BRITISH STANDARD
BS EN 639:1995 Incorporating Corrigendum No. 1
Common requirements for concrete pressure pipes including joints and fittings
The European Standard EN 639:1994 has the status of a British Standard
ICS 23.040.50
12&23<,1*:,7+287%6,3(50,66,21(;&(37$63(50,77('%<&23<5,*+7/$:
BS EN 639:1995
Committees responsible for this British Standard The preparation of this British Standard was entrusted to Technical Committee B/505, Water supply, upon which the following bodies were represented: Association of Consulting Engineers Association of Manufacturers of Domestic Unvented Supply Systems Equipment (MODUSSE) British Bathroom Council British Foundry Association British Non-Ferrous Metals Federation British Plastics Federation British Plumbing Fittings Manufacturers’ Association Department of the Environment Department of the Environment (Drinking Water Inspectorate) Fibre Cement Manufacturers’ Association Limited Institute of Plumbing Institution of Water and Environmental Management Local Authority Organizations Scottish Association of Directors of Water and Sewerage Services Water Companies Association Water Research Centre Water Services Association of England and Wales The following bodies were also represented in the drafting of the standard, through subcommittees and panels: Association of Metropolitan Authorities British Precast Concrete Federation Ltd. Concrete Pipe Association Concrete Society Department of Transport Federation of Civil Engineering Contractors Institution of Civil Engineers Institution of Highways and Transportation This British Standard, having been prepared under the direction of the Sector Board for Building and Civil Engineering, was published under the authority of the Standards Board and comes into effect on 15 May 1995 © BSI 7 December 2004 The following BSI references relate to the work on this British Standard: Committee reference B/505 Draft for comment 92/12536 DC ISBN 0 580 23997 7
Amendments issued since publication Amd. No.
Date
Comments
15452
7 December 2004
National foreword amended
Corrigendum No. 1
BS EN 639:1995
Contents Committees responsible National foreword Foreword Text of EN 639
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BS EN 639:1995
National foreword This British Standard has been prepared by Technical Committee B/504 and is the English language version of EN 639:1994 Common requirements for concrete pressure pipes including joints and fittings, published by the European Committee for Standardization (CEN). Together with BS EN 642 it supersedes BS 4625, which is withdrawn. EN 639 was published as a result of international discussion in which the UK took an active part. Cross-references Publication referred to
Corresponding British Standard
EN 29001:1987
BS EN ISO 9001:1994 Quality systems — Model for quality assurance in design, development, production, installation and servicing (Identical) BS EN ISO 9002:1994 Quality systems — Model for quality assurance in production, installation and servicing (Identical) BS EN ISO 9003:1994 Quality systems — Model for quality assurance in final inspection and test (Identical)
EN 29002:1987
EN 29003:1987
This publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations.
Summary of pages This document comprises a front cover, an inside front cover, pages i and ii, the EN title page, pages 2 to 20, an inside back cover and a back cover. The BSI copyright notice displayed in this document indicates when the document was last issued.
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© BSI 7 December 2004
EUROPEAN STANDARD
EN 639
NORME EUROPÉENNE EUROPÄISCHE NORM
October 1994
ICS 23.040.30; 23.040.50 Descriptors: Water pipelines, pressure pipes, potable water, water pipes, concrete tubes, specifications, materials, definitions, computation, dimensions, tests, quality, implementation, marking
English version
Common requirements for concrete pressure pipes including joints and fittings
Prescriptions communes pour tuyaux pression en béton y compris joints et pièces spéciales
Allgemeine Anforderungen für Druckrohre aus Beton einschließlich Rohrverbindungen und Formstücken
This European Standard was approved by CEN on 1994-10-26. 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 Central Secretariat 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 Central Secretariat has the same status as the official versions. CEN members are the national standards bodies of Austria, Belgium, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom.
CEN European Committee for Standardization Comité Européen de Normalisation Europäisches Komitee für Normung Central Secretariat: rue de Stassart 36, B-1050 Brussels © 1994 Copyright reserved to CEN members
Ref. No. EN 639:1994 E
EN 639:1994
Foreword This European Standard for concrete pipes is a standard which was prepared by WG 5, Concrete pipes, of the Technical Committee CEN/TC 164, Water supply, the Secretariat of which is held by AFNOR. During preparation of this standard the provisional results already available of CEN/TC 164/WG 1, General requirements for external systems and components, and of CEN/TC 164/165/JWG 1, Structural design, were considered. This European Standard shall be given the status of a national standard, either by publication of an identical text or by endorsement, at the latest by April 1995, and conflicting national standards shall be withdrawn at the latest by April 1995. In accordance with the CEN/CENELEC Internal Regulations, the following countries are bound to implement this European Standard: Austria, Belgium, Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom.
Contents Page 2 4 4 4 4 6 6
Foreword Introduction 1 Scope 2 Normative references 3 Definitions 4 General 4.1 Concrete pipe behaviour 4.2 Plans and data to be supplied by purchaser 4.2.1 Design data 4.2.2 Specifications and drawings 4.2.3 Design responsibility 4.3 Data to be submitted by the manufacturer 4.3.1 Parameters for surge calculation 4.3.2 Detail drawings and schedules 4.3.3 Tabulated layout schedule 4.4 Design requirements 5 Materials 5.1 Cement 5.2 Aggregates 5.3 Mixing water 5.4 Admixtures and additives 5.5 Steel for cylinders, fittings and specials
2
7 7 7 7 8 8 8 8 8 8 8 8 8 8 8
5.6 Steel for joint rings 5.7 Reinforcing steel 5.8 Sealing rings 5.9 Chloride content 6 Common requirements for products 6.1 Geometry and dimensions 6.1.1 Nominal sizes 6.1.2 Internal diameters 6.1.3 Lengths 6.1.4 Straightness and surface evenness 6.1.5 Squareness 6.1.6 Wall thickness 6.1.7 Joints 6.1.8 Structure of steel joint with an elastomeric sealing ring 6.1.9 Structure of a site welded joint 6.1.10 Elastomeric sealing rings 6.1.11 Steel cylinder 6.2 Curing 6.3 Rework during manufacturing process (repairs) 6.4 Test methods 6.4.1 Internal diameter 6.4.2 Internal barrel length 6.4.3 Straightness and surface evenness 6.4.4 Squareness 6.4.5 Wall thickness 6.4.6 Steel joint rings 6.4.7 Hydrostatic testing of steel cylinder for pipe 6.4.8 Liquid penetrant test 6.4.9 Sealing rings (elastomeric gaskets) 6.4.10 Concrete strength 6.4.11 Concrete crack 6.4.12 Deflection and shear test 6.5 Fittings and specials 6.5.1 General 6.5.2 Materials 6.5.3 Fabrication 6.5.4 Design of fittings and specials 7 Quality control 7.1 General 7.2 Receiving inspection 7.3 Testing rates 7.4 Records
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7.5 Access to manufacturer’s facilities 7.6 Responsibility 7.7 Product construction directive 8 Marking 9 Interconnection for products 10 Installation and testing 10.1 Installation 10.2 Preparation for testing 10.3 Site test Annex A (informative) Notation of main parameters Annex B (informative) Span pipe calculations Figure 1 — Lengths Figure 2 — Gauge for evaluating deviation from straightness Figure 3 — Dimensions of feeler gauge for inspecting cracks Figure B.1 — Support loading diagram Figure B.2 — Longitudinal loading diagram Table 1 — Typical nominal sizes: DN/ID Table 2 — Tolerances on design internal diameter Table 3 — Allowable angular deflections Table 4 — Tolerances on circumference, in mm Table 5 — Tolerances for out-of-roundness, in mm
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EN 639:1994
Introduction The product1) in permanent or temporary contact with water, intended for human consumption, shall not adversely affect the quality of the drinking water and shall not contravene the CE Directives and EFTA Regulations on the quality of drinking water. This standard is not intended to be used alone. It shall be used as a combined document with one of the following as appropriate: EN 640, Reinforced concrete pressure pipes and distributed reinforcement concrete pressure pipes (non cylinder type) including joints and fittings. EN 641, Reinforced concrete pressure pipe, cylinder type, including joints and fittings. EN 642, Prestressed concrete pressure pipes, non cylinder and cylinder type, including joints, fittings and specific requirements for prestressing steel for pipes. or any future additional product standard referring to this standard. When the relevant EN dealing with general requirements, such as General requirements for external systems and components (CEN/TC 164/WG 1) Materials in contact with water (CEN/TC 164/WG 3) and Structural design (CEN/TC 164/165/JWG 1) are adopted, the present standard shall be revised, where appropriate, in order to ensure that these requirements comply with the relevant EN’s. To the present standard, are attached: — Annex A (informative): Notation of main parameters; — Annex B (informative): Span pipe calculations.
1 Scope This European Standard specifies common requirements for the following components: concrete pressure pipes, joints and fittings including jacking pipes. These components are intended to be used in water systems which carry water for human consumption, industrial purposes, irrigation or waste water.
2 Normative references This European Standard incorporates by dated or undated reference, provisions from other publications. These normative references are cited at the appropriate places in the text and the publications are listed hereafter. For dated references, subsequent amendments to or revisions of any of these publications apply to this European Standard only when incorporated in it by amendment or revision. For undated references, the latest edition of the publication referred to applies. EN 29001, Quality systems — Model for quality assurance in design/development, production, installation and servicing. EN 29002, Quality systems — Model for quality assurance in production and installation. EN 29003, Quality systems — Model for quality assurance in final inspection and test.
3 Definitions For the purposes of this standard, the following definitions apply. adjustable joint joint which permits significant angular deflection at the time of installation but not thereafter contractor the person, company or corporation executing the contract or agreement for installation and commissioning of the pipeline
1)
4
Shall be considered as such any product used for the conveyance and distribution of water intended for human consumption.
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dead loads the pipe weight, water weight, and all superimposed static loads applied to the outside of the pipe after installation design internal diameter the internal diameter specified in the manufacturer’s documents and to which manufacturing tolerances are applicable design pressure the maximum sustained internal hydrostatic pressure to which the pipe is to be subjected as specified by the purchaser. Generally, the design pressure for each pipe, or portion of the pipeline, shall be the operating pressure or the static head specified by the purchaser, whichever is the greater DN/ID numerical designation of size of component, which is a convenient integer approximately equal to the specified internal diameter expressed in mm effective length internal barrel length plus joint gap (provided by the manufacturer) (See Figure 1.)
Figure 1 — Lengths
external diameter the mean external diameter of the pipe barrel at any cross section factory test pressure the hydrostatic pressure applied for a relatively short duration to a pipe to test its integrity, watertightness and/or design flexible joint joint which permits significant angular deflection, both during and after installation and which can accept a slight offset of the centre line internal diameter the mean internal diameter of the pipe barrel at any cross section joint the connection between the adjacent ends of two components including the means of sealing
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EN 639:1994
live loads all superimposed external transient loads applied to the outside of the pipe during and after installation, e.g. traffic loading manufacturer the person, company or corporation that actually manufactures the pipe maximum design pressure design pressure plus surge pressure normal operating conditions a combination of design pressure and dead loads purchaser a person, company, corporation or agency entering into a contract or agreement to purchase pipes and fittings from the manufacturer rigid joint joint that does not permit significant angular deflection, either during or after installation surge pressure increases of short duration, to the operating pressure caused by changes in fluid velocity system test pressure the hydrostatic pressure applied for a relatively short duration to a newly laid pipeline in order to test its integrity and tightness transient conditions conditions due to surge pressures or live loads that vary normal operating conditions and are of short duration
4 General 4.1 Concrete pipe behaviour 4.1.1 Reinforced and prestressed concrete pipes are normally used in a buried situation. In a homogenous environment, they perform satisfactorily. However where a heterogenous environment exists special arrangements may be necessary and agreed between purchaser and manufacturer. In some cases, the environment may require specific arrangements for example: — high sulfate content: if total soluble sulfate content greater than 3 000 mg/kg of soil or greater than 600 mg/kg of ground water then sulfate resisting cement shall be used; — high chloride content: if total soluble chloride content greater than 500 mg/kg of soil or ground water then appropriate precautions shall be taken, to be determined in consultation with the manufacturer; — sea-water: sea-water resisting cement shall be used (or sulfate-resisting cement). Note that in the case of sea-water the above mentioned contents of sulfate and chloride shall not apply; — lime carbonic dissolving acid: if greater than 60 mg/l of ground water then appropriate precautions shall be taken, to be determined in consultation with the manufacturer.
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4.1.2 If concrete pipes are exposed to atmospheric environment, its effects shall be considered, for example: — carbonation; — thermal expansion; — freeze-thaw. 4.1.3 If the pipeline carries aggressive fluids (distilled water, some industrial waste, etc.) appropriate precautions shall be taken to be determined in consultation with the manufacturer. 4.2 Plans and data to be supplied by purchaser 4.2.1 Design data The purchaser shall specify the following design data applicable to each section of pipeline for which the pipe shall be manufactured, for example: — design pressure; — maximum design pressure equal to design pressure plus surge (calculation of surge is recommended); — external loads and installation conditions, including bedding, backfilling and trench support; — fluid characteristics (type of fluid, chemical composition, temperature if over 50 °C, etc.); — site investigation and soil data; — special conditions: for example, if longitudinal beam strength is a design condition, the purchaser shall designate the load and support conditions for which the pipe is to be designed. 4.2.2 Specifications and drawings The purchaser shall provide the manufacturer with plans, profiles and specifications, for example: — internal diameters; — alignment and grades; — location of all outlets, connections, valves and special fittings; — design and maximum design pressures for each section of the pipeline. 4.2.3 Design responsibility The purchaser or the purchaser’s engineering representative is responsible for the overall concept and design of the pipeline project, including supporting structures. The manufacturer is responsible for supplying pipe in accordance with the criteria defined in 4.2.1 and any additional requirements specified by the purchaser. The purchaser shall be aware of the following different types of concrete pressure pipes covered by this standard and may wish to state his options: — —
reinforced non-cylinder pipe distributed reinforcement non-cylinder pipe EN 640
—
reinforced cylinder pipe
—
prestressed cylinder pipe prestressed non-cylinder pipe
EN 641 EN 642
Should the purchaser wish to state his options, this shall be done at the time of invitation to tender.
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4.3 Data to be submitted by the manufacturer 4.3.1 Parameters for surge calculation Calculation of surge shall be provided by the purchaser. All necessary data relative to the pipe for such calculations shall be provided by the manufacturer, e.g. wave velocity. 4.3.2 Detail drawings and schedules The manufacturer shall prepare drawings and schedules showing full details of reinforcement, concrete, and joint dimensions for the pipe and fittings. These shall be submitted to the purchaser for approval when required in the contract documents. All pipes and fittings shall be fabricated in accordance with the approved drawings and schedules. Pipes may be supplied from stock unless the purchaser has indicated otherwise. 4.3.3 Tabulated layout schedule When specifically required, the data submitted by the manufacturer shall include a tabulated layout schedule with reference to the stationing and grade line shown on the drawings supplied by the purchaser. The schedule shall show pressure zones, each of which shall be designated by the design pressure applicable therein. The point of change from one zone to the next shall be clearly indicated by station number. The diameter of the pipe and the area of circumferential steel reinforcement (per unit length of pipe wall) shall be listed for each portion of the pipeline. 4.4 Design requirements Dead and live loads, coefficients for moments and thrust calculations and bedding angle shall be determined in accordance with appropriate national standards, transposing EN as available, or in the absence of such standards, with the appropriate regulations or recognized and accepted methods at the place where the pipeline is installed.
5 Materials 5.1 Cement Cement and cementitious materials shall comply with the national standards, transposing EN as available. Minimum 28 day compressive strength for cement and cementitious materials shall be 35 MPa. 5.2 Aggregates Aggregates shall consist of materials complying with the national standards, transposing EN as available. Gradings may be modified to suit the production process. Aggregates shall not contain harmful constituents in such quantities as may be detrimental to the performance of the final product. 5.3 Mixing water The mixing water shall comply with the national standard, transposing EN as available. The mixing water shall not contain harmful constituents in such quantities as may be detrimental to the performance of the final product (in general in Europe, drinking water from public supply is suitable for concrete). 5.4 Admixtures and additives Admixtures and additives shall comply with the national standards, transposing EN as available. They shall not be detrimental to the performance of the final product. 5.5 Steel for cylinders, fittings and specials Steel for cylinders, fittings and specials shall comply with the national standards, transposing EN as available. 5.6 Steel for joint rings Steel for joint rings shall comply with the national standards, transposing EN as available.
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5.7 Reinforcing steel Reinforcing steel shall comply with the national standards, transposing EN as available. 5.7.1 Steel or wire for reinforced concrete may be plain, indented or deformed and it shall be of weldable quality (where appropriate). Welded fabric shall be produced using these materials. 5.7.2 Prestressing steel shall be plain except for longitudinals where it may be indented or deformed and may be combined in strands. 5.8 Sealing rings Sealing rings shall be of elastomeric material complying with the national standards, transposing EN 681-1 as available. 5.9 Chloride content The maximum allowable calculated chloride content in the concrete or mortar shall be, in percentages of weight of cement: — reinforced concrete pipes: 0,4 %; — prestressed concrete pipes: 0,2 %.
6 Common requirements for products 6.1 Geometry and dimensions Internal diameter, wall thickness(es), internal barrel length and geometrical characteristics of the joint shall be in accordance with the factory documents. 6.1.1 Nominal sizes The list of typical nominal sizes (DN/ID) is given in Table 1. Table 1 — Typical nominal sizes: DN/ID 200 700 1 250 2 000 2 800
250 800 1 300 2 100 3 000
300 900 1 400 2 200 3 200
400 1 000 1 500 2 400 3 500
500 1 100 1 600 2 500 4 000
600 1 200 1 800 2 600
The above-mentioned nominal sizes (DN/ID) shall be normative from December 31st, 2000. 6.1.2 Internal diameters After December 31st, 2000, the design internal diameter shall be equal to DN/ID expressed in mm. Until then, it may be greater as shown in the manufacturer’s documents, but shall not be less than DN/ID expressed in mm. The tolerances applicable to the design internal diameter are given in Table 2. Table 2 — Tolerances on design internal diameter DN/ID
DN/ID k 400
Tolerance on mean mm
Tolerance on individual value mm
20 DN/ID ± --------------------------- 1 000
40 DN/ID ± --------------------------- 1 000
400 < DN/ID k 1 200
5 DN/ID ± 6 + ------------------------ 1 000
DN/ID ± 12 + ------------------ 100
DN/ID U 1 200
±12
±24
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6.1.3 Lengths The design internal barrel length shall be declared by the manufacturer and subject to a tolerance of ±10 mm for straight elements and ±20 mm for other elements. The design effective length declared by the manufacturer is equal to the design internal barrel length plus the joint gap between end of spigot and back of socket. The joint gap shall have a (±) tolerance specified by the manufacturer for straight draw and where appropriate angular deflection. The ratio of design effective length to DN/ID expressed in mm of a pipe shall not exceed the following: — 21 for cylinder pipes; — 14 for non-cylinder pipes. 6.1.4 Straightness and surface evenness The inside surface of straight pipes shall not deviate from straightness by more than 0,5 % of the design internal barrel length or 5 mm whichever is the greater the same tolerances shall apply to protrusions. Surface voids which have a cross dimension greater than 15 mm and a depth greater than 6 mm shall be repaired with materials as specified in 6.3. 6.1.5 Squareness The tolerance of the squareness of the ends of the pipes shall be 0,02 DN/ID mm but not less than 10 mm and not more than 20 mm. 6.1.6 Wall thickness The wall thickness shall not be less than the design thickness by more than 5 % or 5 mm whichever is the greater. The manufacturer shall declare the wall thickness for any given design. 6.1.7 Joints The profile of a concrete or a steel joint shall comply with the dimensions and tolerances stated in the manufacturer’s documents for its size and design. The sealing rings (if any) shall be supplied by the pipe manufacturer and may be integral with the pipe or supplied separately. At the option of the manufacturer, the joints can be rigid, adjustable, semi-flexible or fully flexible and restrained or non restrained. The minimum values of the allowable angular deflection shall be as given in Table 3. The manufacturer can declare higher values. The manufacturer shall declare when a pipe has been designed with restrained joints. The flexible joints shall be type tested by pressure and shear in accordance with 6.4.12. For each joint design, one diameter from each of the four following diameter ranges shall be type tested: — — — —
DN/ID > 2 000; 1 000 < DN/ID k 2 000; 600 < DN/ID k 1 000; DN/ID k 600.
The same type-test shall apply to adjustable joints that include elastomeric sealing rings. 6.1.8 Structure of steel joint with an elastomeric sealing ring The steel socket and spigot joint rings shall be so designed and fabricated that when the pipe is laid and jointed it will be self-centring. The rings shall be formed and finished accurately to obtain a close sliding fit for the self-centred surfaces. Each ring shall be formed by one or more pieces of steel butt welded together. Welds on gasket contact surfaces shall be smooth and flush with the adjacent surfaces. The parts of the steel joint rings exposed during service shall be protected either by concrete or by a suitable coating to prevent corrosion. Any coating shall be non-toxic and suitable for potable water where applicable.
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The circumference of the inside socket-ring surface of a steel joint shall not exceed the greatest outer circumference of the spigot-ring by more than: — 5 mm for sealing rings less than 17 mm in diameter (or smaller side of the circumscribed rectangle); — 6,5 mm for sealing rings equal to or greater than 17 mm in diameter (or smaller side of the circumscribed rectangle). Moreover the complete socket ring shall have a minimum thickness of: — — —
4 mm for DN/ID k 600; 5 mm for 600 < DN/ID k 1 000; 6 mm for DN/ID > 1 000.
The joint shall be so designed that when the pipe is laid and the joint completed the sealing ring will be enclosed on all four sides and confined under compression adequate to ensure watertightness under the specific conditions of service. The design compression of the sealing ring is normally of the order of 30 %. 6.1.9 Structure of a site welded joint The steel socket and spigot joint rings shall be so designed and fabricated that when the pipe is laid and jointed it will be self-centring. The rings shall be formed and finished accurately to obtain a close sliding fit for the self-centred surfaces. Table 3 — Allowable angular deflections DN/ID
Adjustable or semi-flexible joints Radian
< 300 300 k DN k 600 600 < DN k 1 000 DN/ID > 1 000
Fully flexible joints
Degree
Radian
Degree
0,03 0,02 0,01
1°43' 1°09' 0°34'
0,06 0,04 0,02
3°26' 2°18' 1°09'
1 0000,01 × ----------------DN/ID
1 00034 × ----------------DN/ID
1 0000,02 × ----------------DN/ID
1 000( 1°09′ ) × ----------------DN/ID
For DN/ID less than 800 the end rings will be site welded externally. For DN/ID between 800 and 1 400 the end rings can be site welded either internally or externally. For DN/ID 1 400 and above the end rings are normally site welded internally but may be welded externally provided the joint is designed appropriately. The exposed sections of the end rings shall be protected, e.g. by placing mortar both inside and outside. Welding of all steel shall be carried out in accordance with the appropriate national standards, transposing ENs when available or in the absence of such standards with the appropriate regulation or recognized and accepted methods at the place where the pipeline is installed. The minimum thickness of both socket and spigot rings shall be 4 mm. The tolerances on the circumference of the completed end rings shall be as stated in Table 4. Table 4 — Tolerances on circumference, in mm All diameters
Socket ring
+8,5, p1,5
Spigot ring
+1,5, p8,5
The tolerances on the out-of-roundness of the internal surface of the socket and the outer surface of the spigot are as stated in Table 5. Table 5 — Tolerances for out-of-roundness, in mm DN/ID
k1 500 >1 500
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Socket ring
+7, p3 +10, p5
Spigot ring
+3, p7 +5, p10
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EN 639:1994
6.1.10 Elastomeric sealing rings The sealing ring shall be of sufficient volume so that when the pipe joint is assembled the ring will be compressed to form a pressure tight seal. The volume of the sealing ring shall not deviate from the design volume by more than 2 %. Not more than two splices in each sealing ring shall be permitted. All sealing rings shall be protected from the direct rays of the sun and stored in a dry place. 6.1.11 Steel cylinder The steel cylinder shall be formed by shaping and welding together cut lengths or coils of specified material and thickness. The cylinders shall be shaped accurately and to the size required. The joint rings shall be welded to the ends before testing. The allowable deviation of the design circumference of the steel cylinder shall not be more than 1,5 % of the design internal diameter of the pipe with a maximum limit of 12 mm. Welding of all steel shall be carried out in accordance with the appropriate national standards, transposing ENs when available or in the absence of such standards with the appropriate regulations or recognized and accepted methods at the place where the pipe is manufactured. Buttwelding, lap welding or offset lap welding shall be used for the longitudinal and circumferential or helical seams. The sheets shall be closely fitted before welding and shall be firmly held during welding. Before casting, the steel cylinder shall be cleaned of all foreign matter that would interfere with the bonding of the concrete. 6.2 Curing Accelerated curing shall be permitted and shall be in accordance with procedures fixed by the manufacturer on the ground of experience in relation to the temperature and the time of curing and the chamber humidity. 6.3 Rework during manufacturing process (repairs) Defective concrete shall be removed to the extent of the defect. Concrete and mortar used for repairs shall meet the same requirements as the one used for pipe manufacturing. Repairs shall be cured as specified in 6.2 or by application of a sealing compound conforming to national standard, transposing EN as available. Reworked pipe shall not be despatched until completion of curing or until a minimum period of 12 h following application of sealing compound. Other materials and methods of repair may be proposed by the manufacturer, all subject to the approval of the purchaser. 6.4 Test methods 6.4.1 Internal diameter The diameter shall be measured at each end of the unit at approximately 50 mm from the ends of the barrel or branch. Two measurements of the internal diameter shall be made at each end and carried out at 90° to each other. At each end the internal diameter (mean) shall be calculated. 6.4.2 Internal barrel length The length shall be measured on four longitudinals a 90° intervals. 6.4.3 Straightness and surface evenness Any deviation from straightness of the bore of pipe shall be assessed by the use of a gauge as shown in Figure 2. When edge Y is used and both ends are not in contact with the pipe bore, it shall be deemed not to comply with this standard. When edge X is used and both ends of the gauge are in contact with the pipe bore, it shall be deemed not to satisfy the requirements of this standard. A = 0,5 % of the design barrel length (minimum 5 mm). NOTE
The studs should be detachable from the basic straight edge to facilitate checking and replacement.
Alternative methods are allowed e.g. measurement is made inside the pipe between the wall and either a thin steel wire (less than 1 mm in diameter) stretched along or a straight edge placed along the internal barrel length so as to be in contact with the concrete lining at at least one point.
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6.4.4 Squareness The squareness of pipe shall be assessed by considering the difference of the lengths of each pair of opposite longitudinals measured as described in 6.4.2. 6.4.5 Wall thickness The wall thickness shall be measured at approximately at 90° to each other, at 50 mm from each end of the component but excluding the spigot and the socket. 6.4.6 Steel joint rings The circumference of each joint ring shall be checked by measurement. 6.4.7 Hydrostatic testing of steel cylinder for pipe Each completed steel cylinder, including end rings, shall be tested for watertightness by a hydrostatic test. The test pressure Pt shall be established as follows: — Pt will be the pressure that stresses the steel sheet in the cylinder to 75 % of its minimum yield strength provided that Pt does not exceed the limits given by equations (1) or (2) below: — for DN/ID k 1 200: Pt = 1/Di2 (1); — for DN/ID > 1 200: Pt = 3/Di2 (2); where Di is the pipe DN/ID expressed in metres. Pt is given in MPa. If stressing the steel to 75 % of its minimum yield strength gives a higher value for Pt than that given by equations (1) or (2) then the test pressure may be limited to the Pt value given by equations (1) or (2) provided that the cylinder is also tested by the liquid penetrant test (see 6.4.8) in addition to the hydrostatic test. When the cylinder is tested in the horizontal it shall be supported to minimize the effects of the selfweight and waterweight. For testing both in the horizontal and vertical the pressure Pt shall be measured at the centre of gravity. While the cylinder is under the pressure test all welds shall be thoroughly inspected for leakage. All points of leakage shall be paired and the cylinder subjected to a further hydrostatic test. Only cylinders which are watertight under the hydrostatic test shall be used for the manufacture of pipe. Any other alternative method proposed by the manufacturer shall require approval by the purchaser and providing that the manufacturer has a quality management system certified in accordance with EN 29001. 6.4.8 Liquid penetrant test On one side of the cylinder a whitewash is spread all along and over the weld. On the other side, coloured paraffin or similar product is spread all along and over the weld. The minimum penetration time shall be fixed in accordance with the penetrant liquid specification, and shall not be less than 12 h. After the prescribed period of time, no coloured spot shall appear on the whitewash. Should any coloured spots appear before the prescribed time, the welds shall be repaired and retested. 6.4.9 Sealing rings (elastomeric gaskets) Volume shall be either measured by displacement of water or checked by weight. In case of splices, each splice shall be thoroughly visually checked by rotating 360°. Splices showing visible separation or cracks shall be rejected. Each sealing ring shall be stretched three times the original length. In case of splices, each splice shall be located on the testing device so as to be well apart from any support (minimum distance shall be ten times the minimum dimension of the ring). Each stretched gasket shall be visually checked and if showing visible separation or cracks shall be rejected.
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6.4.10 Concrete strength The cylinders or cubes used to determine characteristic strength shall be manufactured and cured either in a manner which reflects the pipe manufacturing process or in accordance with the national standards, transposing EN as available, at the option of the manufacturer. The compressive strength to be considered is the characteristic value based on a fractile of 95 % given by tests made on cylinders. Other sizes of cylinders may be used provided that conversion factors are used to relate to the 150 × 300 standard. If cubes are used, conversion factors shall be used. If cubes 150 are used, the test results shall be divided by a conversion factor of: — 1,20 for test results less than 45 MPa; — 1,10 for test results equal to or above 45 MPa. If cubes 100 are used the test results shall be at first divided by 1,05 before applying the above-mentioned conversion factors. 6.4.11 Concrete crack Measurement of concrete crack shall be as follows: — use a feeler gauge as detailed in Figure 3. — the thickness of the gauge shall be the one prescribed for the crack width in the requirement. Where a maximum crack width is a requirement, failure shall constitute penetration to a depth of at least 2 mm at short intervals of no more than 50 mm over the prescribed minimum length. 6.4.12 Deflection and shear test Flexible joints shall be tested whilst simultaneously deflected to the allowable angular deflection and subjected to a transverse shear across the joint of twenty times DN/ID, expressed in newtons, or to a greater shear load if determined by the manufacturer. The test pressure shall be declared by the manufacturer equal to the maximum allowable system test pressure. For joints whose tightness or gasket stability is influenced by the pressure, a second test shall be carried out under the same conditions but with a test pressure of 80 kPa below atmospheric. 6.5 Fittings and specials 6.5.1 General Fittings and specials shall include closures, adapters, flanged connections to valves, bends, tees, angle branches, reducers, bifurcations (wyes), bevelled pipes, short pipes and more generally any kind of pipeline component integrated in a given arrangement. Fittings and specials may be manufactured in reinforced or prestressed concrete with or without a cylinder, or in steel, or in iron or a combination of these materials. All fittings and specials shall be capable of being jointed to the pipe with which they are used, by means of appropriate joints. 6.5.2 Materials The materials used for manufacturing the fittings and the specials shall comply with the relevant materials standards. 6.5.3 Fabrication Reinforcement for fittings and specials shall be similar to the reinforcement of the standard pipes and the same cover requirements shall apply. Unless the steel cylinder is hydrostatically tested to 75 % of the minimum yield of the steel, its watertightness over the full length of all welds shall be established by the liquid penetrant test or other approved methods. 6.5.4 Design of fittings and specials The reinforcement of the fittings and specials shall be designed to take all forces and stresses resulting from their specific shape. For bends typical angles are: 11°15', 22°30', 30°, 45° and 90° but any other angle can be manufactured if required by the purchaser. 14
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Figure 2 — Gauge for evaluating deviation from straightness
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Figure 3 — Dimensions of feeler gauge for inspecting cracks
7 Quality control 7.1 General The manufacturer shall establish and maintain a documented quality management system (including factory production control) in accordance with EN 29002 (or EN 29001 at the manufacturer’s discretion), the requirements of this standard and of the relevant product standards2). Within 36 months from the implementation of this standard or within 24 months from the implementation of a product standard2) or 36 months from the start of production, whichever is the longest, the manufacturer shall have this quality management system certified by a third party. 7.2 Receiving inspection Until the manufacturer complies with EN 29002 in accordance with subclause 6.1 and within the time limits given in that subclause, acceptance conditions shall be established between the purchaser and the manufacturer based on this standard and the relevant product standard(s) and EN 29003 in order to define for each batch a receiving inspection. 7.3 Testing rates Where tests are stated but testing rates are not specified, then the manufacturer shall apply out testing rates to prove compliance with a 95 % fractile. 7.4 Records Records shall include, as appropriate: date of core manufacture; date and details of winding, date of coating; dates and results of tests; date of despatch; and any other information on activities that could affect product quality. The manufacturer shall retain these records to ensure traceability of the product, for seven years from despatch. 7.5 Access to manufacturer’s facilities The purchaser or his representative, by arrangements with the manufacturer, shall at all reasonable times have free access to the place where the pipes are manufactured and tested for the purpose of examining quality management system including factory production control, procedures and records and witnessing of the testing and marking of pipes. 7.6 Responsibility Inspection by the purchaser, or failure of the purchaser to undertake inspection, shall not relieve the manufacturer of the responsibility to supply materials and to perform work in accordance with this standard.
In this Clause 7, product standard means any standard to be used as a combined document with this standard such as EN 640, EN 641 or EN 642.
2)
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7.7 Product construction directive The manufacturer shall conform to the product construction directive (EEC 89/106) and to any relevant subsequent documents arising from this directive including attestation of conformity.
8 Marking Each component shall be marked indelibly and in a clearly visible manner giving at least the following information (on the socket or spigot end): — — — — — — — — — — —
EN product standard number such as EN 640, EN 641, EN 642; pipes suitable for use with potable water shall be marked with “P” following the EN product standard number; identification of manufacturer and site of production; identification of date of manufacture; identification of third party certification, (if any); identification of diameter and strength class, where applicable; identification of special use, where applicable; special marks of identification sufficient to show the proper location of the pipe or fitting in the line by reference to layout drawings and schedules specified under subclause 4.2.2 shall be placed on the pipe if specifically required in the contract documents; all bevelled pipes shall be marked with the angle of the bevel and the short side shall be identified; if elliptical reinforcement is used, the minor axis of the reinforcement shall be identified; the CE mark (when implemented).
When the dimensions of the component do not allow the marking in full, the identification of the component shall be made in such a way that no doubt is possible.
9 Interconnection for products Components that are not manufactured to be interconnected can be interconnected by means of adaptors.
10 Installation and testing 10.1 Installation National standards, transposing EN as available shall be complied with, or in the absence of such standards, any applicable regulation at the place of installation shall be followed. 10.2 Preparation for testing Prior to testing, the pipeline shall be filled with water and pressurized during a period of time depending on local conditions, varying generally from a few hours to 48 h. The quantity of water necessary to maintain the pressure shall be recorded. This procedure shall be continued until this quantity of water per hour being added has reduced to the prescribed maximum. 10.3 Site test When the system test pressure has been applied, the additional quantity of water necessary to maintain the site test pressure shall not exceed: — — —
reinforced concrete non-cylinder pipes: 0,15 litre per hour per square metre internal surface area; prestressed non-cylinder pipes: 0,025 litre per hour per square metre internal surface area; cylinder pipes: 0,01 litre per hour per square metre internal surface area.
The duration of the test shall not be less than 3 h and not more than 24 h.
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Annex A (informative) Notation of main parameters This is a generic form of notation which can be qualified by the use of suitable suffixes. Notation
Description
A D E f I k L M N n P Q r t y Z ¾ ¹ ¼ Î
Cross-sectional area per unit length Pipe diameter Elastic modulus Stress or strength (force/unit area) Moment of inertia Coefficient Length Moment Force Modular ratio (Es/Ec) Pressure Load or weight Radius Thickness Dimension with stressblock representation Section modulus Load factor or safety factor Change in state Shrinkage Creep
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Annex B (informative) Span pipe calculations B.1 Principle When considering a span pipe resting on supports, the support reactions are taken into account through the equivalent self-weight qe that would create the same circular bending moment. The support reaction Qr being exerted through distributed shear forces, its effect can be compared to that of the self weight: Qr q e = --------------------------- (rm = mean radius) 2 Ï rm L2
Figure B.1 — Support loading diagram Since no discontinuity in deformation can occur on the support edge, ovalization gradually decreases along both sides of support. Experience has shown that the concerned pipe length L2 extends over half a diameter on both sides of support. B.2 Moments and forces B.2.1 Circular moments The bending moment is calculated using the same formulae and coefficients as for self-weight, depending on the assumed support conditions. This neglects normal forces. B.2.2 Longitudinal forces and moments In the case of an end-loaded pipeline, the normal axial force should be taken into account. NOTE
If other methods are used, all the assumptions of this method should be reconsidered.
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Figure B.2 — Longitudinal loading diagram
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BS EN 639:1995
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