The new standard for ductile iron pipes

EN 545:2010

Ductile iron pipes for drinking water supply An investment in the future

A new standard
WHAT HAS CHANGED?
For centuries now, cast iron has been used for the pipelines laid for drinking water supply. Today it takes the form of ductile cast iron which, thanks to its ductility, up-to-date connecting techniques and ongoing developments in the internal and external coatings used, will give an assured working life of up to 140 years. The requirements to be met by the material and coatings are laid down in European standard EN 545. A revised version of this standard appeared in December 2010 and the most important changes it contains relate to the changeover from wall thickness classes K to pressure classes, and to the reduction in the minimum wall thickness required for class 40, a class which was already included in EN 545:2006.
A cast iron pipe from the past

External diameter [mm] DN Nominal 80 100 125 150 200 250 300 350 400 500 600 700 800 900 1000 98 118 144 170 222 274 326 378 429 532 635 738 842 945 1048 Limit deviations +1/-2.7 +1/-2.8 +1/-2.8 +1/-2.9 +1/-3.0 +1/-3.1 +1/-3.3 +1/-3.4 +1/-3.5 +1/-3.8 +1/-4.0 +1/-4.3 +1/-4.5 +1/-4.8 +1/-5.0 6.8 7.5 8.4 9.3 Class 20 Class 25

Minimum wall thickness [mm] Class 30 Class 40 3.0 3.0 3.0 3.0 3.1 3.9 4.6 4.7 4.8 5.6 6.7 7.8 8.9 10.0 11.1 5.3 6.0 7.5 8.9 10.4 11.9 13.3 14.8 Class 50 3.5 3.5 3.5 3.5 3.9 4.8 5.7 6.6 7.5 9.3 11.1 13.0 14.8 16.6 18.4 Class 64 4.0 4.0 4.0 4.0 5.0 6.1 7.3 8.5 9.6 11.9 14.2 16.5 18.8 Class 100 4.7 4.7 5.0 5.9 7.7 9.5 11.2 13.0 14.8 18.3 21.9

Notes: The figures printed in bold indicate the standard range of pipes supplied. The boxes in the table which are shaded in dark grey represent products to which EN 545 does not apply. The minimum wall thickness for pressure pipes of lower DN sizes is determined by a combination of production-related restrictions, producibility and requirements relating to laying or handling. The minimum wall thicknesses quoted are for joints not subject to longitudinal forces. Pipes of pressure classes between 50 and 100 can be calculated and supplied to special order. Values in boxes shaded in blue correspond to class K9 of EN 545:2006

Ductile iron

A demonstration of load-bearing capacity

What do these changes mean

FOR MANUFACTURERS AND USERS?
Under the new standard EN 545:2010, a ductile iron pipe of, for example, DN 150 and class 40 is supplied in a minimum wall thickness of 3 mm. With non-restrained joints, this wall thickness guarantees a maximum allowable operating pressure PFA of 40 bars. If a ductile iron pipe of a nominal size of DN 150 with the tried and tested nominal wall thickness of 6 mm as used in the past is required, either a K9 pipe under the old EN 545:2006 or a class 100 pipe can tendered or ordered. The following points should be taken into account when deciding to use such a pipe The pressure classes given do not apply when the joints used are restrained. For restrained joints, the pressures ranges for use should be found from the current product documentation issued by the manufacturer. A reduction in wall thickness inevitably means a reduction in the safety margins. A ductile iron pipe is forgiving (e.g. in case of problems during transportation) and can handle high traffic loads without any problems. There is a reduction in diametral stiffness as the wall thickness goes down. What we recommend As well as pipes of pressures classes up to class 100 under EN 545:2010, Duktus also continues to supply pipes to EN 545:2006 with no change to the safety margins or to the quality that our customers have come to expect. We know that ductile iron pipes, due to their long working life, are the most sustainable investment in the future in water supply. According to the DVGW (German Technical and Scientific Association for Gas and Water) (document W 401 Entscheidungshilfen fr die Rehabilitation von Wasserrohrnetzen [Aids to decision-making for the rehabilitation of water-pipe networks]), ductile iron pipes with a cement mortar coating are the only material that allows pipelines to be costed for an operating life of 140 years. An investment in Duktus pipes means a significant increase in the life of water-pipe networks, reduces demand for raw materials and spares future generations from the financial burden and the need for renovation work.

Minimum wall thickness [mm] DN 80 100 125 150 200 250 300 350 400 500 600 700 800 900 1000 Class 40 [EN 545:2006] 3.5 3.5 3.5 3.7 3.9 4.2 4.8 5.3 6.1 Class 40 [EN 545:2010] 3.0 3.0 3.0 3.0 3.1 3.9 4.6 K9 2,700 1,500 810 480 230 160 110 89 72 52 41 34 30 26 24

Minimum diametral stiffness [kN/m] Class 40 [EN 545:2006] 1,200 680 370 250 130 91 68 67 63 Class 40 [EN 545:2010] 850 480 260 160 78 74 68 Class 30 [EN 545:2010] 46 34 27 26 Class 25 [EN 545:2010] 17 15 15 14.5

The casting process

On-site laying practices

Your contacts
GERMANY
Baden-Wrttemberg/Saarland Alexander Bauer M +49 (0) 160 719 76 69 alexander.bauer@duktus.com Rhineland Harald Oster M +49 (0) 172 73 12 936 harald.oster@duktus.com Saxony-Anhalt/Leipzig Uwe Hoffmann M +49 (0) 172 72 21 174 uwe.hoffmann@duktus.com Bavaria Wilhelm Faulstich M +49 (0) 172 73 14 807 wilhelm.faulstich@duktus.com Rhine-Main/Southern Palatinate Heinz-Jrg Weimer M +49 (0) 151 16 76 87 62 heinz-joerg.weimer@duktus.com Thuringia Uwe Strich M +49 (0) 172 81 23 089 uwe.strich@duktus.com T +49 (0) 6441 49 1251 anwendungstechnik@duktus.com Berlin/Brandenburg/MV Lutz Rau M +49 (0) 172 72 21 175 lutz.rau@duktus.com Rhine-Ruhr/NW-Germany Jrgen Schtten M +49 (0) 160 71 97 668 juergen.schuetten@duktus.com Applications Engineering Hesse/Southern Lower Saxony Karl-Wilhelm Rmer M +49 (0) 172 72 21 162 karl-wilhelm.roemer@duktus.com Saxony Michael Klee M +49 (0) 172 72 39 895 michael.klee@duktus.com

AUSTRIA Tyrol & Vorarlberg Werner Siegele M +43 (0) 664 44 30 721 werner.siegele@duktus.com Vienna, Lower Austria, Burgenland Robert Bladsky M +43 (0) 664 61 18 595 robert.bladsky@duktus.com Upper Austria, Northern Salzburg Ingo Krieg M +43 (0) 664 61 18 599 ingo.krieg@duktus.com Vienna, Lower Austria, Burgenland Gerald Pasa M +43 (0) 664 32 28 835 gerald.pasa@duktus.com Styria, Carinthia, Southern Salzburg Walter Korenjak M +43 (0) 664 54 88 353 walter.korenjak@duktus.com Styria, Carinthia Rudolf Stelzl M +43 (0) 664 83 48 083 r.stelzl@aqua-austria.at

ITALY South Tyrol/Trentino Christoph Obkircher M +39 (0) 345 66 08 948 christoph.obkircher@duktus.com

WESTERN & NORTHERN EUROPE & POLAND

Duktus Rohrsysteme Wetzlar GmbH T +49 (0) 6441 49 2260 F +49 (0) 6441 49 1613 manfred.hoffmann@duktus.com

SOUTH-EASTERN EUROPE & CIS

Duktus Tiroler Rohrsysteme GmbH T +43 (0) 5223 503-105 F +43 (0) 5223 503-111 andreas.weiler@duktus.com

CZECH REPUBLIC AND SLOVAK REPUBLIC

Duktus litinov systmy s.r.o. T +420 311 611 356 F +420 311 624 243 obchod@duktus.com

MIDDLE EAST AND NORTH AFRICA

Duktus Pipe Systems FZCO T +971 (0) 4 886 56 80 F +971 (0) 4 886 56 40 sales@duktus.com

Duktus S.A. Innsbrucker Strae 51 6060 Hall in Tirol Austria T +43 (0) 5223 503-215 www.duktus.com

Duktus Rohrsysteme Wetzlar GmbH Sophienstrae 52-54 35576 Wetzlar Germany T +49 (0) 6441 49 2401 F +49 (0) 6441 49 1455 www.duktus.com

Duktus Tiroler Rohrsysteme GmbH Innsbrucker Strae 51 6060 Hall in Tirol Austria T +43 (0) 5223 503-0 F +43 (0) 5223 43619 www.duktus.com

Duktus litinov systmy s.r.o. Ko tlkova 1527 s 266 01 Beroun Czech Republic T +420 311 611 356 F +420 311 624 243 www.duktus.cz

Duktus Pipe Systems FZCO South Jebel Ali Free Zone JAFZA View 18/Office No. 909 Dubai/U.A.E. T +971 (0) 4886 56 80 F +971 (0) 4886 56 40 www.duktus.ae

038 01/11 e 500 BD