Bsi bs en 12842 2012 (2015)

1 Scope This European Standard specifies the requirements and associated test methods applicable to ductile iron fittings, ductile iron and mild steel couplings and flange adaptors and t

BSI Standards Publication

Ductile iron fittings for PVC-U or PE piping

systems — Requirements and test methods

A list of organizations represented on this committee can be obtained

on request to its secretary

This publication does not purport to include all the necessary provisions

of a contract Users are responsible for its correct application

© The British Standards Institution 2015

Published by BSI Standards Limited 2015ISBN 978 0 580 92366 1

Amendments/corrigenda issued since publication

31 October 2013 National Annex added

30 November 2015 Implementation of CEN correction notice

26 September 2012: Figure 3 key and subclause 7.1.2 modified

NORME EUROPÉENNE

EUROPÄISCHE NORM

August 2012

English Version

Ductile iron fittings for PVC-U or PE piping systems -

Requirements and test methods

Raccords en fonte ductile pour systèmes de canalisations

en PVC-U ou en PE - Prescriptions et méthodes d'essai Rohrleitungssyteme - Anforderungen und Prüfverfahren Duktile Gussformstücke für PVC-U oder

PE-This European Standard was approved by CEN on 23 June 2012

CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN-CENELEC Management Centre or to any CEN member

This European Standard exists in three official versions (English, French, German) A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the CEN-CENELEC Management Centre has the same status as the official versions

CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania,

Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom

EUROPEAN COMMITTEE FOR STANDARDIZATION

C O M IT É E U R O P É E N D E N O R M A LIS A T IO N EUROPÄISCHES KOMITEE FÜR NORMUNG

Management Centre: Avenue Marnix 17, B-1000 Brussels

© 2012 CEN All rights of exploitation in any form and by any means reserved Ref No EN 12842:2012: E

Contents Page

Foreword 3

1 Scope 4

2 Normative references 5

3 Terms and definitions 5

4 Technical requirements 8

4.1 General 8

4.2 Dimensional requirements 10

4.3 Material characteristics 12

4.4 Coatings 13

4.5 Marking 14

4.6 Leak tightness 14

5 Performance requirements for joints 14

5.1 General 14

5.2 Leak tightness of flexible joints 15

5.3 Long term hydrostatic strength test 17

5.4 Flanged joints 19

6 Test methods 19

6.1 Tensile testing for ductile iron 19

6.2 Brinell hardness for ductile iron 20

6.3 Works leak tightness test 21

7 Performance tests 21

7.1 Leak tightness of joints to internal hydrostatic pressure 21

7.2 Leak tightness of joints to negative internal pressure 23

7.3 Leak tightness of joints to dynamic internal pressure 24

7.4 Long term hydrostatic strength test for joints of fittings for PE pipes 24

7.5 Pull out test at 25 ºC for restrained joints for PE pipes 25

7.6 Long term hydrostatic strength test for joints of fittings for PVC-U pipe 25

8 Tables of dimensions 26

8.1 Dimensions of sockets for push-in flexible joints 26

8.2 Dimensions of sockets for mechanical flexible joints 28

8.3 Dimensions of fittings 29

9 Evaluation of conformity 44

9.1 General 44

9.2 Initial performance testing 45

9.3 Factory production control (FPC) 46

Bibliography 49

at the latest by February 2013

Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights This document supersedes EN 12842:2000

The significant changes made since the previous version are as follows:

a) Wording (relating to accessories, fittings, coupling and flange adaptor) modified in accordance with

EN 545;

b) Improvement of shear load test for flange adapter and one socket fitting;

c) Addition of aging test for PE pipe fittings and accessories

This European Standard was prepared in co-operation with CEN/TC 155 "Plastics piping systems"

This standard is in conformity with the general requirements already established by CEN/TC 164 in the field of water supply

In respect of potential adverse effects on the quality of water intended for human consumption caused by the product covered by this standard:

 this standard provides no information as to whether the product may be used without restriction in any of the member states of the EU or EFTA;

 it should be noted that, while awaiting the adoption of verifiable European criteria, existing national regulations concerning the use and/or the characteristics of these products remain in force

According to the CEN/CENELEC Internal Regulations, the national standards organisations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and the United Kingdom

1 Scope

This European Standard specifies the requirements and associated test methods applicable to ductile iron fittings, ductile iron and mild steel couplings and flange adaptors and their joints to be used with poly(vinyl chloride) (PVC-U) pipes or polyethylene (PE) pipes It is in conformity with EN 1452-1 to -5, ENV 1452-6 and -

7 and EN 12201-1 to -5 respectively, for the construction of pipelines:

 to convey water (e.g water intended for human consumption);

 with or without pressure;

 to be installed below or above ground, inside or outside buildings

This European Standard is not intended to cover sewerage applications, where additional requirements may

be necessary

This European Standard is applicable to fittings which are:

 manufactured with socketed, flanged or spigot ends;

 supplied externally and internally coated;

 suitable for PE and PVC-U pipes with fluid temperatures between 0°C and 25°C, excluding frost, and for pressures up to 16 bar (PFA) For higher temperatures (up to 45°C for PVC-U or 40°C for PE) the PFA is derated as given in EN 1452 and EN 12201;

 not intended for use in areas subjected to reaction to fire regulations

NOTE 1 This does not preclude special arrangements for the products to be used at higher temperatures Temperature limitations and pressure limitations are those coming from the PVC-U or PE pipes

This European Standard covers ductile iron fittings, couplings and flange adaptors cast by any type of foundry process or manufactured by fabrication of cast components, as well as corresponding joints, in a size range extending from DN 60 to DN 700, to be used with pipes of external diameter from 63 mm to 710 mm

As long as no equivalent European Standard exists for mild steel accessories, this European Standard also covers couplings and flange adaptors for use with PVC-U and PE pipes which are fabricated partly or entirely from mild steel as well as corresponding joints, in a size range extending from DN 60 to DN 700, to be used with pipes of external diameter from 63 mm to 710 mm

This European Standard specifies requirements for materials, dimensions and tolerances, mechanical properties and standard coatings It also gives minimum performance requirements for all components, including restrained and non-restrained flexible joints Joint design and gasket shapes are outside the scope

to declare this in the relevant literature

NOTE 3 In this European Standard, all pressures are relative pressures, expressed in bars (100 kPa = 1 bar)

2 Normative references

The following documents, in whole or in part, are normatively referenced in this document and are indispensable for its application For dated references, only the edition cited applies For undated references, the latest edition of the referenced document (including any amendments) applies

EN 681-1, Elastomeric seals  Material requirements for pipe joint seals used in water and drainage applications  Part 1: Vulcanised rubber

EN 805:2000, Water supply  Requirements for systems and components outside buildings

EN 1092-2, Flanges and their joints  Circular flanges for pipes, valves, fittings and accessories, PN designated  Part 2: Cast iron flanges

EN 10025-1:2004, Hot rolled products of structural steels  General technical delivery conditions

EN 10310, Steel tubes and fittings for onshore and offshore pipelines  Internal and external polyamide powder based coatings

EN 14901, Ductile iron pipes, fittings and accessories  Epoxy coating (heavy duty) of ductile iron fittings and accessories – Requirements and test methods

EN 15189, Ductile iron pipes, fittings and accessories  External polyurethane coating for pipes 

Requirements and test methods

EN 15655, Ductile iron pipes, fittings and accessories  Internal polyurethane lining for pipes and fittings 

Requirements and test methods

EN ISO 1167-1:2006, Thermoplastics pipes, fittings and assemblies for the conveyance of fluids 

Determination of the resistance to internal pressure  Part 1: General method (ISO 1167-1:2006)

EN ISO 4016, Hexagon head bolts  Product grade C (ISO 4016)

EN ISO 4034, Hexagon nuts  Product grade C (ISO 4034)

EN ISO 6506-1, Metallic materials  Brinell hardness test  Part1: Test method (ISO 6506-1)

EN ISO 7091, Plain washers  Normal series  Product grade C (ISO 7091)

EN ISO 9001:2008, Quality management systems  Requirements (ISO 9001:2008)

EN ISO 13846:2000, Plastic piping systems  End-load-bearing and non-end-load-bearing assemblies and joints for thermoplastics pressure piping  Test method for long-term leaktightness under internal water pressure (ISO 13846:2000)

3 Terms and definitions

For the purposes of this document, the following terms and definitions apply

[SOURCE: EN 545]

3.3

flange

end of a fitting or flange adaptor extending perpendicular to its axis, with bolt holes equally spaced on a circle

Note 1 to entry: A flange can be fixed (e.g integrally cast or welded) or adjustable; an adjustable flange comprises a ring, in one or several parts assembled together, which bears on an end joint hub and can be freely rotated around the axis before jointing

push-in flexible joint

flexible joint assembled by pushing the spigot through the gasket in the socket of the mating component

3.10

mechanical flexible joint

flexible joint in which sealing is obtained by applying pressure to the gasket by mechanical means, e.g a gland

3.11

restrained flexible joint

flexible joint in which a means is provided to prevent separation of the assembled joint

alphanumeric designation of size for components of a pipework system, which is used for reference purposes

Note 1 to entry: It comprises the letters DN followed by a dimensionless whole number which is indirectly related to the physical size, in millimetres, of the bore or outside diameter of the end connections

Note 2 to entry: Adapted from EN ISO 6708:1995, definition 2.1

3.14

nominal outside diameter (d n )

specified outside diameter, in millimetres, assigned to a nominal size DN/OD

[SOURCE: EN 12201-1]

3.15

minimum socket inside diameter (d i min )

minimum value of the internal diameter of the socket mouth

3.16

nominal pressure PN

alphanumerical designation, which comprises a convenient rounded number used for reference purposes

Note 1 to entry: All components of the same nominal size, DN, designated by the same PN have compatible mating dimensions

Note 2 to entry: Adapted from EN 1333:2006

Note 3 to entry: In EN 1452 and EN 12201, the term nominal pressure (PN) at 20°C is used in place of PFA

3.17

allowable operating pressure (PFA)

maximum hydrostatic pressure that a component is capable of withstanding continuously in service

[SOURCE: EN 805:2000]

Note 1 to entry: In EN 1452 and EN 12201, the term nominal pressure (PN) at 20°C is used in place of PFA

3.18

leak tightness test pressure

pressure applied to a component during manufacture in order to ensure its leak tightness

3.19

allowable maximum operating pressure (PMA)

maximum pressure occurring from time to time, including surge, that a component is capable of withstanding

in service

[SOURCE: EN 805:2000]

3.20

allowable test pressure (PEA)

maximum hydrostatic pressure that a newly installed component is capable of withstanding for a relatively short duration, in order to ensure the integrity and tightness of the pipeline

3.23

length

effective length of a fitting, as shown on the figures of Clause 8

Note 1 to entry: For flanged fittings, the effective length L (l for branches) is equal to the overall length For socketed fittings, the effective length is designated Z in plastics piping systems standards and Lu (lu for branches) in EN 545; it is equal to the overall length minus the spigot insertion depth as given in the manufacturer's catalogues

 is used in a pipeline to make the connection between two spigots of pipes, fittings or valves, etc.; and

 allows for angular and axial displacements for unrestrained joints and angular displacements for restrained flexible joints

Note 1 to entry: Some couplings are designed such that they can be slid over the pipes in order to facilitate easy assembly

Note 2 to entry: As defined in EN 545, Couplings are accessories

4.1.2 Standardized sizes

The standardised sizes of fittings, corresponding to the nominal outside diameter dn (in millimetres) of the pipes to which they shall be connected, are as follows: 63, 75, 90, 110, 125, 140, 160, 180, 200, 225, 250,

280, 315, 355, 400, 450, 500, 560, 630, 710

4.1.3 Surface condition and repairs

Fittings, couplings and flange adaptors shall be free from defects and surface imperfections which could lead

to non-compliance with Clauses 4 and 5

When necessary, fittings, couplings and flange adaptors may be repaired, for example by welding, in order to remove surface imperfections and localised defects which do not extend through the entire wall thickness, provided that:

 the repairs are carried out according to the manufacturer’s written procedure;

 the repaired products comply with all the requirements of Clauses 4 and 5

4.1.4 Types of joints and interconnection

4.1.4.1 General

Rubber gasket materials shall comply with the requirements of EN 681-1 for the type WA When materials other than rubber are necessary (e.g for high temperature flanged joints), they shall comply with the appropriate European Technical Specification or, where no European Technical Specification exists, the appropriate International Standard

4.1.4.2 Flexible joints

The dimensions of sockets for push-in and mechanical, restrained and non-restrained flexible joints shall comply with 4.2.4 and with any additional requirements related to the gasket design This ensures interconnection between all fittings and all PVC-U and PE pipes

In addition, each type of flexible joint shall be designed to fulfil the performance requirements of Clause 5 Taking into account the temperature and pressure effects on PE pipe, all joints intended for use with PE pipe shall be restrained

Supporting sleeves (inserts) may be necessary depending on pipe material, on pipe wall thickness, on joint design and on national requirements; they should provide adequate support over the entire compression area

of the gasket and restraining mechanism

Where applicable, the minimum thickness of the PE pipes should be declared by the manufacturer of the fittings

4.1.4.3 Flanged joints

Flanges shall be designed such that they can be attached to flanges whose dimensions and tolerances comply with EN 1092-2 This ensures interconnection between all flanged components (pipes, fittings, valves etc.) of the same PN and DN

Bolts and nuts shall comply as a minimum with the requirements of EN ISO 4016 and EN ISO 4034, grade 4.6 Where washers are required, they shall comply with EN ISO 7091

Although it does not affect interconnection, the manufacturer shall state whether his products are normally delivered with fixed flanges or adjustable flanges

Flange gaskets may be one of any type given in EN 1514 (all parts)

4.1.5 Materials in contact with water intended for human consumption

Components of a pipe system include several materials given in this standard When used under the conditions for which they are designed, in permanent or in temporary contact with water intended for human consumption, ductile iron/mild steel fittings and their joints shall not change the quality of that water to such an extent that it fails to comply with the requirements of national regulations

For this purpose, reference shall be made to the relevant national regulations and standards, transposing EN standards when available, dealing with the influence of materials on water quality and to the requirements for external systems and components as given in EN 805

4.2 Dimensional requirements

4.2.1 Minimum wall thickness of ductile iron fittings, couplings and flange adaptors

The minimum wall thickness of the ductile iron, at any point, shall be as given in Table 1, provided that the requirements of 4.3, 4.6 and Clause 7 are complied with

Table 1 — Minimum wall thickness of ductile iron fittings, couplings and flange adaptors

4.2.2 Minimum wall thickness of mild steel couplings and flange adaptors

The minimum wall thickness of the steel, at any point, shall be as given in Table 2, provided that the requirements of 4.3, 4.6 and 7 are complied with

Table 2 — Minimum wall thickness of mild steel couplings and flange adaptors

d n

Minimum wall thickness for material grade as specified in 4.3.2

4.2.4 Dimensions of sockets

The minimum internal diameter of sockets and the minimum depth of engagement of sockets shall comply with the values given in Tables 7 and 8

4.2.5 Jointing gap for couplings and flange adaptors

The manufacturer shall declare his maximum jointing gap for couplings and flange adaptors for PVC-U pipes (see Figure 1) and it shall not be less than the values given in Table 3

NOTE The jointing gap between the pipes or the flange to be connected might be affected by the pipe contraction or expansion occurring as a result of temperature or pressure change

Jointing gaps for PE pipes and restrained joints for PVC-U pipes are related to the joint design; the manufacturer shall declare these where relevant

The manufacturer shall declare the minimum depth of engagement in the jointing instructions The minimum depth of engagement shall be such that the pipes can support the loads imparted by the jointing/anchorage system

Table 3  Dimensions of jointing gap for non-restrained couplings and flange adaptors for PVC-U

pipes

PVC-U Pipes Nominal outside diameter

of pipe Coupling jointing gap Flange adaptor jointing gap

4.3.2 Mild steel for couplings and flange adaptors

Mild steel for couplings and flange adaptors shall comply as a minimum with the requirements of

EN 10025-1:2004, grade S275

4.3.3 Fastener for couplings and flange adaptors

The maximum operating load on a fastener should not be greater than 80% of the yield strength of the fastener

Fasteners shall be suitably protected to inhibit corrosion The following coatings may be supplied:

 polymeric (e.g epoxy/polyamide);

 zinc based corrosion protection;

1) polyamide in accordance with EN 10310;

2) polyurethane in accordance with EN 15189;

3) enamel1)

b) Internal coatings (linings):

1) polyamide in accordance with EN 10310;

2) polyurethane in accordance with EN 15655;

3) enamel1)

These external and internal coatings and their application process shall comply with the corresponding EN standards or, where no EN standard exists, they shall comply with ISO standards or with national standards valid in the place of use of the product, or with an agreed technical specification

All coatings shall be works-applied

1) Enamel is a glass material containing raw material oxides fully or partly molten in the glass This non-organic preparation can be laid

in one or more layers on the metal part at a temperature higher than 480°C.

4.5 Marking

All fittings, couplings and flange adaptors shall be legibly and durably marked and shall bear at least the following information:

a) a reference to this European Standard (EN 12842);

b) the manufacturer's name or mark;

c) identification of the year of manufacture;

d) the identification of ductile iron or mild steel;

e) the dn and/or the DN as relevant;

f) the PN rating of flanges for flange components;

g) “PVC” and/or “PE”

Items b) to f) shall be cast-on or cold stamped Item a) and g) can be applied by any method e.g painted on the castings or attached to the packaging

4.6 Leak tightness

4.6.1 Fittings, couplings and flange adaptors

Fittings, couplings and flange adaptors shall be leak tight at their allowable test pressure (PEA)

Ductile iron fittings, couplings and flange adaptors shall be tested in accordance with 6.3 and shall exhibit no visible leakage, sweating or any other sign of failure

4.6.2 Joints

Joints shall be designed in conformity with Clause 5 in order:

a) to durably withstand without leakage the allowable maximum operating pressure (PMA) of corresponding pipes and fittings under all normal service conditions, including foreseeable surge pressures and joint movements (angular and axial);

b) to be leak tight under negative internal pressure, which may occur under surge conditions

5 Performance requirements for joints

One end of a coupling is classified as the joint as long as both ends are to the same design Where the joint design for a coupling is the same as a flange adaptor, testing need only be carried out on either coupling or flange adaptor

One dn is representative of a grouping when the performances are based on the same design parameters throughout the size range Performance tests shall be carried out with PVC-U pipes and with PE pipes when the joint is meant to be used with either PVC-U pipes or PE pipes

If a grouping covers products of different designs and/or manufactured by different processes, the grouping shall be sub-divided

If for a manufacturer a grouping contains only one dn, this dn shall be tested instead of the preferred dn

The PFA for a fitting with a flange on one or more sides cannot under any circumstance be higher than the rating of the flange(s)

5.2 Leak tightness of flexible joints

5.2.1 General

The allowable angular deflection per joint declared by the manufacturer shall be not less than those given in Table 4

Table 4 — Allowable angular deflection

Push in joints and mechanical restrained

All non-restrained joints shall be designed to provide axial movement; thereby the allowable withdrawal shall

be declared by the manufacturer

NOTE This permits the installed pipeline to accommodate ground movements and/or thermal effects without incurring additional stresses

The manufacturer shall declare the lowest and the highest pipe pressure class for which the fitting is intended

a) joint of maximum annulus (see 5.2.3.1), aligned, withdrawn to the allowable value declared by the manufacturer, and subjected to shear (see 5.2.3.2);

b) joint of maximum annulus (see 5.2.3.1), deflected to the allowable value declared by the manufacturer (see 5.2.1)

The application of a shear load, as stated in 5.2.2 a), is only required for PVC-U pipes

The joints shall exhibit no visible leakage when subjected to the following tests:

 test 1: positive internal hydrostatic pressure in accordance with 7.1; the test pressure shall be (1,5 p) bar, where p is the allowable operating pressure (PFA) of the joint declared by the manufacturer;

 test 2: negative internal pressure in accordance with 7.2 of 0,8 bar below atmospheric pressure (approximately 0,2 bar absolute pressure);

 test 3: cyclic internal hydraulic pressure in accordance with 7.3 The test shall comprise at least 24 000 cycles between 0,5p and p, where p is the allowable operating pressure (PFA) of the joint declared by the manufacturer

NOTE The test pressures in test 1 and test 2 and the test durations given in 7.1 and 7.2 are in accordance with, or slightly more stringent than, the requirements of PVC-U and PE piping systems standards

Table 5 summarises the test requirements and the test conditions given in 5.2.2, 5.2.3, 5.2.4, 7.1, 7.2 and 7.3

Table 5 — Summary of test conditions

PVC-U pipes Test conditions PE pipes

 temperature between 15 °C and 25 °C

 joint of maximum annulus, aligned and withdrawn

 temperature between 15 °C and 25 °C

 joint of maximum annulus, deflected

 temperature between 15 °C and 25 °C

 joint of maximum annulus, deflected

 temperature between 15 °C and 25 °C

 temperature between 15 °C and 25 °C

 joint of maximum annulus, aligned and withdrawn

 temperature between 15 °C and 25 °C

 joint of maximum annulus, deflected

 temperature between 15 °C and 25 °C

 joint of maximum annulus, deflected

 temperature between 15 °C and 25 °C

 test period: 24 000 cycles

 joint of maximum annulus, aligned, withdrawn and subjected to shear load

 temperature between 15 °C and 25 °C

 joint of maximum annulus, aligned and withdrawn

 temperature between 15 °C and 25 °C

5.2.3 Test parameters

5.2.3.1 Annulus

All joints shall be performance tested at the extremes of manufacturing tolerance such that the annular gap

minus 5 % It is permissible to machine socket internal surfaces to achieve the required annulus for the performance test even though the resultant diameter can be slightly outside the normal manufacturing tolerance

5.2.3.2 Shear

When applicable, joints shall be performance tested with a resultant shear force across one joint of not less than 10 x dn in Newton, taking into account the weight of the pipe and of its contents and the geometry of the test assembly (see 7.1)

5.2.4 Restrained flexible joints

All restrained joint designs shall be performance tested in accordance with 7.1, 7.2 and 7.3 following the requirements of 5.2.2 and 5.2.3 except that:

 the withdrawal condition of 5.2.2 a) shall not apply;

 there shall be no external axial restraint in positive internal pressure tests so that the joint is subjected to the full end thrust

During the positive internal pressure tests, the axial movement shall reach a stable value and cease

When the restraining mechanism and the sealing component of the restrained joint are independent, such a joint need not be subjected to test 2 of 5.2.2 if the unrestrained version of the joint has passed this test

5.3 Long term hydrostatic strength test

5.3.1 PE pipes

This test is applicable to restrained joints for PE pipe

When tested by the method described in 7.4, the jointed assembly shall not leak nor shall the pipe fracture when subjected to the test pressures resulting from the stresses given in the following test options:

a) PE 100 pipes:

1) Temperature 80 °C with a circumferential stress of 5,3 N/mm2 for 165 h;

2) Temperature 80 °C with a circumferential stress of 5,0 N/mm2 for 1 000 h;

3) Temperature 60 °C with a circumferential stress of 6,8 N/mm2 for 165 h;

4) Temperature 60 °C with a circumferential stress of 6,5 N/mm2 for 1 000 h;

5) Temperature 50 °C with a circumferential stress of 7,8 N/mm2 for 165 h;

6) Temperature 50 °C with a circumferential stress of 7,4 N/mm2 for 1 000 h

b) PE 80 pipes:

1) Temperature 80 °C with a circumferential stress of 4,3 N/mm2 for 165 h;

2) Temperature 80 °C with a circumferential stress of 4,1 N/mm2 for 1 000 h;

3) Temperature 60 °C with a circumferential stress of 5,5 N/mm2 for 165 h;

4) Temperature 60 °C with a circumferential stress of 5,2 N/mm2 for 1 000 h;

5) Temperature 50 °C with a circumferential stress of 6,3 N/mm2 for 165 h;

6) Temperature 50 °C with a circumferential stress of 6,0 N/mm2 for 1 000 h

The pressure to be applied for the options (a) to (f) shall be calculated using the following Formula (1):

n

20

e d

e

where

P is the test pressure, in bars;

σ is the circumferential stress to be induced by the test pressure (a) to (f) in 5.3.1, in megapascals;

dn is the nominal outside diameter of the test piece, in millimetres;

en is the nominal wall thickness of the free length of the test piece, in millimetres

If after the test period the sample has not failed, the test shall be discontinued and the sample subjected to the test as detailed in 5.3.2

5.3.2 Pull out test at 25 ºC

After having been subjected to the requirements of 5.3.1, the assembly shall be tested by the method described in 7.5

The pipe shall not fracture within the jointed assembly Whilst initial movement of the pipe within the joint is allowed, no further such movement is permitted after the test loads calculated from Formula (2) has been attained:

4

2

104

F is the longitudinal test force to be applied, in kilonewtons;

1,2 is the safety factor;

p is the maximum working pressure (PFA) of the pipe, in bars;

D is the external diameter, in millimetres

5.3.3 PVC-U pipes

This test is applicable to both non-restrained and restrained joints for PVC-U pipe

When tested by the method described in 7.6, the jointed assembly shall not leak at any point of the jointing areas during the test period when subjected to the test pressure from one of the following test options:

a) Pipe with a design stress of 10 MPa:

1) Temperature 20ºC for 1000 hours; test pressure = 1,7p

b) Pipe with a design stress of 12,5 MPa:

1) Temperature 20 ºC for 1 000 h; test pressure = 1,65p

2) Temperature 40 ºC for 1 000 h; test pressure = 1,3p

where p is the nominal pressure rating of the pipe/fitting, in bars

The thickness of the sample and the diameter of the test bar shall be as given in Table 6

At the manufacturer’s discretion, samples shall be either cast integrally with the castings or cast separately In the latter case it shall be cast from the same metal as that used for the castings If the castings are subjected

to heat treatment, the samples shall be subjected to the same heat treatment cycle

6.1.2 Preparation of test bar

A test bar shall be machined from each sample to be representative of the metal at the mid thickness of the sample, with a cylindrical part having the diameter given in Table 6

The test bar shall have a gauge length equal to at least five times the nominal test bar diameter The ends of the test bar shall be such that they will fit the testing machine

The surface roughness profile of the cylindrical part of the test bar shall be such that Rz ≤ 6,3

If the specified diameter of the test bar is greater than 60 % of the measured minimum thickness of the sample, it is allowed to machine a test bar with a smaller diameter, or cut another sample in a thicker part of the fitting

Table 6 — Dimensions of test bar

the test bar Limit deviations on diameter Tolerance on shape a

a) Integrally cast samples

b) Separately cast samples:

1) sample thickness 12,5 mm for casting

thickness less than 12 mm

2) sample thickness 25 mm for casting

thickness 12 mm and over

5,0 6,0 12,0 or 14,0

± 0,06

± 0,06

± 0,09

0,03 0,03 0,04

a Maximum difference between the smallest and the largest measured diameter of the test bar

The tensile strength shall be calculated either:

 from the nominal diameter of the test bar when it has been machined to fulfil all the tolerances given in

Table 6, or if it is not the case,

 from the actual diameter of the test bar measured before the test

The actual diameter shall be measured using a measuring device having an error limit ≤ 0,5 % and shall be

within ± 10 % of the nominal diameter

6.1.3 Apparatus and test method

The tensile test shall be carried out in accordance with EN 10002-1

6.1.4 Test results

Test results shall comply with 4.3.1.1 If they do not comply, the manufacturer shall:

a) in the case where the metal does not achieve the required mechanical properties, investigate the reason

and ensure that all castings in the batch are either re-heat treated or rejected Castings which have been

re-heat treated are then re-tested in accordance with 6.1;

b) in the case of a defect in the test bar, carry out a further test If it passes, the batch is accepted; if not, the

manufacturer may proceed as in a) above

The manufacturer may limit the amount of rejection by making tests until the rejected batch of castings is

bracketed, in order of manufacture, by a successful test at each end of the interval in question

6.2 Brinell hardness for ductile iron

When Brinell hardness tests are carried out (see 4.3.1.2), they shall be performed either on the casting in

dispute or on a sample cut from the casting The surface to be tested shall be suitably prepared by local

grinding to ensure a flat surface and the test shall be carried out in accordance with EN ISO 6506-1 using a

ball of 2,5 mm or 5 mm or 10 mm diameter

6.3 Works leak tightness test

6.3.1 General

At the discretion of the manufacturer, fittings, couplings and flange adaptors shall be submitted to an air test (see 6.3.2) or to a hydrostatic pressure test (see 6.3.3) or to any other leak tightness test of equivalent performance Fittings shall be tested before application of their internal and external coatings

The test apparatus shall be suitable for applying the specified test pressures to the fittings It shall be equipped with an industrial pressure gauge with an error limit of ± 3 %

6.3.2 Air test

When the air test is carried out, it shall be with an internal pressure of at least 1 bar and a visual inspection time not less than 10 s For leak detection, the castings shall be either uniformly coated on their external surface by a suitable foaming agent or submerged in water

6.3.3 Hydrostatic pressure test

When the hydrostatic pressure test is carried out, it shall be with the following minimum test pressures:

 dn 63 to dn 630: 16 bar;

 dn 710: 10 bar

The internal hydrostatic pressure shall be raised steadily until it reaches the test pressure which shall be maintained for a sufficient time to allow visual inspection The total duration of the pressure cycle shall be not less than 15 s, including 10 s at test pressure

7 Performance tests

7.1 Leak tightness of joints to internal hydrostatic pressure

7.1.1 Couplings and 2 sockets fittings

The test shall be carried out on an assembled joint comprising a fitting, including sockets, and two plastic pipes section (see Figure 2)

The test apparatus shall be capable of providing suitable end and lateral restraints whether the joint is in the aligned position, deflected or subjected to a shear load It shall be equipped with a pressure gauge with an accuracy in relation to the range of measured pressures of ≤ 3 %

Key

1 plastic pipe section

2 ductile iron fitting

a distance between block support and socket face

b length of pipe section

W vertical force

Figure 2 — Internal hydrostatic testing for couplings and 2 sockets fittings

The testing equipment shall be as shown in Figure 2 The plastic pipes shall be supported by means of V shaped blocks with an angle of (120 ± 10)°, located at a distance, a, of 0,2dn in mm, from the socket face, and

up to a maximum of 50 mm The length of each pipe section, b, shall be at least 2dn, in mm, and with a minimum of 1 m The vertical force, W, shall be applied to the fitting The vertical force, W, shall be such that the resultant shear force, F, across the joints is equal to the value specified in 5.2.3.2 taking into account the mass, M, of the fitting and its contents and the geometry of the test assembly, as given in Formula (3):

The test assembly shall be filled with water and suitably vented of air The test shall not begin before the temperature of the test assembly has stabilised between 15 °C and 25 °C The pressure shall be raised steadily until it reaches the test pressure given in 5.2.2; the rate of pressure increase shall not exceed 1 bar per s The test pressure shall be kept constant within ± 0,5 bar for at least 2 h

All necessary safety precautions should be taken for the duration of the pressure test

For a restrained joint, the test assembly, the test apparatus and the test procedure are identical, except that there shall be no end restraint so that the axial thrust is taken by the restrained joint under test

7.1.2 Flange adaptors and 1 socket fitting

For a flange adaptor and 1 socket fitting, half of the test apparatus shall be used (see Figure 3)

The test apparatus shall be capable of providing suitable end and lateral restraints whether the joint is in the aligned position, deflected or subjected to a shear load It shall be equipped with a pressure gauge with an accuracy in relation to the range of measured pressures of ≤ 3 %

Key

1 plastic pipe section

2 1 socket fitting or flange adaptor

a distance between block support and socket face

b length of pipe section

W Vertical force

Figure 3 — Internal hydrostatic testing for flange adaptor and 1 socket fitting

The testing equipment shall be as shown in Figure 2 The plastic pipes shall be supported by means of V shaped blocks with an angle of (120 ± 10)°, located at a distance a, of 0,2dn in mm, from the socket face, and

up to a maximum of 50 mm The length of each pipe section, b, shall be at least 2dn, in mm, and with a minimum of 1 m The vertical force, W, shall be applied to the fitting The vertical force, W, shall be such that the resultant shear force F across the joints is equal to the value specified in 5.2.3.2 taking into account the mass, M, of the fitting and its contents and the geometry of the test assembly, as given in Formula (4):

The test assembly shall be filled with water and suitably vented of air The test shall not begin before the temperature of the test assembly has stabilised between 15 °C and 25 °C The pressure shall be raised steadily until it reaches the test pressure given in 5.2.2; the rate of pressure increase shall not exceed 1 bar per s The test pressure shall be kept constant within ± 0,5 bar for at least 2 h

All necessary safety precautions should be taken for the duration of the pressure test

For a restrained joint, the test assembly, the test apparatus and the test procedure are identical, except that there shall be no end restraint so that the axial thrust is taken by the restrained joint under test

7.2 Leak tightness of joints to negative internal pressure

The test assembly and test apparatus shall be as given in 7.1 with the pipe sections axially restrained to prevent them moving towards each other

The test assembly shall be empty of water and shall be evacuated to a negative internal pressure of 0,8 bar (see 5.2.2) and then isolated from the vacuum pump The test assembly shall be left under vacuum for 2 h during which the pressure shall not have changed by more than 0,08 bar The test shall begin at a temperature between 15 °C and 25 °C, which is then kept constant at ± 2 °C for the duration of the test

For a restrained joint, the test assembly, the test apparatus and the test procedure are identical

7.3 Leak tightness of joints to dynamic internal pressure

The test assembly and test apparatus shall be as given in 7.1 The test assembly shall be filled with water and suitably vented of air

The pressure shall be steadily increased up to p, the allowable operating pressure of the joint and then automatically monitored according to the following pressure cycle:

a) steady pressure reduction to 0,5 p;

b) maintain 0,5 p for at least 5 s;

c) steady pressure increase to p;

d) maintain p for at least 5 s

The pressure may vary during steps b) and d) either side of the specified pressure, but the difference between the mean pressure b) and the mean pressure d) shall be at least 5 bar

The number of cycles shall be recorded and the test stopped automatically in the occurrence of a failure of the joint

For a restrained joint, the test assembly, the test apparatus and the test procedure are identical, except that there shall be no end restraint so that the axial thrust is taken by the restrained joint under test In addition any axial movement at the spigot shall be measured every 15 min

All necessary safety precautions should be taken for the duration of the pressure test

7.4 Long term hydrostatic strength test for joints of fittings for PE pipes

7.4.1 Test piece

A test piece shall be assembled with PE 100 or PE 80 pipe in accordance with the manufacturer’s instructions Specimens shall be conditioned prior to test by being kept at (25 +0/-4) ºC in air for not less than 24 h For hydrostatic tests involving liquid immersion, the specimens shall be conditioned in the liquid at the test temperature for not less than 24 h

The end caps used shall comply with EN ISO 1167-1:2006, type A There shall be a free length of pipe, between the two fittings or a fitting and an end cap, of not less than three times the nominal size of the fitting for test pieces of nominal size up to and including 315 and a minimum of 1 m for sizes greater than nominal size 315

an error limit of ± 0,5mm

7.5 Pull out test at 25 ºC for restrained joints for PE pipes

7.6 Long term hydrostatic strength test for joints of fittings for PVC-U pipe

7.6.1 Test piece

A test piece shall be assembled with PVC-U pipe in accordance with the manufacturer’s instructions

Specimens shall be conditioned prior to test by being kept in the test room or conditioning chamber for at least

3 h for test temperatures more than 25 ºC or for at least 20 min for test temperatures equal to or less than

25 ºC If the test temperature is specified as ‘ambient temperature’, carry out the conditioning at any temperature between 15 ºC and 25 ºC During subsequent testing, maintain the test temperature constant to within ± 2 ºC and within the range of 15 ºC to 25 ºC

There shall be a free length of pipe, between the two fittings or a fitting and an end cap, equal to dn, but not less than 150 mm

For non-restrained joints, tie rods or external frames shall be used as necessary to prevent any separation

dn nominal outside diameter of pipe

di socket inside diameter

Figure 4 — Description of dimensions for push-in flexible joints