The Spirit of the Original. Cast Iron Pipe Technology

Transcription

1 The Spirit of the Original Cast Iron Pipe Technology

2 THE SPIRIT The company Quality is our tradition - Buderus cast iron pipes for more than 100 years Buderus has been producing pipes in Wetzlar since In the beginning cast iron pipes were produced using the sand-casting process. As one of the fi rst pipe manufacturers, Buderus adopted the tube spin-casting process from Lavaud in And today Buderus is one of the leading manufacturers of ductile cast iron pipes in Europe. Buderus Gussrohrtechnik represents highest quality and state-of-the art production. It stands for fl exibility and responsibility, which starts with engineering consultations for projects and continues in production and support on the construction site where the pipes are installed. Cast iron pipe technology is supported by a team of qualifi ed employees, who assume the responsibility for their products the pipes and their connections by utilizing their ideas, the capabilities in applying the material and their knowledge about pipe constructions. Buderus Gussrohrtechnik uses a quality management system certifi ed in accordance with DIN EN ISO Products and production processes are frequently monitored by the Materialprüfungsamt [material test offi ce] Nordrhein- Westfalen. 2 Additionally, Buderus Giesserei Wetzlar GmbH uses an environmental management system certifi ed in accordance with DIN EN ISO

3 OF THE ORIGINAL Ductile cast iron pipe systems Ductile cast iron an innovative material Ductile cast iron pipes are now essential for the transport of our most valuable food component, drinking water. This is a clear indicator for the outstanding characteristics of the proven material. What does ductile mean? Ductile means shapeable. Ductile cast iron material is not rigid, it can bend based on its structural condition. This makes it strong! Ductile cast iron a tough iron-carbon material, with a carbon content that is mainly present as graphite in a free form is a development based on grey cast iron, which was used in the past. In contrast to grey cast iron, which contains the free graphite in lamina shape, the ductile, shapeable cast iron contains graphite spheres the spherolites which positively infl uence the characteristics of the primary structure. This increases the strength characteristics of ductile graphite iron in comparison to grey cast iron. 3

4 PIPES AND FITTINGS Socket pipes made from ductile cast iron for drinking water and waste water High strength and extreme overlap Root resistant Integrity even at high internal pressures, vacuum and high ground water levels High cost effectiveness due to long product life Defl ection of the connections up to 5, depending on the nominal diameter Socket pipes made from ductile cast iron for drinking water and waste water with cement mortar lining (ZMU) High mechanical strength Can also be used in soils with rock content (up to 100 mm diameter) and for strongly aggressive soil conditions Soil exchange is not necessary, excavation soil must not be removed Socket pipes made from ductile cast iron for drinking water and waste water can be delivered in accordance with the following external protection types: Zinc coat with cover coating Zinc-aluminum coat with cover coating Cement-mortar coating WKG coat Other designs on request Fittings A comprehensive fi tting assortment is available to provide a complete system solution for all applications. 4

5 SUMMARY OF ADVANTAGES Plan by utilizing the capabilities of ductile cast iron pipes from Buderus. Our advantages are as certain as the ductile pipes are safe in the ground. Technical advantages Cast iron pipes can handle high static stress. Due to the TYTON connection, they can be deflected, they are inured against position changes, they are root resistant and they withstand high internal pressures and surrounding groundwater. Innovative internal and external coatings protect the pipes against attack by water and soil. Ecological advantages Ductile cast iron pipes are almost completely made from recycled material and are therefore recyclable. The internal lining consists exclusively of cement, sand and drinking water. Economic advantages high installation performance due to large construction length long product life due to innovative internal and external coatings reuse of the excavation material for pipes with external cement-mortar coating simple and therefore fast installation 5

6 DRINKING WATER PIPES Water as a strategic resource This foundation of all life is not evenly distributed in the world. The main objective is to supply people with clean drinking water. Even if you are living in an area with plenty of water, please do not waste a drop of this valuable food component. The utilization of ductile cast iron pipes for the drinking water supply ensures for many decades now that this main food component is safe and reaches the user unchanged. Functional safety and cost effectiveness are the main criteria for pipe systems made from ductile cast iron pipes. The wide application variability is another criterion or in other words, another advantage of the ductile drinking water systems. The ductile cast iron material and the TYTON pushin socket connections provide outstanding safety reserves to meet the requirements of a stable and long-lasting drinking water supply. Depending on the requirements, BLS and BRS push-in socket connections are available as longitudinal force-fi t push-in socket connections. 6

7 WASTE WATER PIPES Safety, tightness, long product life Waste water must safely arrive at the treatment facilities, because clean groundwater is vital! The use of ductile waste water pipes provides you this safety. Why are ductile waste water pipes safe? Because they do not leak. Groundwater cannot penetrate the channel. Materials and connections prevent the leaking of waste water and therefore the contamination of soils and groundwater. They can absorb high external loads easily, which are caused by earth pressures and traffi c loads. They provide high safety reserves to compensate for unpredictable loads. A clear economic advantage is the extreme long product life. Waste waters are aggressive, and that is no issue for waste water pipes from Buderus, because the internal lining with high alumina cement-mortar ensures that the pipes are protected even against strongly biogenic sulfuric acid attacks. Buderus ductile cast iron waste water pipes and fi ttings can be used almost everywhere, among others as gravity lines and for pipes through drinking water protection areas. One guarantor for the safety is the TYTON push-in socket connection. This connection is defl ectable. It works like a joint and follows the soil movements, without transferring bending forces to the next pipe or fi ttings. And it is root resistant. stant. The TYTON push-in socket connection provides tightness against high internal pressures and against surrounding groundwater. 7

8 COATINGS Well coated Buderus cast iron pipes for drinking water and waste water are reliably protected against external corrosion attacks. A zinc coat with cover coating or cement-mortar coating qualify the cast iron pipe for almost all existing soil types. The following coatings are available: Zinc coat with cover coating Zinc-aluminum coat with cover coating Zinc coat with cement-mortar coating Pipes with zinc coats and cover coating when used in combination with an additional heat insulation (WKG) can also be used for pipes that are subject to frost or heat losses. 8

9 LININGS Well lined Pipes that are used for the transport of drinking water receive an internal cement mortar lining based on blast-furnace cement (HOZ), while waste water pipes are covered with a cement mortar lining based on high alumina cement (TZ). These are purely mineral linings, which consist of a cement sand water mixture. They are attached to the pipe by a rotational spin process. The bonding area is protected by an epoxy resin lining. Other internal linings available on request. 9

10 CONNECTIONS Good connections are important Pipe systems are used as part of the supply and disposal pipes and that is exactly the reason why pipe connections are so important. The effi ciency of the pipe depends on its reliability. Buderus uses the proven TYTON push-in socket connection for all ductile pressure pipes. It is root resistant and highly resistant to stress. The tightness of the pipes is also guaranteed by the TYTON push-in socket connections for high internal pressures, vacuums and high groundwater levels. A specially shaped sealing assumes the sealing function. The sealing consists of a soft and a harder rubber mixture. The sealing in the sealing chamber is pre-pressured after the socket has been put in place. A design coordination between sealing chamber, sealing rim and pipe diameter results in a high deformation of the sealing and therefore in a high contact pressure on the sealing surface. The harder, claw shaped ring part, which is positioned in the fastening groove of the socket, keeps the sealing in its position during the insertion of the pipe end and it provides the same service later against stress due to internal pressures. Defl ection of the connections up to 5, depending on the nominal diameter. However, the TYTON push-in socket connection does not have a natural longitudinal force-fi t. The following longitudinal force-fi t designs of the TYTON push-in socket connection are available if the forces created by the internal pressures in the pipe cannot be absorbed by the concrete anchor block. 10

11 CONNECTIONS The longitudinal force-fi t BRS push-in socket connection (Buderus-Restrain-System) is a development based on the proven TYTON - SIT connection. The result of this development is the TYTON - SIT- PLUS connection. The BRS connection with its friction force fi t is highly resistant to stress due to the sealing and can therefore be used for extreme applications. The pipes with a length of 6 m can be installed in a radius a short as 115 m because the push-in socket connection is defl ectable up to 3. This reduces the requirements for fi ttings and the installation time. The innovative connection technology and the friction force-fi t of the BRS push-in socket connection provide a large number of advantages and application possibilities, which far exceed the application options of the TYTON - SIT connection. Quick overview Replacement for concrete counter bearings Suitable for loads of up to 32 bar Simple and fast installation Defl ectable up to 3 Extensive fi ttings program The longitudinal force-fi t BLS push-in socket connection (Buderus-Lock-System) provides a form fi t and is highly resistant to stress, which means it can be used for extreme applications. A welding bead on the insertion end transfers the shearing force through bars to a safety chamber, which is attached to the socket. The proven TYTON sealing provides tightness for the connection. The BLS push-in socket connection is defl ectable up to 5 and is therefore superior to all other longitudinal force-fi t push-in socket connections. Narrower curve radius can be achieved during installation. These characteristics are desirable when pipe lines get installed with modern trench processes, plowed in by rocket plows or if they are installed as culvert pipes in rivers. The BLS connection is the optimum solution for pipes above ground, such as bridge pipes, whose connections must absorb length changes due to temperature variations. Quick overview Replacement for concrete anchor blocks Horizontal drilling Plowing with the rocket plow Trenchless exchange of pipes on the same track with the press-pull process Burst lining process Culvert pipes Bridge pipes Collector pipes Pipe systems for snow making facilities Turbine pipes Fire extinguisher pipes Pipe relining Defl ectable up to 5 11

12 TRENCHLESS INSTALLATION Trenchless construction processes for the replacement of pressure pipe systems are important for inner-city installations and culvert construction in rivers. The application shows a clearly increasing trend, because it is much more cost effective if compared to the open construction and the environmental impact is significantly lower. Ductile cast iron pipes with longitudinal force-fit BLS connections are especially qualified for trenchless pipe installations based on their high stress-resistance. Press-pull process This process pushes the old pipe out of the ground by using a pull linkage and a special pull or pressure head, and it inserts during the same process the new ductile cast iron pipe with the BLS push-in socket connection and cement-mortar coating into its place. A nominal diameter increase is possible when using this process. The press-pull process provides high efficiency, speed, reliability and therefore high cost efficiency. Horizontal directional drilling The controlled horizontal drilling technology is for the last 15 years a fixture for pipe installations and many other areas. It was developed in the US in the seventieth for deep drilling applications. It is used as trenchless installation technology for pipeline constructions. The drilling technology has been accepted at a fast speed. The pipes are installed without an installation trench by using a drilling system. 12

13 PROJEKT IRGENDWO Rather than implementing extensive excavations, a pilot drill hole will first be calculated and executed. Obstacles and direction changes are not important, because the drill head tip has a functionally controlled sensor. This means that the drilling progress can be monitored and controlled. This is followed by the trenchless installation of the supply pipes. Only a start and a target excavation have to be established. Burst lining The burst lining process is an environmentally sound trenchless replacement of pipelines through the same routes. The old pipe is burst with the help of a burst head and is pressed into the surrounding soil. The resulting cavity is enlarged in such a way that a pipe with the same or a larger diameter can immediately be inserted. The burst lining is divided into a dynamic and a static process. rocket plow process The rocket plow is used to install pipes in new routes. The rocket plow is a development based on the pipe and cable plows, which have been used for more than 30 years for the installation of cables and flexible pipes. The rocket plow process is suitable for ductile cast iron pipes up to a nominal diameter of DN 300. The components of the process are basically the pull machine with a cable winch and a plow. The most important machine part of the plow is the plow blade. The plow is connected to the pull vehicle by a steel cable. A start hole, which slopes downwards, leads the pipe to an appropriate installation depth and there it is connected to the plow blade. During this process, the plow blade thrusts the soil to the side in the area of the pipe zone due to the pull forces of the cable winch. This creates a cavity which is used to immediately install the pipe. The plow process is especially suitable for rural areas with low population densities where large pipe lengths with few connections are required. This process is currently only used for the installation of pressure pipes. Pipe relining The consumption of drinking water and therefore the generation of waste water have continuously decreased during the last years and decades. This is the reason why the long pipe lining has become more important, because smaller pipe diameters can now be utilized due to the lower water quantities. And this is why the long pipe lining is increasingly used. This process pulls or pushes ductile cast iron pipes into existing pipes that are no longer suitable for water transport. Excavations are only required at the start and at the target location. This results in relatively small efforts for civil engineering and for road construction and it has little effect on traffic and the residents. The cavity between old and new pipe can be insulated after completed installation. 13

14 TURBINE PIPES Power from hydroelectric power plants means clean energy. Turbine pipes are often installed in extreme environments. However, a fast and safe installation is still possible sib with ductile cast iron pipes, because the connections guarantee good bending characteristics and the pipes can be installed without problems even if the weather is bad. The surrounding area can easily be re-cultivated, because only small trench excavations are required. The outstanding stability characteristics of the ductile cast iron pipes and the push and pull safe connections guarantee power plant pipe operations free of malfunctions. For many generations.

15 FIRE EXTINGUISHER PIPES The lack of effi cient fi re extinguishing capabilities often results in human and economic disasters. A fi re extinguisher pipe is non-fl ammable, absorbs stress and makes water for fi re fi ghting available when needed. Due to their high safety reserves against internal pressure stresses (pressure surges) and external loads, ductile cast iron pipes are used for fi re extinguishing systems at airports, industrial facilities and street and railway tunnels. All l available connection types and external protection types may be used depending on the requirement profi le.

16 SNOW MAKING FACILITIES The use of snow making facilities and therefore the guarantee that the ski slopes are ready for skiing are mandatory for attractive ski villages to ensure the most important economic factor for tourism dependent operations. The technical advantages of ductile cast iron pipes are the basis for the sales success of this special application. The basis for the effi cient functioning of a snow making facility is a safe water supply, which meets all requirements at high and medium altitudes and which can withstand very high pressures. Buderus has delivered more than 1000 snow making pipes throughout Europe during the last years. The robustness of the material, the mobile socket system and the fast and easy installation and assembly have made Buderus and its sister company, Tiroler Röhren- und Metallwerke AG, the market leader of pipes and fi ttings for snow making facilities. 16

17 HEAT INSULATED PIPES Heat insulated cast iron pipes (WKG pipes) with longitudinal force-fi t push-in socket connections are used as bridge pipes. The heat insulation prevents freezing of the fl ow medium even if it does not move for a longer time. A support heating can be integrated if required. The WKG pipe system consist of pipes and socket bends (MMK, MMQ) made from ductile cast iron in accordance with DIN EN 545 (water) or DIN EN 598 (waste water) with TYTON pushin socket connection in accordance with DIN , longitudinal force-fi t if required. The pipes are covered with a heat insulation made from FCKW free polyurethane (PUR) hard foam with an average total density of 80 kg/m 3. For open pipes (FL), the hard foam is protected against weather related impacts by a roll fold coat pipe made from galvanized steel sheets in accordance with DIN or stainless steel. For earth covered pipes (EL) that are subject to frost, the hard foam is protected by a coat pipe made from PE-HD in accordance with DIN 8074/

18 QUALITY Certified quality management system The quality of the manufactured products and the satisfaction of the customers is the highest company goal for Buderus Gussrohrtechnik. Buderus Gussrohrtechnik uses a quality management system certified in accordance with DIN EN ISO The products and production processes are frequently monitored by the Materialprüfungsamt [material test office] Nordrhein-Westfalen. Additionally, Buderus Giesserei Wetzlar GmbH uses an environmental management system certified in accordance with DIN EN ISO The comprehensive quality assurance system starts with the chemical analysis of the raw and auxiliary materials, because the melting and the treatment of the molten iron require a very high pureness and uniformity of the raw materials, monitoring of the melting process, the stability of the chemical composition and the seeding. The pipe manufacturing process must especially monitor the solidification and shrinking characteristics of the ductile cast iron. The review of the annealed pipes must test the material characteristics, which are defined in DIN EN 545 (for drinking water pipes) and DIN EN 598 (for waste water pipes). The sockets and the insertion ends of the annealed pipes are tested with limit gauges, the wall thickness is measured with calipers. All pipes are subject to a comprehensive visual inspection for internal and external defects. Depending on the pipe and the diameter, the pipes must withstand the specified test pressures during the internal pressure test with water. 18

19 Cement-mortar lining The cement-mortar linings of the pipes are also subject to the rigorous quality controls. Depending on the nominal diameter, the required coat thickness must be met, in addition to a test of the basic materials of the fresh mortar. External coating The external coating is also subject to such a rigorous control. The ductile cast iron pipes from Buderus always receive an external coating, which consists of a zinc coat and a cover coating. It is also possible to optionally cover Class 40 pipes with a zinc-aluminum coat with cover coating (Buderus Zink-Plus ) to increase corrosion protection. A high quality plastic modified cement-mortar coating with a high mechanical resistance and a thickness of 5mm is available for use in strongly aggressive and rocky soils. The final inspection is performed after the pipes are marked. The material is marked as ductile cast iron by a parallel indentation on the inside of the socket. It is approximately 3 mm deep. 19

20 Buderus Giesserei Wetzlar GmbH Cast Iron Pipe Technology P.O. Box 1240 D Wetzlar Phone: +49 (0) Fax: +49 (0) BGW/RV /06 e DN