date of manufacture.

• Width of sleeving and corresponding nominal pipe size.

• Nominal film thickness.

10.4 Elastomeric joint seals

10.4.1 Elastomeric seals – supplied by WOCO for use on vonRoll DI pipe and

ECOFIT DI fittings

These elastomeric joint seals are marked with the following

• Nominal Size

• The quarter and year of Manufacture

• Manufacturer’s identification

• The abbreviation for the rubber, e.g. EPDM or NBR

• The reference to standard with type of application and hardness category as suffix; e.g.

EN 681-1/WB/50

Example: DN150 WOCO TYTON 026004/9 EN 681-1 WAL WCL 50 EPDM

WAL refers to the designation of elastomeric joint seals by type. Type WAL refers to cold

potable water supply application. In the above example 50 refer to the hardness category.

10.4.2 Special Transition Elastomeric seals – for use on vonRoll DI pipe and AS/NZS

2280 manufactured socketed fittings

The TYTON® Special transition elastomeric seals are slightly thicker than the Australian

Standard TYTON elastomeric seal. Gulf Rubber supplies these special transition seals.

FIGURE 25: GULF RUBBER TYTON® SPECIAL ADAPTOR ELASTOMERIC SEAL

These elastomeric seals are marked with:


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• The DN

• Year of manufacturer

• Manufacturer’s code

• Name of seal

• The reference to Standard

• Orange Spot

11 TRACEABILITY

All vonRoll ductile iron pipes and ECOFIT ductile iron fittings are provided with identification

batch marking and recording on inspection and test reports.

12 PACKAGING AND TRANSPORTATION

vonRoll pipes transported from Switzerland to Australia will be in the standard bundle (pack)

configuration stacked inside transport container units. Pipes bundles have wooden supports

and spacers and are restrained with plastic strapping (See Figures 26, 27 & 28).

FIGURE 26: PLASTIC STRAPPING

FIGURE 27: WOODEN SUPPORTS

FIGURE 28: SPACERS

The normal method of transporting vonRoll ductile iron pipes is as follows:

• DN 80 to DN 300 Socket / Spigot DI pipes are delivered in bundles (packs).

• Pipes larger than DN 300 are delivered as single pipes.

vonRoll DI pipe bundles are covered with UV protective film. This covering should only be

opened when necessary and should be closed again afterwards. Each pipe is sealed on

socket and spigot end with caps. Experience to date shows there has been very little damage

to the pipe coating during transport from Switzerland.

Only wide synthetic lifting belt should be used when loading and unloading the pipes to

prevent damage to the polyurethane coating.

Piping components made of elastomers, e.g. EPDM jointing rings, can be affected by heat,

light, ozone, dampness, solvents and storage under tension. For this reason particular care

must be taken with the storage and handling of these items. Precautions include:

• Max temperature 25°C and Minimum -10°C

• Keep away from UV light

• Relative Humidity under 65%

• No ozone exposure e.g. keep away from electric motors


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• Stored without tension e.g. not hung on any part of their circumference

FIGURE 29: PIPE BUNDLES

TABLE 16: PIPE BUNDLES / PERMISSIBLE STAKING HEIGHT

DN Pipe

Length m

Pipes per

Bundle

Bundle Height

cm

Bundle Width

cm

Bundle Length LB

m

Weight per Bundle

kg

Max. No. of Bundles

Stackable

80 6 14 30 74 6.3 1200 15

100 6 12 35 78 6.3 1250 13

125 6 10 40 78 6.3 1260 12

150 6 8 45 77 6.3 1280 11

200 6 6 58 73 6.3 1315 9

250 6 4 67 62 6.35 1040 8

300 6 4 80 75 6.35 1360 7

13 PRODUCT WARRANTY

The standard warranty according to vonRoll hydro (suisse) ltd sales conditions is 12 months.

However vonRoll can provide additional warranty as per Customer request.

14 WATER AGENCY EXPERIENCE WITH THE PRODUCT OR FIELD TESTING

REPORT

Examples of long and short-term use by the water industry were sought. The longer-term

information focused on the polyurethane coating performance and was obtained overseas.

The shorter-term experiences of local water Agencies were obtained to gauge installation

practices.

14.1 Long Term

The polyurethane lined pipe and more recently the lined and coated pipe has been used

widely by Zürich Water in Switzerland since the product was first developed in 1972. Some

problems were encountered with the first generation internal lining that resulted in a change

of coating formulation. The original polyurethane was of the flexible type and when this

showed signs of blistering, further research was carried out which led to the development of

a rigid polyurethane version. This later generation of coating has much higher adhesion

strength to the ductile iron that provides superior performance. The change to rigid

polyurethane was made in 1978.

A section of first generation pipe was inspected which had 20 years’ service and while this

showed considerable blistering, minimal rusting of the substrate was apparent. It was

reported that similar aged rigid polyurethane pipe performed very well without any blistering

or deterioration. Zürich Water have also carried out controlled tests since 1990 to monitor

the performance of the ECOPUR® and DUCPUR® pipes in different soil types and at the end

of 1998 they are satisfied with the results.


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14.2 Short Term

Locally, City West Water in Melbourne has been using both ECOPUR® and DUCPUR® pipes

for approximately 16 years. Feedback from the construction crews has been positive and no

major problems have been encountered. It was reported that it was eas ier to lay the pipe as

the jointing pressures being quite low. The pipe was also easier to handle and there did not

seem to be a major problem in external coating damage to the ECOPUR® during normal

handling.

On a precautionary note, a greater input into the supply logistics is required to ensure that

the correct fittings and adaptor rings are available and supplied. The repair coating used to

make good cut ends of the pipe also took considerable time to cure but this was usually

avoided by better planning.

Refer to Appendix H for site photographs of vonRoll ECOPUR® ductile iron pipes used at

City West Water in Melbourne

15 AVAILABILITY OF PRODUCTS

Reece is a national supplier of pipes, fittings and ancillary items for the water industry around

Australia. Reece have large stock holdings of vonRoll products in their local warehouses and

a major central warehouse with overnight deliveries to all states. The office locations with

contact details are shown in Appendix F as follows:

Head Office is located in Victoria at: Reece Australia Limited, 118 Burwood Highway,

Burwood VIC 3125; Tel: 03 9274 0132; Website: www.reece.com.au

16 REPAIRS TO POLYURETHANE COATING

Users should be mindful to watch for external damage to the polyurethane coating of

ECOPUR® DI pipe as it may be difficult to detect damage in a black coating on a black pipe.

One product is available for the repair of the polyurethane coating and lining. Repairs are

recommended when ECOPUR® pipes are cut or damaged. The repair material is an epoxy

repair kit. The epoxy repair kit is used for repairs of smaller surfaces, e.g. cut ends up to DN

300 and repairs with area up to approximately 100 Sqcm. Either repair kit can be used on

the interior green lining or exterior black coating. Similarly where cut or drilled holes are

made in the pipe, repairs should be made or if that procedure is carried out under pressure,

an anti-tuberculation insert should be provided to prevent blockage of the outlet. As stated

in Section 7.3, where possible the Pre-Tap Connectors be utilised in providing new services

instead of drilling holes on the pipe to provide services using ball valves / ferrules and tapping

bands.

Zürich Water is one the long term users of vonRoll DI pipes. Feedback from Zurich Water

indicated that they no longer repair cut ends as the level of corrosion is minimal and is

unlikely to constitute a future failure point in pressure mains.

17 DISCUSSION

vonRoll has pioneered polyurethane materials for use as a pipe lining and coating over the

last 42 years. During this time the product has been used extensively in some European,

African and Middle East markets. The direct information from one of the larger and longest

users, Zürich Water, has been positive with excellent performance reported.

The polyurethane coatings are now being adopted by some pipe manufacturers in the USA

and several recent technical papers have provided testing data of various pipe linings. While

the data does not provide any details of long-term performance the information does provide

data which demonstrates superior physical properties of polyurethane coatings compared to

other more conventional linings. This information from users and current trends in other parts

of the world give confidence that the vonRoll product will provide a long life pipe system.

http://www.reece.com.au/


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One of the advantages of this pipe is the relative inertness of the lining that has no adverse

effect on the water quality. Additional corrosion protection is not required with the ECOPUR®

pipe.

The literature claims that the ECOPUR® pipe can be directly backfilled and buried with the

original trench excavation material. The polyurethane coating has high levels of adhesion

and is reported to have high resistance to damage and undercutting. If the external coating

is damaged, corrosion will occur and depending on the extent of damage a perforation may

occur in the longer term. While in some cases the use of trench excavation material could

be used, a number of risks emerge if this practice is adopted.

Increases the risk to damage if stony or rocky material is used up to 60 mm size.

Some trench excavation material, bigger than 100 mm, would be very difficult if not

impossible to compact which would be a problem under a carriageway.

In general it is felt that for maximum protection, selected bedding and backfills should be

utilised to minimise damage to the external coating. It is recommended to use bedding

material as sand or gravel up to 32 mm size.

In a similar context the DUCPUR® pipe with a combined external coating of zinc and bitumen

is claimed to overcome the need to use loose fit polyethylene sleeving in low corrosivity

soils. The use of the zinc/bitumen external coating is widely used in some parts of the world

without sleeving and specific criteria has been set down where sleeving is and isn’t required.

Similar criteria can be used for ductile iron with a bitumen coating but the majority of

Australian Water agencies have adopted the policy of full sleeving of all ductile iron pipe with

zinc/bitumen coating. It is well documented that the application of a zinc coating will not

detract from the performance and in some environments there are definite improvements to

the performance of the pipe. Unless the environment is known to be low corrosivity, the use

of the sleeving in conjunction with the DUCPUR® pipe is recommended.

Like all pipes, it is better to avoid the cutting of holes which can act as points of corrosion or

stress failures so it is felt that the use of pre tapped connector fitt ings for the connection of

services should be adopted in the first instance to minimise this effect. Where holes have to

be cut the use of plastic inserts is recommended to prevent the growth of rust tubercles that

can reduce flow in the longer term.

For the tapping of the vonRoll ECOPUR® and DUCPUR® DI pipes, there will be no damage

to the coating and lining if the right equipment/device is used. Tapping with saddle under

pressure is always possible for the vonRoll DI pipes up to and including DN 400.

If copper services are used in conjunction with these pipes it is essential to use insulated

fittings to prevent galvanic attack of the ductile iron.

18 OUTCOMES OF EXPERT PANEL PRODUCT REVIEW

Comments received by members of the Expert Panel during the peer review period have

been addressed in this version of the Report.

19 LIFE EXPECTANCY

Operational experience with cast iron pipe in Australia has shown a life expectancy of over

100 years. The new generation of ductile iron pipes with the specialist coatings can only be

expected to extend this life even further. On this basis an operational pipe life of well over

100 years can be expected.

The manufacturing standards used for the pipe have similar performance requirements to

AS/NZS 2280 in that testing of dimensions, mechanical properties, joint performance and

pressure testing are all performed on the pipes during manufacture. The ductile iron has

equivalent mechanical properties to AS/NZS 2280 i.e. Minimum tensile strength of 420 MPa

and Minimum elongation of 10%. The certification from MPA NRW confirms conformity to

the relevant EN standards; i.e. EN 545 and EN 598.


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vonRoll have been manufacturing centrifugally cast iron pipes since 1925. In 1965 the pipe

material changed from grey cast iron to ductile iron and in the early 1970’s the internal

coating was changed to polyurethane.

vonRoll have supplied approximately 60-70% of all pipe in Switzerland, most of which has

been lined with polyurethane since its introduction. Zürich Water has been a major user and

was involved in the initial development of the polyurethane lining and they have been

monitoring the pipe’s performance since that time. They have exhumed some early

polyurethane coated installations and the coating was reported as being as good as when it

was installed.

20 FUTURE WORKS

There are no future work requirements.

21 DISCLAIMER

This Product Appraisal Report (Report) is issued by the Water Services Association of

Australia Limited on the understanding that:

This Report applies to the product(s) as submitted. Any changes to the product(s) either

minor or major shall void this Report.

To maintain the recommendations of this Report any such changes shall be detailed and

notified to the Product Appraisal Manager for consideration and review of the Report and

appropriate action. Appraisals and their recommendations will be the subject of continuous

review dependent upon the satisfactory performance of products.

WSAA reserves the right to undertake random audits of product manufacture and installation.

Where products fail to maintain appraised performance requirements the appraisal and its

recommendations may be modified and reissued. Appraisal reports will be reviewed and

reissued at regular intervals not exceeding five (5) years.

The following information explains a number of very important limits on your ability to rely on

the information in this Report. Please read it carefully and take it into account when

considering the contents of this Report.

Any enquiries regarding this report should be directed to the Program Manager Asset

Creation, Carl Radford, Phone: (03) 8605 7601 email: [email protected].

21.1 Issue of Report

This Report has been published and/or prepared by the Water Services Association of

Australia Limited and nominated Project Manager and peer group of technical specialists

(the Publishers).

The Report has been prepared for use within Australia only by technical specialists that have

expertise in the function of products such as those appraised in the Report (the Recipients).

By accepting this Report, the Recipient acknowledges and represents to the Publisher(s)

and each person involved in the preparation of the Report that the Recipient has understood

and accepted the terms of this Disclaimer.

21.2 Limits on Reliance on Information and Recommendations

21.2.1 Disclaimer of liability

Neither the Publisher(s) nor any person involved in the preparation of the Report accept(s)

any liability for any loss or damage suffered by any person however caused (including

negligence or the omission by any person to do anything) relating in any way to the Report

or the product appraisal criteria underlying it. This includes (without limitation) any liability

for any recommendation or information in the Report or any errors or omissions.

tel:%2803%29%208605%207601

mailto:[email protected]


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21.2.2 Intellectual Property and other rights

The Water Services Association of Australia Limited does not undertake any assessment of

whether the importation, manufacture, sale or use of the Product the subject of this Report

infringes the intellectual property rights or proprietary rights of any person. Recipients of the

report should undertake their own assessment of whether (as relevant) the importation,

manufacture, sale or use of the relevant Products infringe the intellectual property rights or

other proprietary rights of any person. If the Product infringes intellectual property rights or

other proprietary rights there is potential for the supply of the Products to be interrupted.

From time to time the Water Services Association of Australia Limited and the other

Publishers may receive notice of allegations that the importation, manufacture, sale or use

of the Product infringes intellectual property rights or other proprietary rights. The Water

Services Association of Australia Limited's policy is to not refer to such allegations in its

reports or take any other steps to put Recipients on notice of such allegations, unless and

until it is aware that the allegations have been admitted or proved in Court. As such,

Recipients acknowledge, agree and accept that the Water Services Association of Australia

Limited may have information in its possession about intellectual property rights infringement

allegations or other infringement allegations in relation to the Product which are not referred

to or disclosed in this Report and which are not otherwise communicated to Recipients.

21.2.3 Need for independent assessment

The information and any recommendation contained (expressly or by implication) in this

Report are provided in good faith (and subject to the limitations noted in this Report).

However, you should treat the information as indicative only. You should not rely on that

information or any such recommendation except to the extent that you reach an agreement

to the contrary with the Publisher(s).

This Report does not contain all information that a person might require for the purposes of

assessing any product discussed or appraised within it (Product). The product appraisal

criteria used in preparing this Report may not address all relevant aspects of the Product .

Recipients should seek independent evidence of any matter which is material to their

decisions in connection with an assessment of the Product and consult their own advisers

for any technical information required. Any decision to use the Product should take into

account the reliability of that independent evidence obtained by the Recipient regarding the

Product.

Recipients should also independently verify and assess the appropriateness of any

recommendation in the Report, especially given that any recommendation will not take into

account a Recipient’s particular needs or circumstances.

WSAA has not evaluated the extent of the product liability and professional indemnify

insurance that the provider of the product maintains. Recipients should ensure that they

evaluate the allocation of liability for product defects and any professional advice obtained

in relation to the product or its specification including the requirements for product liability

and professional indemnity insurance.

21.2.4 No Updating

Neither the Publisher(s) nor any person involved in the preparation of this Report [has] [have]

any obligation to notify you of any change in the information contained in this Report or of

any new information concerning the Publisher(s) or the Product or any other matter.

21.2.5 No Warranty

The Publisher(s) do[es] not, in any way, warrant that steps have been taken to verify or audit

the accuracy or completeness of the information in this Report, or the accuracy,

completeness or reasonableness of any recommendation in this Report.


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APPENDIX A – GERMAN ACCREDITATION SYSTEM

German Accreditation System for Testing (DAP) is a member of the German Accreditation

Council (DAR), the European co-operation for Accreditation (EA), the International

Laboratory Accreditation Co-operation (ILAC), the International Accreditation Forum (IAF)

and their Multilateral Agreements for Recognition (MLA and MRA), a member of the

European Federation of National Associations of Measurement, Testing and Analytical

Laboratories (EUROLAB), the European Organisation for Quality (EOQ), the German

Society for Quality (DGQ) and the German Institute for Standardization (DIN).

DAP is a legally independent accreditation bodies in the German. It is responsible for the

accreditation of testing and research laboratories, of certification bodies and of inspection

bodies in the voluntary area. DAP’s primary activity is the accreditation of material testing

and chemical analytical bodies in Germany. The European Series of Standards DIN EN

45000, the DIN EN ISO/IEC 17025 and the ISO/IEC-Guides are the basis for the

accreditation.

The equivalence of the accreditation systems of many countries in Europe is determined

through the European co-operation for Accreditation (EA) Multilateral Mutual Recognition

Agreements (MLA), which are signed for accreditation programmes of specific conformity

assessment activities, such as testing laboratories and product certification bodies.

Signatories to the EA MLAs recognise mutually each other's accreditation systems as being

equivalent to their own.

Bilateral agreements between EA and other accreditation bodies outside Europe have also

been signed, thereby facilitating the mutual recognition of these accreditation systems

outside of EA. Membership of the EA MLA is achieved by successfully undergoing a system

of peer evaluations. DAP is a signatory to the EA MLA for testing laboratories and product

certification bodies since 1999. In addition, DAP also signed (through DAR) the Mutual

Recognition Arrangement of International Laboratory Accreditation Cooperation (ILAC) of

International Laboratory Accreditation Cooperation (ILAC) on 02.11.2000 and on 09.10.2004

the Mutual Recognition Arrangement of International Accreditation Forum (IAF). These

Agreements and the Arrangement would in general form the prerequisite for the recognition

of test reports and certificates issued by DAP conformity assessment bodies (testing

laboratories, certification bodies for products and inspection bodies) in the respective

countries of ILAC signatories.

The vonRoll Catalogue pages mentioned in the above A1 and A2 are available for

downloading from the WSAA Members Website or from the Von Roll website at




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APPENDIX B – QUALITY CERTIFICATIONS

Copies of the following Quality Certification Certificates are available from the WSAA

Member’s Website.

TABLE B1: REECE AUSTRALIA LTD – MANAGEMENT SYSTEMS

Head Office: 118 Burwood Highway, Burwood VIC 3125

Reece Quality Processes: Although Reece does not have a formal certified Quality Management System, they have, over the past 95 years, been developing a significant management system, the Reece Business Management System (RBMS) which underpins the delivery of Customer Projects. Please see the letter issued by Reece in the following page.

TABLE B2: VONROLL HYDRO (SUISSE) AG – MANAGEMENT SYSTEMS

Head Office: 4702 Oensingen, Switzerland

Quality Systems Standard ISO 9001:2008

Certificate of Registration 20430

Certifying agency SQS / IQNet

Issued 1 April 2017

Expiry date of certification 31 March 2020

TABLE B3: VONROLL HYDRO (SUISSE) AG – CERTIFICATE OF CONFORMITY

Enterprise and Factory: VonRoll-Strasse 24 – CH-4702, Oensingen / Factory: vonRoll Casting (pipe system) sa, CH-2830, Courrendlin

Product Standard EN 545:2010 – Ductile iron pipes, fittings, accessories and their joints for water pipelines

Certificate No. 11 7416-1

Certifying agency MPA NRW

Original Issued Date 30 November 2012

Expiry date of certification 1 December 2018

TABLE B4: VONROLL HYDRO (SUISSE) AG – CERTIFICATE OF CONFORMITY

Enterprise and Factory: VonRoll-Strasse 24 – CH-4702, Oensingen / Factory: vonRoll Casting (pipe system) sa, CH-2830, Courrendlin

Product Standard EN 598:2009-2010 – Ductile iron pipes, fittings, accessories and their joints for sewerage applications

Licence 11 7417-1

Certifying agency MPA NRW

Original Issued Date 30 November 2012



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TABLE B5: KEULAHÜTTE GMBH, GERMANY – MANAGEMENT SYSTEMS

Keulahütte GmbH, Geschwister-Scholl-Straße 15, 02957 Krauschwitz, Germany


Certificate of Registration 01 100 4186

Certifying agency TÜV Reheinland Cert GmbH

Issued 28 September 2015

Expiry date of certification 14 September 2018

TABLE B6: KEULAHÜTTE GMBH, GERMANY – CERTIFICATE OF CONFORMITY

Keulahütte GmbH, Geschwister-Scholl-Straße 15, 02957 Krauschwitz, Germany

Product Standard

EN 545:2010 – Ductile iron pipes, fittings, accessories and their joints for water pipelines

EN 598:2009-2010 – Ductile iron pipes, fittings, accessories and their joints for sewerage applications

Licence DV-7705BM0164

Certifying agency DVGW CERT – DakkS, Germany

Original Issued Date NA

Expiry date of certification 22.03.2018

TABLE B7: REX ARTICOLI TECNICI SA – MANAGEMENT SYSTEMS

Rex Articoli Tecnici SA, 6850 Mendrisio, Suisse



Certifying agency SQS / IQNet

Original Issued Date 2 August 2013

Issued 3 August 2016


NOTE: This Certificate is in French Language


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TABLE B8: REX ARTICOLI TECNICI SA AND VONROLL HYDRO (SUISSE) AG –

CERTIFICATE OF CONFORMITY FOR INTERNAL RESTRAINT JOINT

Rex Articoli Tecnici SA, 6850 Mendrisio, Suisse and VonRoll-Strasse 24 – CH-4702, Oensingen

Product Standard EN 545:2007 – Ductile iron pipes, fittings, accessories and their joints for water pipelines

Licence 1130-700197 15-01

Certifying agency MPA NRW – DakkS, Germany

Original Issued Date NA

Issued 11 May 2015

Expiry date of certification 11 May 2018

NOTE: This Certificate is in German Language

TABLE B9: WOCO INDUSTRECHNIK GMBH – MANAGEMENT SYSTEMS

Hanauer LandstraBe 16, 63628 Bad Soden-Salmunster, Germany

Quality Systems Standard ISO/TS 16949:2009


Certifying agency TUV SUD

Current Issued Date 18 January 2016


TABLE B10: GULF RUBBER AUSTRALIA AND THONG NHAT RUBBER COMPANY

RUTHIMEX – MANAGEMENT SYSTEMS

Business Location: 12-13 Green Street Revesby NSW 2122 Australia:


Certificate No. QEC 23575

Certifying agency SAI Global

First date of certification 26 November 1998

Current date of certification 18 May 2015

Expiry date of certification 14 May 2018


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TABLE B11: GULF RUBBER AUSTRALIA AND THONG NHAT RUBBER COMPANY

RUTHIMEX – PRODUCT CERTIFICATION

Business Location: 12-13 Green Street Revesby NSW 2122 Australia: Hamlet #12, Tan Thanh Dong Village, Cu Chi District, Vietnam

Product Standard AS 1646:2007 – Elastomeric seals for waterworks purposes

Certificate No. SMKP20133

Certifying agency SAI Global

First date of certification 10 December 2003

Current date of certification 19 May 2014


TABLE B12: VAN BAERLE AG – MANAGEMENT SYSTEMS

Manufacturing Plant: van Baerle AG, 4142 Münchenstein, Switzerland


Certificate No. 10727

Certifying agency SQS, Bernstrasse 103, 3052 Zollikofen, Switzerland

First date of certification 28 August 2003

Current date of certification 28 August 2015

Expiry date of certification 27 August 2018


TABLE B14: VAN BAERLE AG – PRODUCT CERTIFICATION

Manufacturing Plant: van Baerle AG, 4142 Münchenstein, Switzerland

Product Standard SVGW W-UK7 / Liquid soap TN2

Certificate No. 1205-6040 / KA 0086/12 / 12 CLP LY 003

Certifying agency SVGW (Switzerland) / TZW (Germany) / CARSO (France)

First date of certification 5 January 2012

Current date of certification 2. March 2013

Expiry date of certification 30 April 2018



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APPENDIX C – VONROLL DI PIPE ‘C’ CLASS AND ‘K’ CLASS


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APPENDIX D – UNRESTRAINED AND RESTRAINED JOINTS FOR VONROLL DI PIPES AND ECOFIT DI FITTINGS

D1: VONROLL DI PIPES DN 80 – 700 – UNRESTRAINED AND RESTRAINED JOINTS

Unrestrained Restrained

Double Chamber

DN 80 - 500

Single Chamber

DN 600 - 700

Pipe with double chamber socket (DN 80 - 500) fitted with unrestrained HYDROTIGHT seal TYTON® EPDM (water), NBR (sewer)

with an additional:

Pipe with single chamber socket (DN 600 - 700) fitted with

unrestrained HYDROTIGHT seal TYTON® EPDM (water), NBR (sewer),

with an additional

HYDROTIGHT seal TYTON® - EPDM (water) Fig 2810

- NBR (sewer) Fig. 2811

HYDROTIGHT seal TYTON® - EPDM (water) Fig. 2810

- NBR (sewer) Fig 2811

Internal Restrained DN 80 – 500 External

Restrained DN 80 - 500

Internal Restrained

DN 600

External Restrained

DN 600 - 700

HYDROTIGHT internal thrust-resisting ring Fig. 2807B for DN 80 to DN 300

HYDROTIGHT internal thrust-resisting ring Fig. 2807A for DN 80 to DN 500

Internal restrained joint combined gasket with steel teeth TYTON®-SIT® Fig. 2504 (DN 80-400) or TYTON®-SIT PLUS® Fig. 2504S (DN 80 – 500)

NOTE: there is no unrestrained HYDROTIGHT seal TYTON®

External restrained joint Fig. 2806 (DN 80 – 500)

Internal restrained joint combined gasket with steel teeth TYTON®-SIT PLUS® Fig. 2504S (DN 600)

External restrained joint Fig. 2805 (DN 600 – 700) with welded bead

D2: ECOFIT DI FITTINGS – UNRESTRAINED AND RESTRAINED JOINTS

Unrestrained Joint Single Chamber DN 80 - 700

Restrained

Internal Restrained Joint Single Chamber DN 80 - 600

External Restrained Joint Single Chamber DN 80 - 700

Hydrotight seal TYTON®

- EPDM (water) Fig 2810 - NBR (sewer) Fig. 2811

Internal restrained joint combined gasket with steel teeth TYTON®-SIT® Fig. 2504 (DN 80 – 400) or TYTON®-SIT PLUS® Fig. 2504S (DN 80 – 600)

External restrained joint Fig.

2806 (DN 80 – 500) without

welded bead

External restrained joint Fig.

2805 (DN 600 – 700) with

welded bead


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APPENDIX E - WSAA PRODUCT SPECIFICATION


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APPENDIX F - SUPPLIER CONTACTS

Although Reece have over 480 branch locations throughout Australia, they have provided a

reduced list as shown in the below that are specialist Civil locations who are being trained

on VonRoll products and have the facilities onsite to distribute.

Reece believe by having more than one location in every state they can provide a greater

service level to their customers.

The Customers have to contact their closest Reece Civil Branch by

visiting www.reece.com.au/civil or phone 1800 032 566

http://www.reece.com.au/civil

tel:1800%20032%20566


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APPENDIX G – MPA NRW AUDIT OUTCOME AT VONROLL’S MANUFACTURING PLANT

a) Manufacturing plants: vonRoll casting sa, Choindez, CH-2830 Courrendlin, Switzerland

b) Scope of the audit: The scope of the audit is defined in line with the requirements in

DIN EN 545 and DVGW GW 337-P, and covers ductile cast iron pipes for water pipelines

designed for conducting drinking water.

c) During the audit: The production facilities were inspected, and mechanical values were

determined in the materials laboratory from reference samples. The officer examined the

microstructure on random samples under a light-optical microscope. In the selected

samples (13 embedded samples from between 14.04.2014, 9:40 and 15.04.2014, 11:50),

the officer found a completely pearlitic microstructure with nodular graphite. The officer

also took measurements on random product samples in the finished parts store.

The audit covered the following:

• Basic requirements for the plant production control system

• Continuous monitoring of production

• Recording and documentation

• Material mechanical characteristic values from reference samples

• Dimension check on pipes (DIN EN 545)

• Coating thickness testing on pipe coating

External coating thickness from 10 measured values: Average coating thickness > 70 µm;

Minimum coating thickness > 50 µm

Internal lining thickness from 10 measured values: DN 80 - DN 300 > 1.3 mm; DN 350 - DN

600 > 1.5 mm; DN 700 > 1.5 mm

d) Outcome of the audit: In conclusion, it has been found that the certificate holder vonRoll

hydro (suisse) ag in Oensingen (Switzerland) has the necessary measures in place in

terms of staff, production and testing, as well as a plant production control system, in

order to ensure that ductile cast iron pipes can be manufactured in accordance with the

requirements.

e) Results of the independent audit: The vonRoll hydro (suisse) ag manufacturing plant

in Oensingen (Switzerland) and its production facility, vonRoll casting sa, in Courrendlin

(Switzerland) have the necessary measures in place in terms of staff, production and

testing, as well as a plant production control system, in order to ensure that ductile cast

iron pipes for water pipelines can be manufactured in accordance with DIN 545 and

DVGW GW 337-P.


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APPENDIX H – SITE PHOTOGRAPHS

Project Details for ECOPUR® Ductile Iron pipe

City West Water, Melbourne

Location: Mt Alexander Road, Moonee Ponds

Project details: Pipe size 200 mm; length 1.1 km

Where these pipes were laid: along roadway

Project type: Watermain renewal dated 26th June 2013

Contractor: Scarriff Pipelines Pty Ltd

City West Water, Melbourne

Location: A’Beckett Street in Melbourne

Project details: Water main upgrade, 235 metres of pipe from 150 mm to 200mm

Where these pipes were laid: along roadway

Project type: Watermain upgrade in Sept 2012

Contractor: Downer EDI Works Pty Ltd


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Mt Alexander Road, Moonee Ponds – Site photos


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A’Beckett Street in Melbourne


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Melbourne Office

Suite 8.02 Level 8,

401 Docklands Drive Docklands VIC 3008

Phone: (03) 8605 7601 Fax: (03) 8605 7612 Sydney Office

Level 11, 39 Martin Place Sydney NSW 2000

GPO Box 915 Sydney NSW 2001

Phone: (02) 9221 5966 Fax: (02 9221 5977

www.wsaa.asn.au

http://www.wsaa.asn.au/

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