Our Products are certified for potable water.

1. CLASS DESIGNATIONS AND CALCULATIONS OF STANDARD WALL THICKNESS OF PIPES AND FITTINGS

1) The system of class designations used in this specification follows that established in ISO 2531.

(a) A prefix K; this initial letter of “Class” in German.

(b) A whole number; This is the selected coefficient inserted into the formula provided for the calculation of mean wall thickness

2) Calculation of standard wall thickness of pipes and fittings.

(a) Except for class K9 pipes up to and including DN 200, the standard wall thickness of pipes and fittings are calculated as a function of their nominal size by the formula.

1. e : is the standard wall thickness in millimeters DN : is the nominal size
2. k : is the selected whole number coefficient (9, 12 and 14 being applicable to the classes designated K9, K12 and K14 respectively).

(b) The standard wall thickness of class K9 pipes up to and including DN 200 are calculated by the formula: e = 5.8 + 0.003 DN

2) Standard pipes with flanges screwed or cast-on shall be class K12.

3) Standard pipes with flanges welded-on shall be class K9.

4) The standard lengths and thickness of pipes are shown in our catalog. Lengths of pipes other than those shown may be supplied by agreement between the purchaser and the manufacturer and shall be deemed to comply with the requirements of this specification.

5) In the case of centrifugally cast pipes, the increase or decrease, in the thickness of the pipe wall shall be obtained variation on the internal diameter only.

3. FITTINGS

1) Standard fittings without branches shall be class K12

2) Standard fittings with branches shall be class K14

3) Modifications to the thickness of the wall of fittings may be obtained by modification of the external diameter (plugs, change pieces and flanged spigot pieces excepted) or of internal diameter.

4. TYPES OF JOINTS

1) Flexible joints

Details of flexible joints, either of the ‘Push in’ type or of the ‘Mechanical’ type, shall be in accordance with the manufacturer’s standard dimensions and tolerances.

As the manufacturing dimensions and tolerances of individual types of joint may differ, the manufacturer’s guidance should be obtained with regard to interchangeability where pipes and fittings of differing design are to be jointed. Unless otherwise specified by the purchaser, the gasket shall be manufactured from elastomeric materials complying with the requirements of BS 2494 and be compatible with the fluid to be carried. The gasket shall be of such size and shape that, when jointed in accordance with the manufacturer’s instructions, it shall provide a positive seal within the manufacturer’s range of maximum joint deflection and withdrawal under all combinations of joint and gasket dimensional tolerance, and in the range of pressure likely to occur in the pipeline including, where applicable, those below atmospheric pressure.

2) Flange joints

(a) Dimensional details of flanges designated PN 10, PN 16 and PN 25 are shown in BS 4772/ISO 2531. The nominal pressure ratings for these flanges are applicable to the temperature range – 10º C to 120º C; the manufacturers should be consulted where pressure-temperature conditions are out of this range.

NOTE: Flanges to this specification are dimensionally compatible with the corresponding flanges BS 4504.

(b) The faces of flanges of pipes shall be at right angles to, and concentric with, axis of the bore, the faces of the flanges on fittings shall be at right angles to the directional axes. Flanges shall be faced over the jointing surface with a tool mark finish having a pitch of 1 ± 0.3mm; serrations may be spiral of concentric.

(c) Bolt holes shall be drilled unless the purchaser agrees that they shall be cored. The pitch circle diameter of the bolt holes shall be concentric with the bore. The bolt holes shall be located off the centre lines (unless otherwise specified by the purchaser) and where there are two or more flanges, the bolt holes shall be aligned.

(d) Ductile iron pipes having ductile iron screwed-on flanges shall be sealed at the threaded joint between the pipe and the flange by a suitable sealing compound. The standard sealing compound applied to the joint shall be suitable sealing for use with raw and potable water up to a temperature of 100º C, natural and town gas and industrial effluents treated so as to be acceptable for discharge into public sewers, alternative types of sealing compound for pipes used for other duties, such as the carrying of industrial effluents of chemicals, shall be the subject of an agreement between the manufacturer and the purchaser.

(e) Ductile iron pipes with ductile iron welded-on flanges shall have a pipe to flange weld attachment of a design proven by tests not to be the limiting factor in the integrity of the flanged pipe when subjected to excessive hydraulic pressure, bending moments and bolting loads.

NOTE: Where this type of flange is laid underground, consideration should be given to external protecting if the soil is aggressive.

 

Essential requirements of the assembly are as follows:

(i) The flanges shall be an interference fit on the end of the pipe barrel which shall have been rounded and cleaned to ensure removal of material detriemental to the welding process and shall be attached to the pipe by fillet weld made at the hub and of the flange. The welding shall be carried out by a proven mechanized factory welding process, E.G. metal inert gas (Mig) – Welding.

(ii) The material used as a welded filler metal shall be selected to be compatible with the ductile iron base material.

(iii) The jointing face of the flange, including the pipe end, shall be machined, if heat treatments is necessary this must be carried out before final machining.

5. MARKING

1) Each pipe, fitting or accessory shall bear at least the following indications:

(a) The mark of manufacture

(b) An indication of the casting is ductile iron

(c) An indication of its nominal size (DN)

If necessary, each fitting shall bear an indication of its main characteristics. The pipes, fittings and accessories with a nominal size greater than DN 300 shall also bear the year of manufacturer.

2) The marks may be cast on, painted or cold stamped.

3) Any special marks required by the purchaser shall be the subject of an agreement between the manufacturer and the purchaser.

6. QUALITY AND QUALITY CONTROL

1) The metal used shall be such that the pipes and fittings are of ductile iron complying with the mechanical properties specified in Table 1.

2) The manufacturer shall carry out test to enable the quality of pipes and fittings to be controlled during manufacture to ensure continuing compliance with requirements of this specification and shall keep records of all such tests records of these tests, shall be available for inspection by the purchaser, or his representative.

Table 1 – Mechanical Properties

Nominal Size DN	Type of casting	Tensile Strength Min.	0.2% Proof Stress Min.	Elogation Min.
mm		N/mm2	N/mm2	%
80 – 100 Over 1000 All sizes	Centrifugally Cast Pipes Centrifugally Cast Pipes Pipes Not Centrifugally Cast and Fittings	420 420 420	300 300 300	10* 7 5

* 7% for pipes thicker class K12

The proof stress shall only be measured when specially agreed between the manufacturer and purchaser and shall be measured under conditions which shall be specified by the purchaser on his enquiry and order.

 

7. HEAT TREATMENT

1) Pipes which are centrifugally cast in unlined water-cooled shall be heat treated in order to achieve the necessary mechanical properties and to relieve casting stresses; provided the specified mechanical properties are met, pipes cast under controlled colling conditions need not be heat treated.

2) The manufacturer may supply fittings in the ‘As Cast’ conditions or alternatively subject them to heat treatment, Whichever method is employed, the representative test results shall conform to the minimum mechanical property requirements of Table 1 and in the case of heat treated fittings, the test pieces shall be subjected to the same heat treatment process.

8. CONDITIONS OF PIPES AND FITTINGS

1) Pipes and fittings shall be removed from the mould with every necessary precaution to avoid warping or shrinkage defects detrimental to their good quality.

2) Pipes and fittings shall be sound and free from surface or other defects detrimental to their functional quality.

3) Minor cavities on jointing faces may only be rectified by a process agreed between the manufacturer and the purchaser.

Rectification of other defects shall be subject to agreement between the manufacturer and the purchaser on each occasion except where simple dressing only is involved.

4) The quality of the casting shall be such that they can be cut, drilled, tapped and machined. Should the purchaser consider that the casting do not comply with this requirement, hardness test shall be carried out as specified in clause 16.

9. TESTING FOR STRAIGHTNESS AND UNIFORMITY

All pipes shall be tested for straightness and uniformity of thickness and diameter.

The deviation of the pipe from the straight shall not be more than 0.00125 times the effective length of the pipe.

10. TOLERANCES ON DIMENSIONS

External diameters of pipes and fittings

1) The tolerances for the external diameter DE of the spigots of pipes, flanged spigot pieces, and change pieces, and of plugs, shall not be greater than those specified in Table 2 measured circumferentially using a diameter tape.

2) For nominal sizes up to and including DN300, the tolerance for the external diameter DE of pipes shall apply to the full length of the barre of pipes.

NOTE: The spigots of pipes cut in field may require preparation in accordance with the manufacturer’s recommendations prior to jointing.

3) No tolerance is specified in this standard for the external diameters of fittings (Flanged spigot pieces, change pieces and plugs excepted,) or for pipes with flanges cast on.

4) The measured difference between the maximum and minimum axes of individual spigots shall not exceed the appropriate value in Table 2.

NOTE: Certain types of flexible joint will accept some degree of spigot ovality. However, where the admissible spigot ovality applicable to such joints is smaller than is detailed in Table 2, the values shall be detailed in the manufacturer’s catalogue.

 

Table 2 – Tolerance on the External Diameters of the Spigots of Pipes and (Where Applicable) Fittings

Nominal Size DN	Tolerance on the external diameter of spigots and of plugs (DE)	Maximum ovality of spigots (DE) +
mm	mm	mm
80 – 150 200 – 350 400 – 500 600 – 800 900 – 1000 1100 – 1200 1400 1600	+1.0 -3.0 +1.0 -3.5 +1.0 -4.0 +1.0 -4.5 +1.0 -5.0 +1.0 -6.0 +1.0 -7.0 +1.0 -8.0	5 10 20 30 40 50 55 65

Tolerance on thickness

The tolerances on the wall thickness shall be in accordance with Table 3

Table 3 – Tolerances on Wall and Flange Thickness

Type of casting	Dimensions	Tolerance in MM
Centrifugally	Wall thickness (e)	- (1.3 + 0.001 DN *)
Cast pipe	Flange thickness (b)	+ / - (1 + 0.05b)
Pipes not	Wall thickness (e)	- (2.3 + 0.001 DN)
Centrifugally	Flange thickness	+ / - (1 + 0.05b)
Cast and Fittings

* For DN 80 – DN 100 class K9 ductile iron pipes only, the minimum wall thickness shall be 4.8mm DN = Nominal size in millimeters B = Thickness of flange in millimeters

Tolerance on length

1) The tolerances on the lengths of pipes shall be in accordance with Table 4.

Table 4 – Tolerances on Lengths of Pipes

Type of casting	DN	Tolerance mm
Socket and spigot centrifugally cast pipes Double plain-ended centrifugally cast pipes	All	+ / - 30
Flanged pipes of up to and including 2M in length	All	+ / - 3.0
Flanged pipes of over 2M but less than 3M in length	All	+ / - 4.0
Flanged pipes of 3M and over in length	All	+ / - 5.0

2) By agreement with the purchaser the manufacturer may supply pipes with flexible joints of each size on the order in lengths shorter than the standard length.

 

3) The manufacturer may supply 10% of the pipes with flexible joints on any one order from which test rings have been taken. It is permissible to supply up to 5% 150mm shorter than the minimum standard length with the balance being no more than 100mm shorter than the minimum standard length.

11. TOLERANCES ON STANDARD MASS

1) The standard mass is dependent upon the design of the ends of pipes and fittings and shall be calculated on the nominal dimensions taking the density of ductile iron 7050 kg / m³

2) The tolerances on standard mass are detailed in Table 5.

Table 5 – Tolerance on Standard Mass

DN	Type of casting	Tolerances
80- 200 250-1600	Centrifugally cast pipes Centrifugally cast pipes	+ / - 8% + / - 5 %
All sizes	Pipes not centrifugally cast	+ / - 8%
All sizes	Standard fittings, excepting bends and fittings with branches	+ / - 8%
All sizes	Standard bends and standard fittings with branches non-standard fittings	- 12% *

* A negative tolerance only is specified

3) Each pipe DN 150 and over shall be weighed individually to ensure compliance with the tolerances specified in Table 5.

4) Fittings, and pipes below DN 150, need not be weighed individually unless otherwise specified by the purchaser on his enquiry, or order.

12. WORKS PROOF TESTS

1) Before being coated, each pipe and fitting shall be hydrostatically tested by a proven means at the foundry to the satisfaction of the purchaser or his representative. The outside surfaces of the pipe or fitting shall be dry before testing.

The hydrostatic pressure shall be applied steadily and maintained for a period sufficient to facilitate adequate inspection but in no case shall this period be less than 15 seconds.

The internal pressure imposed on the pipe or fitting shall be measured by an accurate pressure gauge and means shall be provided for attaching the gauge of the purchaser or his representative. The pipes and fittings shall withstand the works hydrostatic test pressure in Table 6 without showing signs of leakage, sweating or other failure of any kind.

 

Table 6 – Works Hydrostatic Proof Test Pressures and Works Leak Tightness Test Pressures

Nominal Size		Proof test Pressure			Leak Tightness test prssure for fittings and for pipes with cast-on flanges
	Centrifugally cast pipes with	Pipes with screwed or welded-on flanges
DN	flexible joints	PN 10 Flange	PN 16 Flange	PN 25 Flange
MM	Bar	Bar	Bar	Bar	Bar
80 – 300 350 – 600 700 – 800 900 – 1200 1400 – 1600	50 40 32 32 25	16 16 16 16 _	25 25 25 25 _	32 32* 32 _ _	25 16 10 10 _

2) All pipes and fittings, except those having restricted pressure ratings, shall be capable of withstand the field test pressure specified in appendix A.

3) Pipes and fittings with flexible joints supplied for pipelines to be used for the conveyance of gas, shall, where specified by the purchaser and agreed by the manufacturer, be tested with air to a pressure of 3.5 bar (gauge) in addition to the hydrostatic test, while under air pressure, the fittings shall be totally immersed in water, or alternatively, coated with a suitable foaming agent in order to check for leakage.

4) Where specially agreed between the purchaser and the manufacturer, standard all flanged ductile iron fittings, and pipes with cast-on flanges may be works hydrostatically tested to pressure up to, but not exceeding 16 bar, 25 bar and 40 bar for casting with PN10, PN16 and PN25 flanges respectively.

NOTE: The hydrostatic test applied to fittings is a leak tightness test only. The application of high hydrostatic pressure to fittings is precluded due to the risk of distortion resulting from the high restraining loads imposed on the fittings by standard test apparatus.

1) Unless otherwise specified by the purchaser on the enquiry and / or order, all pipes and fittings shall be coated internally and externally with, at the manufacturer’s option, one of the materials specified in Table 7.

2) Where specified by the purchaser on the enquiry and / or order, pipes and fittings shall be cement mortar lined in accordance with appendix B and shall, unless otherwise specified, be coated externally with, at the manufacturer’s option, one of the materials specified in Table 7.

3) Coating may be applied by dipping, brush, spray or roller

4) No coating shall be applied to any casting unless its surfaces are clean, dry and free of rust.

 

14. MANUFACTURER’S CERTIFICATE

The manufacturer shall, on request, supply to the purchaser a signed certificate, at the purchaser’s option, either:

(a) That the pipes or fittings comply in all respects with the provisions of this specification: or

(b) The results of all the specified tests.

15. INSPECTION

The inspector appointed by the purchaser and accredited by the manufacturer shall have access at all reasonable times to those parts of the works engaged on the manufacture and testing of the pipes or fittings he has ordered.

If, at the time of placing the order, the purchaser states that he wishes to carry out inspection during manufacture up to the point of dispatch, the manufacturer may inform the purchaser or his agent in advance of the manufacturing date. Should the purchaser or his agent not be present at the agreed time, then the manufacturer will be entitled to proceed with production and inspection and shall not be required to reinspect. Records of the inspection will be available for examination by the purchaser or his agent at a later date.

16. PURCHASER’S OPTIONAL TENSILE TEST

Selection of bar test pieces

1) If stated on the enquiry and subsequent order that the purchaser wishes to witness the tests on bar test pieces in respect of the pipes and fittings to the order, the bar test pieces may be selected by the purchaser or his representative during the manufacture.

2) Should the purchaser or his representative not be present at the agreed time of manufacture, then the manufacturer shall be entitled to proceed with the selection of test pieces and testing. The results of tests will be recorded for examination by the purchaser at a later date and the test pieces shall be retained for a minimum of 14 days.

3) For the purpose of selection and approving the bar test pieces, the pipes and fittings to that order shall be divided arbitrarily into batches as follows.

Pipes and fittings	Size	Batches
Pipes centrifugally	DN 80 to DN 300	100 pipes
cast	DN 350 to DN 600	50 pipes
	DN 700 to DN 1200	25 pipes
	DN 1400 to DN 1600	10 pipes
Pipes not centrifugally cast, and fittings	All sizes	4 tonnes

Any pipes remaining after dividing into batches as specified, should be considered as a batch and where the total order is less than the appropriate batch size, then the order shall be considered as a batch. The batch may contain pipes of any size within the groups specified above.

One bar test piece shall be taken from each batch and, should the batch contain pipes of more than one size, the bar test piece selected shall be regarded as being representative of all the pipes in the batch, irrespective of size.

Bar test pieces representative of pipes, not centrifugally cast, and fittings may be taken from a sample cast separately but shall be cast from the same iron as that used for the manufacture of the castings they represent and, where applicable, shall have been subjected to the same heat treatment. Alternatively, bar test pieces may be taken from a sample cast integrally with the pipe or fittings at the manufacturer’s option.

Dimensions of bar test pieces

1) Bar test pieces taken from centrifugally cast pipes shall be cut from the spigot end, and when prepared of testing, shall be representative of the metal at approximately mid-thickness, and the axis of the bar test piece shall be paralleled to the axis of the pipe from which it was taken. Each bar test piece shall include a cylindrical and having a diameter of 3.565 to 3.580 mm part having a gauge length of 3.54 or 5.0 times its diameter.

2) Where the sample is cast separately, its dimensions shall conform to the requirements of BS 2789. Where sample is internally cast it shall comply with the dimensions given in Table 8.

Table 8 – Dimensions of Integrally Cast Test Samples

Description of casting represented		Dimensions
	Length	Width	Thickness
	MM	MM	MM
Non-centrifugally cast pipe and fittings, having a wall thickness of up to and including 12.5MM	55-75	45-65	12.5
Non-centrifugally cast pipe and fittings, having a wall thickness of over 12.5MM	55-75	45-65	16

3) Method of test. The method of testing shall be in accordance with that normally used for quality control purposes by the manufacturer, unless otherwise agreed between the manufacturer and the purchaser.

4) Results of tensile test. Each bar test piece selected in accordance with 16.1) shall be tested and shall be considered satisfactory if the test results comply with the mechanical properties specified in Table 1.

5) Retests. Should a bar test representing any batch fail the tensile test, two further tests shall be carried out on bar test pieces selected by the purchaser, or his agent from two other pipes of the same batch. If either of these additional bar test pieces fail the tensile test, the batch represented shall be deemed not to comply with this specification.

17. HARDNESS TEST

1) Should the purchaser consider that the quality of the casting does not comply with the requirements of 8.4) hardness tests shall be carried out on the castings after slight grinding.

2) The tests shall be in accordance with BS 240: Part 1, except the period of application shall be 15 ± 1s.

3) The results of the hardness tests shall not exceed 230 HB in the case of centrifugally cast pipes, and 250 HB in the case of all other castings. Should the surface hardness of the casting exceed these values, the castings shall be deemed not to comply with this standard.

Appendix A

Pressure ratings and maximum field hydrostatic test pressures for standard thickness ductile iron pipes and fittings after installation.

Table 9 – Hydraulic pressure ratings for ductile iron pipes and fittings in accordance with BS4772

Nominal size DN	Hydraulic pressure rating
	Pipelines incorporating flanges to:			Pipelines without any flanged joints
	PN 10	PN 16	PN 25
80 to 350 350 to 1200 1400 to 1600 *	bar (gauge) 10 10 _	bar (gauge) 16 16 _	bar (gauge) 25 25 _	bar (gauge) 40 25 _

* Hydraulic pressure ratings for pipes and fittings DN 1400 to DN 1600 shall be by agreement between the purchaser and the manufacturer.

NOTE 1. The hydraulic pressure ratings for pipes and fittings with flanges are applicable to the temperature range - 10º C to 120º C. the manufacturer should be consulted in connection with pressure ratings for temperatures outside this range.

NOTE 2. Attention is drawn to CP 2010: Part 2, which provides guidance on the field testing of pipelines.

Table 10. Maximum field hydrostatic test pressures for ductile iron pipes and fittings in accordance with BS 4772

Nominal size DN	Maximum field hydrostatic test pressure
	Pipelines incorporating flanges to:			Pipelines without any flanged joints
	PN 10	PN 16	PN 25
80 to 300 350 to 600 700 to 1200 1400 to 1600 *	bar (gauge) 16 16 16 _	bar (gauge) 25 25 25 _	bar (gauge) 40 30† 30‡ _	bar (gauge) 45 30 30 _

* Field hydrostatic test pressures for pipes and fittings DN 1400 to DN 1600 shall be by agreement between the purchaser and the manufacturer.

† 40 bar for pipelines having all joints flanged.

‡ Higher pressures may be agreed between the purchaser and the manufacturer, but fittings may, depending on operating conditions, require strengthening.

NOTE. These field test pressure should be applied only to ductile iron pipelines when the pipeline and its fittings are properly anchored. This explains why field test pressures for ductile iron pipelines may be greater than the factory test pressures for fittings since the test rig at the factory does not allow proper anchoring under high pressures without distortion of the casting. For further information relating to field testing of pipelines see CP 2010: Part 3.

Appendix B

Specification for cement mortal lining

C.1 Materials

C.1.1 Cement. The cement used shall be ordinary Portland cement in accordance with BS 12, except that, where specified by the purchaser, or at the manufacturer’s option, sulphate-resisting cement in accordance with BS 4027 or Portland blast furnace cement in accordance with BS 146: Part 2 may be used.

C.1.2 Sand. The sand shall consist of inert, granular material having hard, durable uncoated grains. The sand shall comply with the requirements of zone 4 of table 2 of BS 882, 1201: Part2:1973 when sampled and tested in accordance with BS 812.

C.1.3 Water. The water shall be obtained from the public water supply and shall contain no constituent that adversely affects the quality of the cement or, in the case of potable water, the water flowing through the main. The presence of solid inorganic particles is, however, admissible, providing they do not contain any constituents that impair the curing of the cement mortar or cause deterioration of water quality in the case of potable water mains.

C.2. Cement mortar mix

C.2.1 The cement mortar mix shall comprise cement, sand and water which shall be thoroughly mixed and be of such consistency as to provide a dense and homogeneous lining. Any additive shall be agreed between the purchaser and manufacturer.

C.2.2 The cement mortar mix shall contain at least one part by mass of cement to 3.5 parts by mass of sand.

C.3 Application of lining

C.3.1 Pipes shall be lined centrifugally or by a centrifugal applicator head. Fittings shall be lined by any process that produces linings having a surface finish comparable with that of the pipes.

C.3.2 The surface on to which the coating is to be applied shall be free from all loose scale, foreign bodies, or any other material that could be detrimental to good contact between the metal and the coating.

C.3.3 The process of lining shall be so controlled as to ensure that a continuous layer of cement mortar is produced over the bore of pipe or fitting.

C.3.4 The inside of the sockets and the faces of flanges shall be free from cement mortar.

C.4 Repair of damaged lining by the manufac turer.

Small areas of damaged linings may be repaired by cutting back the lining to the metal surface, by thoroughly wetting the exposed surfaces of the

 

metal and of the adjacent lining, and by patching with fresh, stiff cement mortar worked in thoroughly to ensure a good bond with the exposed surfaces. The repaired area shall be cured in accordance with C.5.

C.5 Curing of lining

C.5.1 Curing of the lining shall be conducted in such a manner as to produce a properly hydrated cement mortar lining that is both hard and durable. Curing shall be carried out at not less that 4º C.

C.5.2 Curing shall be effected under controlled atmosphere conditions. Curing by the application of bitumen coating shall be by agreement between the purchaser and the manufacturer.

C.5.3 The bitumen coating shall comply with the requirements of BS 3416 for type 2 material applied by spray or brush while the lining is still moist. The bitumen coating shall not impart colour, taste or odour to potable water drying for 48h.

C.6 Thickness of lining

C.6.1 The thickness of linings shall be as specified in Table 11.

Table 11. Thickness of linings

Nominal		Thickness
size		Minimum	Individual
DN	Nominal	arithmetical	minimum
		mean value
80 to 300	mm	mm	mm
350 to 600	3.0	2.5	1.5
350 to 600	5.0	4.5	2.5
700 to 1200	6.0	5.5	3.0
1400 to 2000	9.0	8.0	4.0

C.6.2 The thickness of linings may be tested by spear measurement or by gauge. Where ‘spear measurement’ is used, the lining shall be pierced using a hardened steel point, not larger than 1.5mm diameter; immediately after application of the lining to the bore of the pipe, or fitting, and before the cement mortar has set. The thickness shall be measured at each end of the pipe in at least one section perpendicular to the pipe axis. At each section which, for pipes DN 200 and above, shall be at least 200mm from the pipe end, measurements being taken in four places at 90º intervals. The arithmetical mean value and the individual minimum values of the four measurements in each section shall be not less than those in Table

11.

C.7 Surface condition of linings

The surface condition of lining shall be substantially smooth but the fine crazing associated with cement rich surfaces shall be permitted. Isolated shrinkage cracks shall be acceptable provided their width does not exceed 0.8mm. The surface shall be substantially free from laitance and any sand segregation present shall be minimal.

C.8 Identification

Where cement mortar lined pipes have been bitumen coated, or coated internally they shall carry a means of identification to distinguish them from pipes that have coated internally and externally, in accordance with 16.1. This identification shall appear on the barrel of the pipe but otherwise the position shall be at the manufacturer’s option.

Appendix C.

Cutting of existing pipelines

Where existing pipes are cut, the outside diameter, as measured circumferentially by diameter tape, may differ in size from the diameter and tolerances specified in Table 2. Pipe manufacturers state that the large majority of pipes so cut generally have diameters in the range shown in Table 12. Manufacturers of slip-on couplings, split couplings, wrap around fittings, or similar fittings and equipment that depend on the outside diameter of the pipe of their location and effective installation, who claim that such items are compatible with the pipes specified in this standard, are advised to note these diameters. Furthermore it is recommended that their catalogues should (a) specify the extent to which their products will meet these requirements, and (b) make recommendations for fitting where necessary.

Table 12. Diameters of the barrels of cut pipes.

Nominal
size	Minimum	Maximum
DN	diameter	diameter
	mm	mm
350	374.5	379.0
400	425.0	431.0
450	476.0	483.0
500	527.0	538.0
600	630.0	640.0
700	732.5	743.5
800	836.0	848.0
900	940.0	948.0
1000	1043.0	1051.0
1100	1146.0	1155.0
1200	1249.0	1258.0

NOTE 1. For sizes above 1200mm the manufacturer should be consulted. NOTE 2. Diameters are measured circumferentially with a diameter Tape.

 

BS 4772/ISO 2531 Ductile Cast Iron Pipes and Fittings

 

BS 4772 / ISO 2531

Specification

Hydrostatic Test Pressure

PIPES …………. STANDARD K = 9 FITTINGS ………STANDARD K = 14 for Tees K = 12 for other fittings

Pipes, DN 450, DN 1100 are according to the extension of ISO Requirements.

Diameter	Pipes	Fittings
DN 80 to DN 300	50 bar	25 bar
DN 350 to DN 600	40 bar	16 bar
DN 700 to DN 1000	32 bar	10 bar
DN 1100 to DN 1200	25 bar	10 bar
DN 1400 to DN 1600	25 bar	10 bar
DN 1800 to DN 2000	25 bar	10 bar
DN 2100 to DN 2600	18 bar	10 bar

Tensile Strength, Elongation & Proof Stress

	Pipe		Fittings
	80 to 1000	1100 to 2600
Tensile Strength	Min. 420 N/mm2		Min. 400 N/mm2
Elongation	Min. 10%	Min. 7%	Min. 5%
Proof Stress	Min. 300 N/mm2		Min. 300 N/mm2

* The proof stress shall only be measured upon special agreement and order conditions which shall be specified in the order.

** 0.102 kgf/mm² = 1 N/mm2

Coating and Lining Materials Tolerance

1. Thickness: + No limit

- (1.3 + 0.001 ND) mm (ND: Nominal Diameter)

2. Weight: Ø 200mm and under: ± 8% Ø 300mm and over: ± 5%

	Pipe	Fitting
Outside (External)	• Zinc Rich Coating • Black Bituminous (Coal-tar Coating) • Tar-Epoxy Coating	• Zinc Rich Coating (Optional) • Black Bituminous (Coal-tar Coating) • Tar-Epoxy Coating
Inside (Internal)	• Black Bituminous (Coal-tar Coating) • Tar-Epoxy Coating • Sulphate-Resisting Cement Mortar Lining • Cement Mortar Lining With Seal Coating • Fusion Bonded Epoxy Lining (Any Colour)	• Black Bituminous (Coal-tar Coating) • Tar-Epoxy Coating • Sulphate-Resisting Cement Mortar Lining • Cement Mortar Lining With Seal Coating • Fusion Bonded Epoxy Lining (Any Colour)

 

BS 4772 / ISO 2531 / BS -EN 545

TYTON STYLE