Certification Scheme

Transcription

1 Certification Scheme WN Glazed vitrified clay pipes, fittings and their accessories for drains and sewers DIN, Part 1-7 (Edition: March 2018)

2 drains and sewers Page 2 of 22 CONTTS Preface...3 Start of validity..3 1 Domain of application Testing and certification basics Symbols and abbreviations Increased requirements... 4 Appearance... 4 Abrasion resistance... 4 Steel... 4 Continuity of invert of jacking pipes... 4 Deviation from straightness... 4 Crushing strength and bending tensile strength of pipes and jacking pipes and compressive strength of jacking pipes... 5 Bending moment resistance... 5 Fatigue strength under cyclic load (jacking pipes)... 5 Water tightness of pipes... 5 Angular deflection... 6 Water tightness of pipes at 2,4 bar... 6 Water tightness of pipes at 1 bar... 6 Airtightness of jointed pipes under positive pressure... 7 Chemical resistance of joint assemblies... 7 Chemical resistance of jointing materials... 8 Dimensions of pipes and fittings Other requirements Quality Management System Pre-testing (ITT) and Factory Production Control (FPC) Purchased products Third Party Control Inspections Third party control Test report Certificate / Quality Label Annex A Scope Factory Production Control and Third Party Control... 16

3 drains and sewers Page 3 of 22 Preface The basis for certification of vitrified clay pipe systems is the familiar and well- established European Standard. This standard covers all requirements which are necessary to guarantee product quality and long lifetime. This certification scheme describes supplementary requirements and sets out principles for testing, monitoring and third-party control. Start of validity This certification scheme is valid as from 1st April Domain of application This certification scheme applies to vitrified clay pipes, fittings, manholes, supplied joints and accessories. 2 Testing and certification basics The basis for testing and certification are the documents listed below. -1 Vitrified clay pipe systems for drains and sewers Part 1: Requirements for pipes, fittings and joints ( ) -2 Vitrified clay pipe systems for drains and sewers Part 2: Assessment and verification of constancy of performance ( ) -3 Vitrified clay pipe systems for drains and sewers Part 3: Test methods ( ) -4 Vitrified clay pipe systems for drains and sewers Part 4: Requirements for adaptors, connectors and flexible couplings ( ) -5 Vitrified clay pipe systems for drains and sewers Part 5: Requirements for perforated pipes and fittings ( ) -6 Vitrified clay pipes systems for drain and sewers Part 6: Requirements for components of manholes and inspection chambers ( ) -7 Vitrified clay pipe systems for drains and sewers Part 7: Requirements for pipes and joints for pipe jacking ( ) C/TR Vitrified clay pipes systems for drain and sewers: Guidance for voluntary third-party certification procedures ( ) Steinzeug-Keramo Certification Scheme WN

4 drains and sewers Page 4 of 22 3 Symbols and abbreviations The symbols and abbreviations of :2013 are applicable to this certification scheme. The following symbols and abbreviations should also be noted: Symbol a m d M e min. Shore A 7 Shore A 7/7 V 7 Meaning Average abrasion depth (abrasion resistance test) Outside diameter of the pipe body in mm for jacking pipes Cylindrical shaft length at the spigots of all fittings Relative change in Shore hardness as % after depositing in the test fluid for seven days at (23 2) C Relative change in Shore hardness after depositing in test fluid for seven days at (23 2) C and subsequent drying-out at normal temperature 23/50 2, DIN Relative change in volume as % after depositing in test fluid for seven days at (23 2) C bz Bending tensile strength, in N/mm 2 4 Increased requirements Appearance The appearance according to -1:2013 section 5.1.4, pipes are always glazed on the inside. Due to the production process a small, unglazed ring at the spigot-end can exist. Abrasion resistance Tested in accordance with -1:2013 section 5.17, a maximum level of a m 0.25 mm must not be exceeded. Steel In accordance with -7:2013, section steel for the sleeves for jacking pipes must comply with material no , under norm DIN Continuity of invert of jacking pipes Tested in accordance with -7:2013 section 4.2.4, a maximum of 1% of the nominal diameter must not be exceeded. Deviation from straightness For those products, produced in 2,5 meter construction length (fast firing process), where the pipes are glazed on the inside and unglazed at the outside, the maximum deviation from straightness must not exceed 2 mm/m.

5 drains and sewers Page 5 of 22 Crushing strength and bending tensile strength of pipes and jacking pipes and compressive strength of jacking pipes When assessing crushing strength, bending tensile strength and compressive strength in factory production control, the 95% fractal must be indicated and maintained at a 75% confidence level. This assessment relates to a period of a maximum of 8 consecutive weeks. Test method for determining the bending tensile strength The bending tensile strength is calculated out of the results of the crushing strength results. To check these calculated results the bending tensile strength is tested, using the four point loading test, on cylindrical test specimens which are drilled from the pipe. The crushing strength calculation, according to -3 section 8 (formula 4), may not be used. Bending moment resistance Whilst testing pipes (which are marked accordingly to the diameters in table 1), tested in accordance with -1:2013 section 5.11, the minimum values in table 1 must be exceeded. Table 1: Bending moment resistance DN FN BMR FN BMR FN BMR , Fatigue strength under cyclic load (jacking pipes) Tested in accordance with -7:2013 section 4.3.6, sample tests will be carried out at varying diameters. Evidence is obtained through the bending tensile strength from one diameter from each nominal-width group. Group 1: DN Group 2: DN 400 Water tightness of pipes When pipes or pipe sections are tested in accordance with -3:2012, Clause 12, the water addition after a testing time of 75 minutes (W 75) under a constant testing pressure of 50 kpa (0,5 bar) shall not exceed 0,04 l/m2 of wetted internal pipe surface area and there shall be no visible leakage. Pipes or pipe sections may not be previously tested with water or preconditioned.

6 drains and sewers Page 6 of 22 Angular deflection Socketed pipes: Tested in accordance with -1:2013 section 6.2, the required water tightness must be ensured, using the deflections shown in table 2: Table 2: Angular deflection for socketed pipes DN 100 to DN 200 DN 225 to DN 500 DN 600 to DN mm/m pipe length 50 mm/m pipe length 30 mm/m pipe length Jacking pipes: Tested in accordance with -7:2013 section 5.3 and section 5.4, the required water tightness must be ensured, using the deflections shown in table 3: Table 3: DN 200 DN 250 to DN 800 Angular deflection for jacking pipes 25 mm/m pipe length 20 mm/m pipe length > DN mm/m pipe length Water tightness of pipes at 2,4 bar Tested in accordance with -1:2013 section 6.2 and -7 section the required water tightness must be ensured by applying a test pressure of 2.4 bar (without shear load or angular deflection). During the testing time of 15 minutes no visual leakage may occur. This test is to be carried out on at least 2 pipes joined together, at room temperature. Water tightness of pipes at 1 bar Tested in accordance with -1:2013 section 6.2 and -7 section the required water tightness must be ensured by applying a test pressure of 1 bar (without shear load or angular deflection). During the testing time of 15 minutes no visual leakage may occur. This test is to be carried out on at least 2 pipes joined together, at room temperature.

7 drains and sewers Page 7 of 22 Airtightness of jointed pipes under positive pressure The airtightness of pipes, bends, junctions and pipe sections is tested in accordance with -1:2013 section 5.18 and for jacking pipes in accordance with -7 section 4.5. The requirements of table 4 must be ensured. This test is to be carried out on at least 2 pipes joined together, at room temperature. The test for bends, junctions and pipe sections is to be carried out on single products. Table 4: Airtightness under positive pressure Application Test procedure p 0 p Test period (minutes) mbar DN 100 DN 125 DN 150 DN 200 DN 250 DN 300 DN 350 DN 400 A LD B LE , ,5 14 Application Test procedure p 0 p Test period (minutes) mbar DN 450 DN 500 DN 600 DN 700 DN 800 DN 900 DN 1000 DN 1200 A LD B LE , DN 1400 Chemical resistance of joint assemblies Tested in accordance with -1:2013 section 6.5, exposed to: - sulphuric acid (ph level about 0) - caustic soda (ph level about 14) - nitric acid (ph level about 0) - sodium hypochlorite bleach (ph level about 14) The water tightness must be ensured.

8 drains and sewers Page 8 of 22 Chemical resistance of jointing materials Sealing elements made of rubber elastomers (KE (NBR / SBR / EPDM), polyurethane elastomers (PU (elastic sealing elements) and Duromers (rigid fairing materials) are used. Testing the chemical resistance of each separate jointing material in accordance with - 1:2013 sections & and -7:2013 section Carried out at four test samples in accordance with -3:2013 section and exposed over 168 hours at a temperature of (23 ± 2) C, to: - sulphuric acid (ph level about 0) - caustic soda (ph level about 14) the maximum levels shown in table 5 may not be exceeded. Table 5: Requirements Material Property Unit Requirement KE, PU, Duromers V 7 % 5 PU Shore A 7 Shore A 10 PU Shore A 7/ 7 Shore A 5 Test procedure After exposing the test samples to the test fluid, the relative change in volume V 7 and change in Shore A hardness Shore A 7 are being determined. After air-drying the change in Shore A hardness Shore A 7/ 7 is being determined. The Shore hardness is measured in accordance with DIN ISO 868 and the volume is determined at cm³. The time between removal of the test samples from the test fluid and the measurement should be not more than 5 minutes. In this context: V 7 Shore A 7 Shore A 7/ 7 relative change in volume as % after depositing in the test fluid for seven days at (23 2) C change in Shore A hardness after depositing in the test fluid for seven days at (23 2) C change in Shore A hardness after depositing in the test fluid for seven days at (23 2) C and then drying out for seven days at normal temperature 23/50-2 DIN 50014

9 drains and sewers Page 9 of 22 Dimensions of pipes and fittings The specifications to be met for pipes and fittings, in addition to :2013 per jointing system, are set out in tables 6 to 13. Test procedure Diameters of pipes and fittings DN 100 to DN 150 are measured at 0.5 mm, all other dimensions at 1 mm. Connection sizes with permissible deviations 1 mm are to be measured at 0.1 mm. The various diameters are to be measured at the following locations, recording the lowest and highest levels: - Internal diameter d1 on the interior side of the pipe shaft, at approx. 50 mm from the socket or spigot end - Outside diameter of the spigot end d3 at the exterior side of the pipe shaft at approx. 50 mm from the spigot end Table 6: Dimensions of pipes and fittings, jointing system F DN TKL FN 1 d 1 d ± ± 1,5 ± 3, ± ± 2,0 ± 3, ± ± 2,0 ± 4, ± ± 3,0 ± 5, ± ± 3,0 ± 5,0 Note: Pipes DN 100 to 200 FN 34, TKL 160 resp. TKL 200 correspond to type Standard Strength Image 1: Examples of jointing system F 1 95% fractal in accordance with section 4.6 does not apply to fittings 2 The maximum deviations apply only to the outside diameter in accordance with U/π (circumference divided by π acc. ) 3 The maximum deviations apply only to the outside diameter measured crosswise (sliding callipers)

10 drains and sewers Page 10 of 22 Table 7: Dimensions of pipes and fittings, jointing system C DN Standard Strength TKL Extra Strength TKL FN 1 d 1 d ± ± 5 260,0 d 4 d 5 260, ± ± 5 260,0 260, ± ± 5 275,0 276, ± ± 6 317,5 318, ± ± 6 341,5 342, ± ± 7 371,5 372, ± ± 7 398,5 399, ± ± 7 433,5 434, ± ± 8 507,5 ± 0,5 508, ± ± 8 515,5 516, ± ± 8 579,0 579, ± ± 9 605,0 605, ± ± 9 637,0 638, ± ± ,0 721, ± ± ,0 759, ± ± ,0 872, ± ± ,0 977,1 ± 0,5 Dimensions and maximum deviations d 3s on the spigot end Type S-joint are declared by the producer. Image 2: Jointing system C (Type K-joint) Image 3: Jointing system C (Type S-joint) 1 95% fractal in accordance with section 4.6 does not apply to fittings 2 The maximum deviations apply only to the outside diameter in accordance with U/π (circumference divided by π acc. )

11 drains and sewers Page 11 of 22 Table 8: Dimensions of plain ended pipes (open trench) DN FN 1 d 1 d M l ± ± ± ± ± ± 1 Dimensions and maximum deviation d 3 and d 3spr on both spigot ends are declared by the producer. Joint type declared by the producer. Table 9: Dimensions of jacking pipes DN FN 1 σbz (N/mm2) d 1 d M l ± 2, / ± ± / ± ± / , 1990 ± ± / , 1990 ± ± / , 1984 ± ± 7, / ± ± / ± ± / ± ± / ± ± / ± ± / ± ± / ± 1 Dimensions and maximum deviation d 3 and d 3spr on both spigot ends are declared by the producer. Joint type declared by the producer. Table 10: Dimensions of bends Image 4: Bend Bend length in mm DN e min. 15 ± 3 30 ± 4 45 ± 5 60 /90 ± 5 in mm x x x x Bends > DN 300 can be manufactured as a segmented bend with 2 or 3 segments. Test procedure The bend length has to be measured, using a talmeter, at the inside of the bend. The measured bend lengths may be below those specified. 1 95% fractal in accordance with section The bend length 90 is declared by the producer

12 drains and sewers Page 12 of 22 Table 11: Dimensions of junctions DN 1 DN 2 e min. in mm a in mm for branch angle of junctions 45 Compactjunction Compactjunction x x x x x x x x x & bis 800 Regular length l1 in mm -1 % to +4 % or min. ± 10 mm x x x x x x x x x x x x x x x x x x x x x x x x x The defined construction lengths are marked (x). The arms of the junctions (DN 2) are normally manufactured in Standard Strength (N). Other junctions are also conform the norm if the joint inter-changeability according to table 6 and 7 of this is being guaranteed and all the requirements of the are met. Image 5: Junction Image 6: Compact junction With regard to the crown marking of junctions jointing system C, right and left junctions are differentiated and marked as from diameter DN > 300. For DN 200 up to 300 the junction arm may be used either at the left or right side. The position of the junction arm should always be at 60 ± 10 from the pipe crown. 1 According to the declaration producer; however not less than 400

13 drains and sewers Page 13 of 22 Table 12: Dimensions of connecting sockets Type 1 Type 2 DN e e a e e / /-0 min / / / / / /-0 min / / / /-0 min / / / / / /-0 min / /-7 Connecting sockets are manufactured in standard strength (N) and are used together with the appropriate B-ring to make connections to the main pipes of the sewer system. The B-ring must be supplied by the manufacturer of the connecting sockets. a Image 7. Connecting socket type 1 Image 8. Connecting socket type 2 Table 13: Dimensions of connecting sockets C DN d 3 Groove depth et 1 Groove depth et Connecting sockets are manufactured in standard strength (N). They are used to make connections to the main pipes of the sewer system and have a factory fitted sealing profile. Shaftlength e Shaftlength e ,5 +1/-0 4,0 ± 0,5 10,5 ± 0,5 40 ± 2,5 59 ± 2, ,5 +1/-0 4,0 ± 0,5 10,5 ± 0,5 70 ± 2,5 89 ± 2, ,5 +1/-0 4,0 ± 0,5 10,5 ± 0,5 100 ± 2, ,5 +1/-0 4,0 ± 0,5 10,5 ± 0,5 200 ± 2, ,0 +1/-0 4,0 ± 0,5 10,5 ± 0,5 70 ± 2,5 102,5 ± 2, ,0 +1/-0 4,0 ± 0,5 10,5 ± 0,5 100 ± 2, ,0 +1/-0 4,0 ± 0,5 10,5 ± 0,5 200 ± 2, R Schaft Image 9: Connecting socket C

14 drains and sewers Page 14 of 22 5 Other requirements Quality Management System The establishment and certification of a quality management system according to the standard series ISO 9001:2015 is required. Pre-testing (ITT) and Factory Production Control (FPC) Pre-testing (ITT) and Factory Production Control (FPC) in accordance with DIN -2. Purchased products For purchased products (sealing elements, stainless steel sleeves and accessories) the quality must be assured. A documented release of drawings (dimensions and materials specifications), that only takes place after pre-testing on the products, must be demonstrated. Significant changes to the recipe of the material, the dimensions, the marking or manufacturing procedures have to be clarified with Steinzeug-Keramo in advance. The manufacturer of the purchased products is obliged to prove, at least twice a year, compliance with the requirements through third party control. The third party control needs to ensure that each compound per production facility of the manufacturer is tested once per year. The third party testing laboratory must be accredited. Product related pre-tests in accordance with DIN 681-1, section 7.3 take place every 5 years after taking samples from the sealing elements manufacturer. Function tests in combination with vitrified clay products are carried out at Steinzeug-Keramo. Kind of testing and frequency of the function tests in accordance with Annex A Scope Factory Production Control and Third Party Control. The results of the factory production control and third party control of the manufacturer needs to be provided to Steinzeug-Keramo.

15 drains and sewers Page 15 of 22 6 Third Party Control The third party control is to be carried out by an independent testing and monitoring body, a third party control contract must exist. Inspections During an inspection the testing and monitoring body checks he requirements mentioned in section 5, these inspections take place twice a year. During this inspection the samples for third party control are determined. The number of the samples is defined in Annex A Scope Factory Production Control and Third Party Control. Third party control Third party control takes place twice a year and is used as evidence to prove if the certified products meet the requirements. Kind and frequency of testing for third party control in accordance with Annex A Scope Factory Production Control and Third Party Control. Test report The testing and monitoring body will inform Steinzeug-Keramo about the results of the inspection and third party control in writing by an Observation Report. Certificate / Quality Label After successful testing and conformity assessment the testing and monitoring body can issue a Certificate and/or Quality Label.

16 drains and sewers Page 16 of 22 Annex A Scope Factory Production Control and Third Party Control Characteristic -1 Requirements conform Testing conform Factory Production Control (FPC) Third party control Batch Up to 8 week batches Each half year, each nominal diameter produced Marking X - - Annual Continuous Type Test Optional Twice a year Each sample Checking FPC X Material X 1 X - - X Manufacturing X 1 X - - X Water absorption on pipes X X - 1 / DN X Material Appearance X 1 X - Chemical resistance X 2 - X - - X Each sample X Hydraulic roughness X - - Abrasion resistance X 3 - X Resistance against high pressure water jetting X X 3 - X 1 According test plan 2 Each kiln 3 One dimension per 3 years per production site

17 drains and sewers Page 17 of 22 Characteristic Pipes , 5.3, , 6.3, 6.4 Requirements conform Testing conform Factory Production Control (FPC) Third party control Batch Up to 8 week batches Each half year, each nominal diameter produced Annual Continuous Type Test Optional Twice a year up to X X - 3 / DN 2 X Checking FPC Junctions 5.2, 5.3, , 6.3, up to X X - 3 / DN 2 X Water seal of trapped fittings X X - 3 / DN 2 X Dimensions Bends Fittings 5.2, , , 5.3, , up to up to X X - 3 / DN 2 X X X - 3 / DN 2 X Connectors and connecting sockets - 5.2, , 5.5, B.2, B.3 Manholes up to up to up to X X - 3 / DN 2 X X X - 1 / DN 2 X 1 Checking d 4 only by measuring on vitrified clay surfaces 2 Each product tested by third party control per 5 years (see testing matrix)

18 drains and sewers Page 18 of 22 Characteristic -1 Requirements conform Testing conform Factory Production Control (FPC) Third party control Crushing strength up to Batch Up to 8 week batches Each half year, each nominal diameter produced Annual Continuous Type Test Optional Twice a year X X X - 3 / DN 2 X Checking FPC Bending tensile strength X 3 X X 4 - X Strength Bending moment resistance DN DN 225 Compressive strength on jacking pipes X - - X - 1 / DN 2 X X X Fatigue strength under cyclic load Bond strength of adhesive used for fixing fired clay parts together X X - - X 1 Statistical evaluation 2 Each product tested by third party control per 5 years (see testing matrix). Whilst testing pipes and jacking pipes for Crushing strength DN 700 the first pipes will tested until it breaks. With the other pipes the test will be ended after reaching the set point (required crushing strength + 20%). 3 Calculated with crushing strength results 4 Tested on samples according to section 4.6

19 drains and sewers Page 19 of 22 Characteristic -1 Requirements conform Testing conform Factory Production Control (FPC) Third party control Batch Up to 8 week batches Each half year, each nominal diameter produced Annual Continuous Type Test Optional Twice a year Checking FPC Water tightness pipes X X - 1 / DN 1 X Water tightness junctions X X - 1 / DN 1 X Water tightness manholes X - X - 1 / DN 1 X Tightness Tightness of fittings, connectors and connecting sockets Airtightness of pipes including the joint assembly under positive pressure X 2, X - 1 / DN 2,3 X X - - X - 1 / DN 1 X Airtightness of junctions under positive pressure X X - 1 / DN 1,3 X Airtightness of bends under positive pressure X 2,3 - - X - 1 / DN 2,3 X 1 Each product tested by third party control per 5 years (see testing matrix) 2 If these products are fired together with pipes in the same process and are made from the same raw materials or are sawed out of pipes, this test is not required. 3 The airtightness must be tested on all products which are fixed together, by using adhesive, from fired clay parts

20 drains and sewers Page 20 of 22 Characteristic Water tightness of pipes joint assemblies under deflection and shear load under internal pressure Water tightness of pipes joint assemblies at 1 bar Water tightness of pipes joint assemblies at 2,4 bar -1 Requirements conform Testing conform Factory Production Control (FPC) Third party control Batch Up to 8 week batches Each half year, each nominal diameter produced Annual Continuous Type Test Optional Twice a year - - X - - X - 1 / DN 1 X X / DN 1 X X / DN 1 X Checking FPC Joint assemblies Water tightness of connecting sockets C under deflection and shear load under internal pressure Joint interchangeability B B X - - X - 1 / DN 1 X X - - X - 3 / DN 1 X Chemical and physical resistance to effluent of joint assemblies B X 2 - X - - X Thermal cycling stability of joint assemblies B X 2 - X - - X Long-term thermal stability of joint assemblies B X 2 - X - - X 1 Each product tested by third party control per 5 years (see testing matrix) 2 Per jointing system per production site

21 drains and sewers Page 21 of 22 Characteristic -1 Requirements conform Testing conform Factory Production Control (FPC) Third party control Batch Up to 8 week batches Each half year, each nominal diameter produced Annual Continuous Type Test Optional Twice a year Checking FPC Material sealing elements Rubber sealing elements Polyurethane sealing elements X 1 X 2 X 3 Each dispensing unit on one sample: Hardness and compression set each day, Tensile strength and elongation at break each month and stress relaxation, ageing and hardness change twice a year X - X X Creep resistance duromers Twice a year X - X X Steel X Load transfer rings X Factory production control per manufacturer 2 Third party control at manufacturer 3 Checking factory production control manufacturer

22 drains and sewers Page 22 of 22 Characteristic -1 Requirements conform Testing conform Factory Production Control (FPC) Third party control Batch Up to 8 week batches Each half year, each nominal diameter produced Annual Continuous Type Test Optional Twice a year Checking FPC Dimensions - A X 1 X 2 X 3 Tension band torque test - A X 1 X 2 X 3 Flexible couplings Type 2 Rubber X 1 X 2 X 3 Water tightness of pipes joint assemblies under deflection and shear load under internal pressure Water tightness of pipes joint assemblies at 1 bar - A X - - X - 1 / DN X / DN 4 - Water tightness of pipes joint assemblies at 2,4 bar X / DN4 - Airtightness of pipes joint assemblies under positive pressure X / DN 4 - Dimensions - B X 1 X 2 X 3 Sealing rings Connecting sockets F Rubber X 1 X 2 X 3 Water tightness of pipes joint assemblies under deflection and shear load under internal pressure Water tightness of pipes joint assemblies at 1 bar Airtightness of pipes joint assemblies under positive pressure - B X - - X - 1 / DN X / DN X / DN 4 - Dimensions - B X 1 X 2 X 3 Rubber X 1 X 2 X 3 Water tightness of connecting sockets under deflection and shear load under internal pressure Water tightness of pipes joint assemblies at 1 bar Airtightness of pipes joint assemblies under positive pressure - B X - - X - 1 / DN 4 X X / DN X / DN 4-1 Factory production control per manufacturer 2 Third party control at manufacturer 3 Checking factory production control manufacturer 4 Each product tested by third party control per 5 years (see testing matrix) 5 Only on marked flexible couplings