Vitrified CLAY PIPE SYSTEMS OPEN TRENCH Future-oriented. Powerful. SUSTAINABLE.

Steinzeug-Keramo
Manufacturing plants Germany: Frechen and Bad Schmiedeberg Belgium: Hasselt The Netherlands: Belfeld Total workforce Employees 500 Products Vitrified clay pipes, fittings, vitrified clay manholes, accessories

markets Europe Middle and Far East Overseas

CONTENT
Company.................................................................. 02 Material and Product characteristics.......................... 04 Glance at the production........................................... 07 Sustainability............................................................. 08 Product portfolio........................................................ 10 Technical data........................................................... 14 Installation instructions .............................................. 25 Testing....................................................................... 33 Quality Assurance, Certification and Labelling............................................................. 36 General hints............................................................. 37 Compact................................................................... 38

SHINY. CERAMICs IN MAXIMUM QUALITY Vitrified clay

Our Company The Steinzeug-Keramo GmbH, a subsidiary of the Wienerberger AG with two production sites in Germany (Frechen and Bad Schmiedeberg), one in Belgium (Hasselt) and one in the Netherlands (Belfeld), is Europes largest manufacturer of vitrified clay pipes and fittings for waste water disposal. In all four facilities, we produce vitrified clay pipes for countries around the globe on a 24/7 basis. Our Self-Conception To make waste water disposal more secure, more reliable and more cost-efficient, we produce vitrified clay pipes and fittings of first class quality, highest performance according to highest standards and use state-of-theart manufacturing technology. At this, our products compliance with environmental safety and sustainability requirements are a matter for us: from the mining of the natural raw material clay via the efficient processing in

technologically highly advanced facilities, the professional installation and the more than a hundred years of service life to the 100 % recyclability. Our Services Integral part of our self-conception is to be there for our clients and partners, to provide them with support and care, and to guide and assist them with all sewer relevant issues. Our service concept, which has earned praise worldwide, starts with the comprehensive consultancy, support and implementation of construction projects and extends to all areas of a well-functioning business partnership. Our highly skilled staff members are available to assist you, anywhere in the world.

Regional contacts Personal project site consultancy Online information system

GENUINE. A TRUE PIECE OF NATURE Vitrified clay PIPES

Vitrified clay Material and Product Characteristics Environmentally sound and responsible solutions today mean reliable and diligent decisions for tomorrow. This also applies to our wastewater networks, which are an indispensable part of our underground infrastructure and have to do particularly hard work. They need to fulfil extremely high performance, quality and functional requirements simultaneously. With the future in mind, vitrified clay pipes are definitely the right choice for the construction of sewers. Vitrified clay pipes fulfil the high requirements for safe, reliable, long term and at the same time cost-efficient operation and this over a period of more than a hundred years. Over these long-term stresses, the vitrified clay pipe systems never lose their reliable functional characteristics, such as e.g. their resistance against high pressure cleaning and abrasion, the efficient removal of sewage residues due to the smooth ceramic interior surface, and so on

Vitrified clay Environmentally Friendly and Sound Today, besides the need for sewer construction tight, endurable and reliable sewage systems, to produce them from environmentally friendly and sound materials and also purposefully reuse them at the end of a long service life, is indispensable. With vitrified clay pipes 100% consisting of the natural and abundantly available resources clay, water and chamotte, this applies of course, because the energy use and CO2-emissions with their production are low, and even lower, considering the particularly long service life of the components in operation condition, underground water and soil are protected the material can be entirely reused without any problems

Clay and chamotte + Water + Fire = 100% vitrified clay

MATERIAL ANd PROdUCT CHARACTERISTICS

Specific weight .................................................... 22 KN/m3 Bending tensile strength............................. 15 to 40 N/mm2 Longitudinal pressure resistance............ 100 to 200 N/mm2 Tensile strength .......................................... 10 to 20 N/mm2 Modulus of elasticity ................................. ~ 50,000 N/mm2

Coefficient of thermal expansion K -1 ...~ 5 x 106 Thermal conductivity .....................~1.2 W/m x K Poissons ratio ..............................................0.25 Crushing strength resistance according to nominal size............................ 34 to 160 kN/m

The products demonstrate excellent characteristics for the use in sewer systems. Smooth interior surfaces, chemical resistance, abrasion resistance and high load capacity allow for the use in all areas of waste water discharge.

Tightness ................................... up to 2.4 bar Corrosion resistance ............................. given Chemical resistance pH ......................0 to 14 Frost resistance ..................................... given Biological resistance ............................. given Ozone resistance ................................... given

Hardness (according to Mohs): ....................................... ~ 7 Fatigue strength ................................................... persistent Fire resistance ............................................. non-flammable Wall roughness k .................................................... 0.02 mm Abrasion resistance ................................................ 0.25 mm High-pressure jetting resistance............................... 340 bar Long service lifetime ........................ > 100 years and more

FASCINATING. A GLANCE AT THE PRODUCTION Vitrified clay PIPES

The whole know-how is required The correct mixture of the natural raw materials clay, chamotte and water and the technologically highly advanced manufacturing process of vitrified clay pipes and fittings ensure consistent good quality at the highest level. Our quality management monitors every single step of this process. Preparation: Clay and chamotte are crushed, mixed with water and homogenized. Molding: The pre-processing is followed by the molding in vacuum extrusion presses; drying and firing periods are shortened. Drying: The pipes are dried at ca. 80C. Today, thanks to modern production techniques, such as e.g. forced drying, the drying periods can be significantly shortened and tolerances minimized. Glazing: After the drying comes the glazing and setting of the pipes. Vitrified clay pipes and fittings are given a raw clay glaze. Firing: The firing is the most crucial process. This is where absolute professionalism is required: When the products are transferred to end confectioning true to size at the end of the firing process. Continuous investments in Research and Development ensure new impulses and prevent stand still in both theory, but particularly practice. Results are the increase of the pipes installation length to 2.50m, optimized connections, and the development of the socket S the increase of the wall thickness for large-diameter pipes the increase of the mechanical strength resistances for large-diameter pipes shaped and cut with tolerances of 1/10 mm

SUSTAINABILITY

No other pipe material has so much to offer, is better suitable for the construction of endurable sewer networks and provides as many benefits at once as vitrified clay.

Vitrified clay pipes for generations The well known three pillar model of sustainable development assumes that a sustainable (long term environmentally sound) development can only be achieved through simultaneous and equal implementation of environmental, economical and social objectives. Sustainable economics thus means: We need to pass an intact ecological, economic and social structure on to our children. In our self-conception, the underground municipal infrastructures, the supply and disposal networks, are a self-evident part of this structure. In this regard, absolutely safe and reliable sewage systems made of vitrified clay are the right choice.

ingenious. ENVIRONMENTAL-friendly economical SOCIAL vitrified clay Pipes

Economical The long service life of more than 100 years and the low maintenance requirements of vitrified clay sewage systems are crucial parameters for their cost-efficiency. As a part of the municipal asset, it maintains its value due to only minimal asset-erosion. Finally, as an essential part of their infrastructure, the communities must cover the cost of the sewerage system via the sewage fees. With vitrified clay pipe systems, the sewerage system is refinanced over the long service lifetime with low depreciation rates and thereby low fees (1 to 1.5 percent). This way, the cost-efficient and one-time design of the sewerage system is a special duty.

Environmental-friendly Safety, tightness and reliability are the crucial factors for environmental soundness. Vitrified clay pipe systems provide them: They behave neutrally in the soil and in the ground water, i.e. no exchange between sewage/soil/ ground water takes place via the material. In addition, wear and corrosion resistance are ensured. Another selfevident argument for the environmental benefit of clay is the natural character of this raw material and its mining process and the 100% recyclability.

Fair to future generations With vitrified clay pipe systems, the following generations are spared from the continued financial load arising from the sewerage systems restoration and renovation requirements. In a pipe service lifetime of more than a hundred years, resources and financial means are best preserved.

Cradle to Cradle-certified Furthermore, we set standards with the implementation of the cradle to cradle design concept (preservation of created values for man and environment in cycles) and the relevant certification of all production sites.

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PRODUCT PORTFOLIO

PRECISE. SOLUTIONS FOR ALL CASES Vitrified clay PIPE SYSTEMS

Our vitrified clay pipes and fittings offer everything you need. They enable excellent planning precise design and to build even better The extensive portfolio for the trench method comprises our product line of vitrified clay socket pipes in the following dimensionings: DN 100 to DN 150 in the installation lengths 1.00 m to 1.50 m with joint L DN 200 to DN 1000 in the installation lengths up to 2.50 m with joint K and S DN 1200 to DN 1400 in the installation length 2.00 m with stainless steel coupling

Connection system joint S Length: 2,50 m Dimensionably stable socket Dimensionably stable spigot Reduced sealing material In-factory mechanical test with test pressure of 2 bar

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PIPES

Joint L Length 1.00 / 1.50 / 2.50 m

Joint K Length 2.00 / 2.50 m

Joint S Length 2.50 m

This product category is suitable for the private, municipal and industrial waste water discharge. Perforated vitrified clay pipes (hole diameter 12 mm) with joint in the nominal sizes DN 150 to DN 300 serve the draining of road ways and rail tracks.

Perforated pipes DN 150 to DN 300 Length: 1.50 m to 2.00 m

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fITTINGS

A complete sewer system is more than just vitrified clay pipes. only with the relevant fittings, accessories and manholes, does it become a safe and reliably functioning waste water discharge system. Fittings Bends, junctions, rocker pipes and special fittings enable directional changes and the converging of waste water streams as well as the exible connection with manholes, buildings and road gullies. our program offers them in the most diversified versions, angles and nominal sizes, respectively installation lengths.

Bends

Junctions

rocker pipes

Adaptors

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ACCESSORIES ANd MANHOLES

accessories The range of accessories is optimally aligned to our pipe program. for the connection and joining technology, it includes: Connection sockets C - dn 150 and dn 200 Metal band exible couplings - Type 2A normal load-high load - Type 2B normal load-high load Sealing rings - Transition rings - Compensation rings - Joining rings - Connection rings - Adapter rings Sealing elements for installation and connection to manholes Test and installation devices

Connection sockets Metal band exible couplings Sealing rings

manholes our complete and combined manholes with the nominal sizes dn 800, dn 1000 and dn 1200 as well as the inspection chamber with the nominal size dn 400 complete our portfolio.

Manholes

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Pipes

Pipes DN 100 to DN 1000 with joint L according to jointing system F and with joint K and S according to jointing system C

d8 d4

d1d3

l1

Nominal size DN

Strength class

Crushing strength FN

Joint

Pipe diameter Internal d1 mm External d3 mm 1313 1593,5 1864 2425 2545 2996 3186 3557 3767 4177 4868 4928 5488 5819 6099 68712 72512 86212 96412 108414 127315

Socket diameter External (max.) d8 mm 200 230 260 340 360 400 440 470 510 525 620 650 720 730 790 860 930 1106 1209 1322 1500

Nominal length l

Average weight

kN/m 100 125 150 200 200 250 250 300 300 350 400 400 450 500 500 600 600 700 800 900 1000 34 34 34 160 240 160 240 160 240 160 160 200 160 120 160 95 160 200 160 120 120 34 34 34 40/*48 48 40 60 48 72 56 64 80 72 60 80 57 96 140 128 108 120 L L L L/S S S S S S K S S K S S S S K K K K

m 1,00/1,25 1,00/1,25 1,00/1,25/1,50 1,00/1,50/2,50 2,50 2,50 2,50 2,50 2,50 2,00 2,50 2,50 2,00 2,50 2,50 2,50 2,50 2,50 2,50 2,00 2,00

kg/m 15 19 24 37 43 53 75 72 100 101 136 152 196 174 230 230 326 468 548 675 895

1004 1264 1515 2005 2005 2506 2506 3007 3007 3487 4048 3988 4478 4969 4969 59712 59712 69412 79212 89114 105615

*Crushing strength 48 kN/m on request; d4 according to EN 295

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Pipes DN 1200 and DN 1400 with stainless steel coupling

bk

Dz dk d1 d3

l1
Nominal size DN Strength class Crushing strength FN Pipe diameter Internal d1 mm 124918 140030 External d3 mm 145718 160030 Joint External (max.) dK mm 1422 1570 Spacer ring Thickness 1mm DZ mm 10 10 Nominal length I1 Average weight

kN/m 1200 1400 95 L 114 90

mm 1981 1981

kg/m 992 1008

Example DN 800 socket pipe class 160

Example DN 1200 open trench

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dl al e

Pipes
d8 aq L1

d1
44
24 72

Drainage pipes DN 150 to DN 300 with joint L and K according to jointing system F and C

d3

L1
140

Perforated vitrified clay pipes (hole diameter 12 mm, type B) for collecting and transporting 44 wastewater and water. To achieve the best possible drainage effect the rows are located in the crown and side areas. Special designs available on request. Perforated vitrified clay pipes according to EN 295-5.

24 72

Nominal size DN

Crushing strength FN

Jointing system

Pipe diameter d3

Nominal length I1

ZR

140

ZL

Water inlet surface

Average weight

kN/m 150 200 250 300 28 32 40 48 F C C C

mm 186 4 254 5 318 6 376 7

m 1,50 2,00 2,00 2,00 6 6 6 6 162 228 228 228

m2/m > 0,01 > 0,01 > 0,01 > 0,01

kg/m 24 43 75 100

ZR = Number of hole rows, ZL = Number of holes The connection to pipes according to DIN EN 295-1 is dependent on the nominal size, the jointing system, and the external pipe diameter d3.

The socket pipe range for water catchment areas

For sewers, for example in water catchment areas, zone II, vitrified clay socket pipes with nominal sizes from DN 150 to DN 600 are used. Additionally, these vitrified clay socket pipes are factory-tested with a test pressure of 2.4 bar.

d3

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Fittings

Bends DN 100 to DN 300 with joint L and K according to jointing system F and C
Nominal size DN Strength class 15 Bend 30 45 90 kg/pce 100 125 150 200 200 250 250 300 300 34 34 34 160 240 160 240 160 240 + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + + 6 7 10 15 22 25 45 37 59 Average weight

150

900

Junctions DN 100 to DN 300 with joint L and K according to jointing system F and C
Nominal size Strength class DN 1/DN 2 Junction 45 5 z (max.) mm 100 125 125 150 150 150 200 200 200 200 200 200 250 250 250 250 300 300 300 300 100 100 125 100 125 150 100 125 150 200 150 200 150 150 200 200 150 150 200 200 34/34 34/34 34/34 34/34 34/34 160/34 160/34 160/34 160/34 160/160 240/34 240/160 160/34 240/34 160/160 240/160 160/34 240/34 160/160 240/160 495 495 545 370 370 370 465 465 465 370 370 370 460 435 435 320 320 320 275 290 285 310 300 355 340 365 a (max.) mm 240 240 260 240 260 270 250 260 250 300 250 250 250 250 250 250 250 250 250 250 170 180 170 180 170 170 180 180 170 170 180 180 230 160 Junction 90 5 z (max.) mm a (max.) mm Nominal length I1 Average weight
DN 2

DN 1

DN 2

m 0,40 0,40 0,40 0,40 0,40 0,40 0,50 0,50 0,50 0,60 0,50 0,60 0,50 0,50 0,60 0,60 0,50 0,50 0,60 0,60

kg/pce 12 15 15 16 18 20 28 30 26 40 36 42 42 55 48 64 73 73 60 86
The measurements z and a are nominal measurements. Other measurements and crushing strengths as pipes. Construction of junction pipe end always in standard load range.

DN1

l1

DN2
a

DN1

l1

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Fittings

Compact junctions 45 DN 200 to DN 300 with joint L and K according to jointing system F and C
Nominal size Strength Class DN 1/DN 2 Junction 45 5 z (max.) mm 200 250 300
z

Nominal length I1

Average weight

2 DN
a

DN 1

DN 2

a (max.) mm 250 250 260

DN1

m 0,50 0,50 0,50

kg/pce 26 41 49

150 150 150

160/34 160/34 160/34

400 400 430

l1

The measurements z and a are nominal measurements. Junctions 45 5. Other measurements and crushing strengths as pipes. Distinguishing for this junction form is its short nominal length and the narrow operating radius (measurement a) of the pipe end. Compact junctions are machine-manufactured from a single piece.

Compact Junctions 90 DN 350 to DN 1400 with joint L and K according to jointing system F and C
Nominal size Strength class DN 1/DN 2 Junction 90 5 z a (max.) mm 70 80 70 70 80 80 70 80 70 70 80 80 70 70 80 80 Nominal length I1 Average weight

DN2
a

DN 1

DN 2

DN1
mm 350 350
z l1

m 1,00 1,00 1,00 1,00 1,00 1,00 1,00 1,00 1,00 1,00 1,00 1,00 1,00 1,00 1,00 1,00

kg/pce 68 70 145 172 145 172 145 148 190 270 190 270 258 360 258 360

150 200 150 150 200 200 150 200 150 150 200 200 150 150 200 200

160/34 160/160 160/34 200/34 160/160 200/160 160/34 160/160 120/34 160/34 120/160 160/160 95/34 160/34 95/160 160/160

250 250 350 350 350 350 350 350 350 350 350 350 350 350 350 350

400 400 400 400

From DN 350 division in left and right junction (in the direction of the flow).

450 450 500 500 500 500 600 600 600 600

The measurements z and a are nominal measurements. Other measurements and crushing strengths as pipes. Construction of junction pipe end always in standard load range.

Larger nominal sizes available on request

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Junction without socket for subsequent installation

2 DN
a

Nominal size DN 1 DN 2

Strength class DN 1/DN 2

Junction 45 5 z a (max.) mm 270 320 320 320 370 370 370 370

Junction 90 5 z a (max.) mm 170 170 180 170 180 170

Nominal length I1

DN1

mm 150 200 200 200 250 250 250 300 150 150 200 150 150 200 150 150 34/34 160/34 160/160 240/34 160/34 160/160 240/34 160/34 400 450 450 450 450 450 450 450

mm 250 300 300 300 300 300

m 0,50 0,60 0,60 0,60 0,60 0,60 0,60 0,60

DN1
DN2

l1

l1

Rocker pipes DN 150 to DN 1400 with joint L and K according to jointing system F and C
Nominal size DN Strength class Inlet (GZ) Joint piece Outlet (GA) Installation (GE) Shaft length m 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25
l1 l1
GA (rocker pipe outlet)
250 250

Nominal length I1 Nominal length I1 m m 150 200 200 250 250 300 300 350 400 400 450 500 500 600 600 700 800 900 1000 1200 1400 34 160 240 160 240 160 240 160 160 200 160 120 160 95 160 200 160 120 120 95 L 0,60 0,60 0,60 0,60 0,60 0,60 0,60 0,75 0,75 0,75 0,75 0,75 0,75 0,75 0,75 0,75 0,75 0,75 0,75 0,60 0,60 0,60 0,60 0,60 0,60 0,60 0,75 0,75 0,75 0,75 0,75 0,75 0,75 0,75 0,75 0,75 0,75 0,75 On request On request

l1
GZ (rocker pipe inlet)

GE (rocker pipe installation)

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Fittings / SPECIAL Fittings

Transition pieces with joint L and K according to jointing system F and C

Nominal size
DN1 DN2

Strength class DN 1/DN 2

Nominal length I1

Average weight

DN 1
DN 100/125 DN 100/150

DN 2

m
DN1
DN 125/150 DN 150/200 DN 200/250 DN 250/300

kg/pce 6 7 8 11 15 21

DN2

100 100 125 150

125 150 150 200 250 300

34/34 34/34 34/34 34/160 160/160 160/160

0,25 0,25 0,25 0,25 0,25 0,25

Sealing and joint see pipe table

200 250

Transition pieces for connecting different strength classes

Additional transition pieces from N to H, spigot N, socket H. We can offer the following transition pieces: DN 200 H / 200 N and DN 250 H / 250 N. The measurements from the socket correspond to the high strength range (H), while the measurements from the spigot correspond to the normal strength range (N). The nominal length is 0.25 m ( 10 mm).

Articulation piece socket (GM) with joint L or K according to jointing system F or C

The articulation piece socket for installation in buildings and manholes is entirely unglazed and roughened on the outside.
Nominal size
Joint L according to jointing system F

Strength class

Average weight

DN kg/pce 100 125 150 200 200 250 34 34 34 160 240 160 240 160 240 160 200 200 230 260 340 360 400 440 470 510 620 650

Joint K according to jointing system C

d8

250 300 300 400

max. 100

400

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Accessories

Connecting element C with joint L according to jointing system F

The sealing element is already pre-installed when using connecting element C. DN 150: bore hole diameter: 200 +1/-0 mm; Minimum nominal size of the pipe to be drilled: DN 400 DN 200: bore hole diameter: 257 +1/-0 mm; Main pipe wall thickness: > 70 mm

Nominal size

Shaft length* e

Weight approx. kg/pce 6 6 8 10 8 9 15

DN 150 150 150 150 200 200 200

mm 40 70 100 200 70 100 200

d1

* Other shaft lengths between 100 mm and 200 mm available

M-seal type 2A and type 2B

KeraMat M-seals for the connection of two pipe spigots in a normal (type 2A) and in a wide (type 2B) design. For normal load and high load pipes in nominal sizes from DN 100 to DN 1400. KeraMat M-seals with adjustment rings available in thicknesses 4, 8, 12, 16, 24 and 32 mm for the connection of two pipe spigots with different external diameters from 160 to 1399 mm.

P-ring (replacement ring)

KeraMat P-rings are used as sealing elements for joint K and S in connection system C for the spigot of shortened pipes and fittings. Furthermore, they are also used as sealing rings for the transition from spigot, connection system F, to joint K, connection system C.

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MANHOLES

Manholes DN 800 to DN 1400

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 H h Cast-iron cover Cast-iron frame Adaptor Reinforced SR-concrete covering according EN 1917 Optional corrosion protection of the covering plate Joint sealing compound for pressure distribution Custom vitrified clay end-piece Joint sealing compound PU soft seal section at spigot end PU hard seal section in the socket Basic chamber (cut pipe) DN 800, DN 1000, DN 1200 or DN 1400 Vitrified clay epoxied connecting socket Benching finished with ceramic tiles or epoxy layer (Keramastic) Half channels in vitrified clay C30/37 strength concrete fill, followed by a PU layer on which a secondary layer of concrete is poured, hoisting aids as reinforcement Hoisting hooks (usually 4 per chamber, in exceptional cases only 3), made from smooth steel 37 and with a diameter of 12 mm. These hooks are also used as reinforcement for the filler concrete. Height between ground level and flow line Distance between the ground level and the top of vitrified clay IP in mm (standard = 400 mm)

The base parts of the manholes can be manufactured in one piece up to a height of 2.30 m. Overall heights of more than 2.30 m can be achieved using extension pipes, which will be assembled on site. The cover is made of reinforced concrete, which is either sealed completely corrosion-proof or covered with vitrified clay tiles on the inside and the area of the access opening. This goes also for the benches, to make the entire inside of the manhole corrosion-proof.

Measurements of the manhole base

Base element DN d1 mm 800 1000 *1200 *1400 792 +/- 12 1056 +/- 15 1249 +/- 18 1400 +/- 30 d3 mm 964 +/- 12 1273 +/- 15 1457 +/- 18 1600 +/- 30 max. 1209 max. 1500 Socket d8 m max. 2.30 max. 2.30 max. 2.30 max. 2.30 150 - 600 N 150 - 600 N 150 - 800 N 150 - 800 N Overall height Connection DN

*Pipe with plain end (differing from drawing)

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Measurements of the manhole pipe

The vitrified clay manhole is usually fitted with a corrosion-resistant manhole ladder. For climbing in and out safely, we recommend using access aids. Connections to vitrified clay manholes are tight and normally have to be made double-jointed on both sides for all incoming and outgoing channels.
Manhole pipe DN d3 mm 800 1000 1200 1400
For measurements see range of pipes

Overall height

m max. 2.30 max. 2.30 max. 2.30 max. 2.30

964 +/- 12 1273 +/- 15 1457 +/- 18 1600 +/- 30

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25

INSTALLATION INSTRUCTIONS

for vitrified clay socket pipes according to EN 295 and ZP WN 295

The installation of sewage channels and pipes is standardized in Europe by EN 1610 Construction and Testing of Drains and Sewers. Some sections of this standard are complemented by manufacturer information. According to EN 1610, vitrified clay pipes and fittings are also installed as sewage channels or pipes and tested for tightness. The chapter INSTALLATION for vitrified clay socket pipes contains detailed information for this procedure.

DELIVERY
Components
Vitrified clay pipes are standardized according to EN 295, sections 1 to 7, Vitrified clay pipes and fittings and pipe joints for drains and sewers. Furthermore, the products are manufactured according to the certification programme ZP WN 295, which includes even higher requirements than EN 295. The quality of all products is assured by self-monitoring and external monitoring. The authority for external monitoring for vitrified clay product is DIN CERTCO. The labelling of product with the DINplus label (label on every pipe and fittings) guarantees the technical properties of all products according to EN 295 and ZP WN 295. At the same, those labels record the existence and use of a quality assurance system according to ISO 9001:2008.

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DELIVERY / INSTALLATION

Unloading and Transport Through cooperation with our market partners, we can directly deliver to any construction site efficiently and ontime using our transport-safe reusable packaging system. At the construction site, the pipes and fittings can be unloaded trouble-free and examined for possible transport damages. This examination is done by dusting the shaft ends with talcum powder. The transport of pipes and fittings on the construction site also has to be carried out with suitable machinery.

Storage With the packaging system (mini- in maxi pack) pipes can be safely stored at the construction site. Single pipes have to be placed on square timber. Fittings have to be stored in boxes or individually, standing on the socket.

INSTALLATION
As a general rule, the original KeraMat lubricant that is included in every delivery has to be used. Vitrified clay pipes of small and medium diameters can be pushed together with a square timber or a bar. Pipes with larger diameters are put together with a puller hoist or a winch. When connecting pipes with a diameter of more than DN 200, attention has to be paid to the marking of the pipe crown, which has to be face up.

27

The installation of the vitrified clay pipes has to be carried out in such a way that the shaft is equally supported by the ground and that the pipes are located centrally in the trench. Socket holes have to be excavated. In case of frost, the trench bottom has to be protected as the vitrified clay pipes may not be installed on frozen earth layers. When protected, an installation is basically possible even below 0C, whereby the insertion forces that increase slightly because of the outside temperature have to be taken into account. Similarly, joints are tested up to a temperature of -10C. For nominal sizes of more than DN 1000, the pipes are inserted in the coupling hanging horizontally.

Statics Steinzeug-Keramo offers its partners and customers the possibility of a free static calculation using the STEINZEUG Infopool. The user can generate static calculations via the online static calculator. Registration at www.steinzeug-keramo.com.

Support and Bedding The way of supporting and bedding the pipes has a major influence on the positioning and the strength class of the pipeline. The installation of vitrified clay pipes has to be carried out in such a way that the shaft is equally supported by the ground and that neither linear nor selective support occurs and a uniform load distribution is guaranteed. As mentioned before, pipes should be placed centrally in the trench. The minimal width of the trench according to EN 1610 has to be taken into account.

2a b a

Our recommendation: Bedding type 1 according to EN 1610

KSA: Gravel and sand bedding

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INSTALLATION

Surface Main backfill Trench walls Cover height

The usage of medium or heavy compactors is not possible below 1.00 m.

c
Intial backfill

Upper bedding layer Lower bedding layer

b a min. 100 mm min. 150 mm (Rock or stony soils)

Trench geometry and specifications according to EN 1610

Nominal size DN

Pipe diameter d3 mm

Height of bedding Support 90 Total (cm) 12,0 12,5 13,0 14,0 14,0 14,5 15,0 15,5 15,5 16,5 17,5 17,5 18,5 19,0 19,0 25,5 26,0 28,0 29,5 31,0 34,0 36,5 38,5 Total (cm) 13,5 14,0 15,0 16,5 16,5 17,5 18,0 19,0 19,5 20,5 22,5 22,5 24,0 25,0 25,5 32,5 33,5 36,5 39,0 42,0 47,0 51,5 55,0

Bedding type 1: Measurements of upper (b) and lower (a) bedding layers for vitrified clay socket pipes according to EN 295 and ZP WN 295

100 125 150 200-N 200-H 250-N 250-H 300-N 300-H 350 400-N 400-H 450 500-N 500-H 600-N 600-H 700 800 900 1000 1200 1400

131 159 186 242 254 299 318 355 376 417 486 492 548 581 609 687 725 862 964 1084 1273 1457 1600

From DN 600: a = 15 cm Rocky or stony soil: a = 15 cm

OD

Sidefill

Line area

Trench depth

min. 100 mm above the socket

min. 150 mm above the pipe body

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Special designs In special cases, hydraulically bound material, such as concrete, is used as bedding material. Constructive actions or static conditions may be decisive for determining a concrete beddings. Concrete beddings with an effective support angle of 90, 120, or 180 correspond with bedding type 1 according to EN 1610. The width is calculated by means of measurement a (a = 10 cm + DN/10) or the trench width.

Trench sheeting Slip surface

Trench width

BA: Concrete support

Our recommendation: Implement support over the trench width!

Nominal size DN 200 250 300 350 400 450 500 600 700 800 900 1000 1200

Required concrete in m/m for concrete supports 90 0,046 0,052 0,059 0,066 0,073 0,080 0,089 0,115 0,144 0,176 0,212 0,251 1,338 120 0,057 0,066 0,076 0,086 0,096 0,107 0,121 0,157 0,198 0,243 0,294 0,350 0,474 180 0,057 0,089 0,103 0,118 0,135 0,170 0,213 0,302 0,405 0,524 0,660 0,812 1,159

BA: Concrete support

120

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INSTALLATION

Compaction and backfilling The mechanical compaction is carried out in layers of 15 to 30 cm. Medium or heavy compactors may only be used above the pipe from a cover layer thickness of 1.0 m. With vitrified clay pipes: For grain sizes > 40 mm in the first layer of the main filling to be compacted, the cover layer has to be at least 300 mm thick. Our recommendation: If possible, use the natural soil as filling material for the trench.

Cutting chains and cutting disks For nominal sizes DN 150 to DN 350 the cutting chain is employed to cut the pipes. For cutting larger nominal diameters, cutting disks are used.

P-rings (replacement rings) Installation of P-rings with joint K and S for nominal sizes DN 200 to DN 600.

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Connections and transition M-seals (type 2A / type 2B) Installation of M-seals in various designs for connecting pipe ends without socket for connecting shortened pipe pieces used as adapter or transition resistant to shear loads for installing subsequent junctions for subsequent connections for repairs Our recommendation: Type 2B offers a higher security! For connecting pipes with different external diameters, M-seals type 2B, bushes are used. Bushes are available in thicknesses 4 mm, 8 mm, 12 mm, 16 mm, 24 mm and 32 mm and made-tomeasure individually for the smaller pipe spigot.

Drilling Connections generally have to be carried out in a flexible way. Subsequent connections are to be made in such a way that they conform to the accepted rules (EN 1610). Drilling is recommended depending on the connection type for nominal diameters (see table). Junctions are to be used for smaller nominal diameters.

Connection DN 150 Connection Element F Connection Element C 40 Connection Element C 70 Connection Element C 100 Connection DN 200 Connection Element F

Socket pipes dn 250 - 350 400 - 600 700 - 800 900 - 1000 Socket pipes dn 400 - 600 -

Jacking pipes dn 200, 250, 300 400 - 800 1000 - 1200 Jacking pipes dn 200, 250, 300 400 - 800 1000 - 1200

Bore hole diameters are:

Connecting elements F F F C C DN 125 DN 150 DN 200 DN 150 DN 200 152 1 mm 172 1 mm 232 1 mm 200 +1/-0 mm 257 +1/-0 mm

Connection Element C 70 Connection Element C 100

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INSTALLATION

Connecting elements F und C For safe and flexible connection to main pipes of different materials. Connecting elements F for connecting vitrified clay pipes DN 125, DN 150, and DN 200 to main pipes of vitrified clay; connecting elements C DN 150 and DN 200 for connection to main pipes from vitrified clay or other materials.

Installation connecting element F

Installation connecting element C

Manhole connection and articulation pieces For incorporating settlements between manhole and pipeline, the transition is made with short pipe pieces. The flexibility of the pipe connections can incorporate the settlements. The short pipes (GZ und GA) have an nominal length of 0.6 m resp. 0.75 m.

Functionality of articulation pieces in different movement conditions

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TESTING

Testing the installed line Testing is carried out according to EN 1610. For the preliminary test at the open trench the connections can be sealed tight with stoppers and fixing hooks or quick release stoppers. Fixing devices are to be secured against movements and must be form-fit. Warning: When testing the pressure no person is allowed to stand in the area of the fixing device, particularly when testing the air pressure, there is an increased risk of danger. As preliminary test, the air pressure test is particularly suitable because it can be carried out quickly. The goal of this test is to check the installed pipes and fittings for tightness in a preliminary test. Our recommendation: Air pressure testing LC 100 The test has to be carried out in such a way that the values W30 for water pressure testing and the permissible pressure drop for air pressure testing, which are to be adhered to, are recorded. Leakages in the sealing devices and the testing device have to be avoided. Test method (W) Water pressure test for EN 1610 Test pressure: 0.1 to 0.5 bar Test duration: 30 minutes Preliminary test duration: 60 minutes Water addition limit W30 0.15 l/m2 Pipeline 0.20 l/m2 0.40 l/m2 Pipeline and manholes Manholes and inspection chambers Our recommendation: Settling time for air pressure test: to DN 500: min. 5 minutes from DN 500: DN/100/minutes Warning EN 1610: The test protocol has to be prepared individually for each test. Our service: You can request protocols for air and water tightness tests.

In a water pressure test, the section to be tested is to be filled without pressure from the lowest-point. The ventilation is carried out at the highest-point of the test section. The test pressure is applied at the lowest-point. Testing for pipe deformation is not required with vitrified clay pipes!

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TESTing

Assembly test If, for technical reasons, a assembly test is necessary, all used test devices should be double packer devices to minimise leaks between packer and pipe wall. Because of the complex and error-prone measurement technology, all results from individual tests are assessed in a deviation evaluation, in relation to the pipeline length.

CCTV sewer testing The inspection and the assessment of the inspection findings are two services that are to be separated in CCTV sewer testing. The assessment has to take into account the technical delivery conditions of the pipes, fittings and joints at the time of delivery.

Test method (L) air pressure test according to EN 1610, permissible pressure drop (P)
Nominal size DN Po 10 LA P 2,5 Po 50 Test method LB P 10 LC Po 100 P 15 LD Po 200 P 15

Permissible water addition for pipelines

Nominal size Filling quantity Permissible water addition l/m 0,05 0,06 0,07 0,09 0,12 0,14 0,17 0,19 0,21 0,24 0,28 0,33 0,38 0,42 0,47 0,57 0,66

mbar

mbar

mbar

mbar

DN 100 125 150 200 250 300 350 400 450 500 600 700 800 900 1000 1200 1400

l/m 8 12 18 31 49 71 96 126 159 196 283 385 503 636 785 1131 1539

Test time in min. 100 125 150 200 250 300 350 400 450 500 600 700 800 900 1000 1200 1400 5 5 5 5 6 7 8 10 11 12 14 17 19 22 24 29 32 4 4 4 4 5 6 7 7 8 9 11 13 15 17 19 22 25 3 3 3 3 3,5 4 5 5 6 7 8 10 11 12,5 14 16 18 1,5 1,5 1,5 1,5 2,0 2,0 2,5 2,5 3,0 3,0 4,0 5,0 5,0 6,0 7,0 8,0 9

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36

UNCOMPROMIZING. QUALITY OF THE PRODUCTS

Quality Assurance, Certification and Labelling All our products stand for quality. Quality means safety and reliability. Safety and reliability create trust trust in our products. And this is exactly why we apply the most advanced technology standards to the manufacturing of our pipes and fittings and this at the highest level. For that stands for example the unique DINplus quality label DIN CERTCO. The voluntary product certification and the utilization right for the DINplus quality label represents a special proof of quality for all our products, whose high quality goes beyond the legal and normative requirements (of the European standards EN 295 and ZP WN 295). But above all, the DINplus label creates confidence for the user that the warranted characteristics are actually present. The KEYMARK, the European CEN/CENELEC label, is an optional standard certification label, with which the compliance of a product with the corresponding European standards is confirmed by an independent institution. And many others more.

CSTB Centre Scientifique et Technique du -Btiment, Marne-la-Valle/France MA 39 Magistrate of the City of Vienna, Test and Research Institute, Vienna/Austria VSA Verband Schweizer Abwasser- und -Gewsserschutzfachleute, Zurich TZS Technical Test Institution for Construction, Prague/Czech Republic IKOBKB NL-BSB Nederlands Bouwstoffenbesluit, Netherlands IKRAM IKRAM QA Services Sdn. Bhd., Malaysia

BENOR

INISMa Institut National Interuniversitaire des Silicates, Sols et Matriaux, Mons/Belgium Gris Gteschutzverband Rohre im Siedlungswasserbau Vienna/Austria Swiss Quality Qplus Certifications Zurich/Switzerland

MA 39

VSA 13001

IGH Institute Gradevinarstva Hrvatske, Croatia PSB Singapore Productivity and Standards Board

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ADVISABLE. Notes OFFLINE AND ONLINE

Though the used raw material is the most crucial factor for the successful, durable and costefficient operation of a sewage network, the professional and competent installation must be paid appropriate attention as well. This purpose serves the Technical Guidelines, notes and information of Steinzeug-Keramo, which are bundled and clearly laid out in our online portal, along with useful links.

Technical Guidelines For the qualified building of sewage pipe and canal systems, the compliance with the standards, guidelines, work sheets etc. contained in the Technical Guidelines is indispensable. They provide manufacturers, contractors and clients with a high degree of assurance with respect to the fulfilment of their tasks according to state-of-the -art technology and at a high quality level. The following apply: Ceramics product standard: EN 295 with the parts 1-7 Installation: EN 1610, EN 752, EN 1295

Steinzeug-Keramo online At www.steinzeug-keramo.com we provide everything that is necessary and useful for a comprehensive overview, the consolidation of information or issue resolving. Registered users additionally have the option to dive even deeper and in more detail into the topics related to the construction of sewer pipes and canals via the well-structured information system. Among others, access to the static, sleeves and hydraulics calculators and to the workshop and event managers as well as to numerous technical data, consultancies and publications per download is enabled here. Also available there for quick and easy download are our model specifications.

Helpful links
www.feugres.eu www.fvst-steinzeug.de www.dwa.de www.vlario.be www.cen.eu

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COMPACT BENCHMARKS

If we place our focus on the clay pipe as a product and its attributes such as function, costefficiency and diversity of its unique characteristics, etc., the following becomes obvious: The material clay and therewith also the pipe systems from vitrified clay set standards in canal construction. Vitrified clay pipe systems fulfil the crucial characteristics and specific requirements to a persistent canal construction object, such as service life, environmental soundness or sustainability, in an exemplary way.

erage ducts for sew ro p y la c d e fi ri Vit . in regard to standards, e.g resistance to ical attack - chemical/phys resses - mechanical st naturalness of

works set hig

the raw materia

ls

es Strength, tightn Abrasion and co

s and hardness

ce rrosion resistan

ce under the inuen s tie er p ro p e Stability of thes water and soil of wastewater, il nd water and so u ro g s d ar w to r u neutral behavio Length of the se rvice lifetime d repair costs

Maintenance an recyclability

environmental as Sustainability

pects

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COMPACT MATERIAL CHARACTERISTICS

The decision to use vitrified clay pipe systems for the construction of sewer canals is a future-oriented decision: in financial, environmental and social terms. Vitrified clay pipe systems fulfil the high requirements for the safe, reliable and long term operation with ease. Ultimately, this is due to both the exceptional characteristics of the material and its sustainability.

Specific weight........................................................................... 22 KN/m3 Bending tensile strength.................................................... 15 to 40 N/mm2 Pressure resistance....................................................... 100 to 200 N/mm2 Tensile strength................................................................. 10 to 20 N/mm2 Modulus of elasticity........................................................ ~ 50,000 N/mm2 Coefficient of thermal expansion K -1 ........................................... ~5 x 106 Thermal conductivity............................................................ ~1.2 W/m x K Poissons ratio..................................................................................... 0.25 Crushing strength resistance according to nominal size.. 34 to 160 kN/m Tightness................................................................................up to 2.4 bar Corrosion resistance..........................................................................given Chemical resistance pH.................................................................... 0 - 14 Frost resistance..................................................................................given Temperature resistance........................................................ -10 to +70 C Biological resistance..........................................................................given Ozone resistance................................................................................given Hardness (according to Mohs):............................................................. ~ 7 Fatigue strength...........................................................................persistent Fire resistance.................................................................... non-flammable Wall roughness k.......................................................................... 0.02 mm Abrasion resistance...................................................................... 0.25 mm High-pressure jetting resistance .................................................... 340 bar Service lifetime ....................................................... > 100 years and more Fair to future generations Environmental-friendly Economical

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COMPACT PRODUCT BRANDS

Whats in a name?, as they say, and this is why we choose the label product brands. They serve the easy overview of the diversified, comprehensive portfolio of vitrified clay pipes, fittings and accessories.

KeraBase are the current, proven normal load socket pipes for municipal and industrial waste water drainage. The positive hydraulic characteristics and the buoyancyresistance ensure the problem-free sewage transit.

KeraPro are the high load socket pipes for special requirements and additional safety for the use in municipal draining and industrial draining. KeraPro is the optimal solution with special conditions.

KeraDrain are the perforated pipes for the draining of roads, rail tracks. Number and diameter of the holes are selected in such way that on the one hand a sufficiently large water entrance area is available, and on the other hand the holes are not blocked by soil particles or iron clogging.

KeraMat is the original line of accessories, which is optimally aligned to our pipe program. For the connection and joining technique, it includes sealing rings, M-seals, connection elements, rocker pipes as well as testing and installation equipment.

KeraPort is the manhole program. The vitrified clay inspection and manholes are individually tailored, suitable for connection to all pipe types and buoyancy-resistant.

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COMPACT Service

We are with you, whenever you like: Our sales representatives readily provide assistance by telephone, per email or in person. You will find help and support beyond this in our information system Infopool on the Internet at www.steinzeug-keramo.com, 24 hours a day. We also readily assist you with your personal advanced training.

Our proven service offer at a glance Infopool services M-seal calculator Static calculator Buoyancy calculation Cost-efficiency calculation Hydraulics calculation program Model specifications

Competent technical consultancy

Information materials Technical documents Planning Design Courses Workshops

Steinzeug-Keramo N.V. Paalsteenstraat 36 B-3500 Hasselt Phone Fax +32 11 21 02 32 +32 11 21 09 44

E-Mail info@steinzeug-keramo.com Internet www.steinzeug-keramo.com