2012 - waga technical manual

7/25/2019 2012 - WAGA Technical Manual

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Georg Fischer Waga N.V.

The connection technology specialistfor the water and gas market

Technical

Manual


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We have what you


Since the foundation of Waga N.V. in 1957 we design, produce and sell a

complete range of couplings, flange adaptors, repair fittings, tapping saddles &

tees and accessories.

In the year 1965 the Swiss company Georg Fischer acquired Waga N.V., comple-

menting the mainly plastic product portfolio with a wide variety of metal fittings.

2000 system.

3000 system.

3000 Plus system.

Our products are used all over the world, in under and above ground pipelines,

for distribution systems and industrial applications for gasses and fluids, but

also for shipbuilding, general piping systems and special applications.

Our mission

To be the technological market leader for connection technology in the

utility market by developing innovative, easy-to-install products.

To be a respected fitting supplier in the industry by offering high quality

products with a clear added value for our customers.

Our vision

We want to maintain our position of technological market leader.

We want to develop and produce high-tech and sophisticated, yet simple

quality products with technical added value for the utility market.

connection technology the standard

in the utility market.

1957:

1965:

1990:

1997:

2008:

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need

wherever you areA global network of distributors - your partners are our partners

Our values

We put customers first.

We act fast.We do what we say.

Connecting Repairing Tapping Additional products

Tailor-made solutions for any application in which fluids or gasses are conveyed.

Competent customer support worldwidewith our sales companies and representatives.

We always work with the best distributors in every country. They are our key partners when it comes to the fastavailability of our products.

Fast deliverywith our electronic inventory management system and flexible production facilities.

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Table of Contents


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1 Preface

1.1 Georg Fischer Waga N.V.

Our mission

nection technology in the utility market by deve-loping innovative, easy-to-install products.

by offering high quality products with a clearadded value for our customers.

Our vision

market leader.

sophisticated, yet simple quality products withtechnical added value for the utility market.

connectiontechnology the standard in the utility market.

1957:Since the foundation of Waga N.V. in 1957 we design,produce and sell a complete range of couplings,flange adaptors, repair fittings, tapping saddles &tees and accessories.

1965:In the year 1965 the Swiss company Georg Fischer

acquired Waga N.V., complementing the mainlyplastic product portfolio with a wide variety of metalfittings.

Our products are used all over the world, in underand above ground pipelines, for distribution systemsand industrial applications for gasses and fluids, butalso for shipbuilding, general piping systems andspecial applications.

Our values

Tailor-made solutionsfor any application in which fluids or gasses areconveyed.

Competent customer support worldwidewith our sales companies and representatives.

We always work with the best distributors in everycountry. They are our key partners when it comes tofast availability of our products.

Fast deliverywith our electronic inventory management systemand flexible production facilities.Our logistics services are consistently improved to

Research & developmentHaving a constant urge for re-newing and improving.Trying to stay ahead of the competition through inno-vation. Having a long experience in the water and gasutility market.

This resulted in the fact that we introduced: 2000, launched in 1988, 3000, launched in

1997.

By keeping close contact with our customers and byclosely monitoring the latest developments in themarket, our research & development department isconstantly working on new, better and simpler con-nection technology products.

ProductionOur production team forms a group of enthusiasticand motivated people, educated and trained accor-ding the Georg Fischer Waga N.V. standards.

Throughout the logistical chain of the productionprocess, we pay special attention to the reproduci-bility and maintenance of our high quality standard,taking into account the environment. Furthermore,thanks to our flexible production units and the factthat we produce on customer order, we are able to

offer customized, tailor made products upon re-quest, while at the same time keeping the deliverytimes short.

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Training facilitiesEmployee and customer training today includesmuch more than learning about the technical fea-tures of our products.

-plication areas, system know-how and know-why,the several jointing methods, as well as recognitionof customer requirements. Next to our state of theart test facilities, we are equipped with a trainingfacility and a showroom demonstrating all possibleapplications of the WAGAproducts in water andgas distribution networks. Theory and practice of

assembling, installing and using WAGAproductsare taught using structured training programs,focusing on the latest developments in connectiontechnology, production methods, materials andproduct applications.

1.2 Quality management

GeneralProducts of Georg Fischer Waga N.V. meet the re-

quirements of the relevant international standardsand carry various approvals. Consistent quality is en-sured by the systematic production self-monitoringsystem, implemented at our factories.

Customer satisfaction

as well as by optimizing our management system by:

system in accordance with ISO 9001/ISO 14001,

management system.

1.2.1 Certification in accordance with ISO 9001All audits concerning compliance with the qualitymanagement system ISO 9001 are carried out byexternal, independent bodies. The first audit wasinitially conducted at Georg Fischer Waga N.V. in

1993 by an internationally recognized institution,Gastec Certification B.V. Ever since, we have beenstriving to enhance our quality management systemin order to further improve customer satisfaction.

International and European StandardsFor many years Georg Fischer Waga N.V. has beenplaying an active role in international and Europeanstandard committees. In the water and gas industrywe are supporting in the development of advancedtest standards and test guidelines for international

certification in order to increase the overall qualitylevel of products used in the water and gas industry.

1.2.2 Certification in accordance with ISO 14001Today, the ecologically acceptable production of pro-ducts and services is of paramount importance andan essential part of the company philosophy atGeorg Fischer Waga N.V. That an environmentfriendly product design and production is possible,is demonstrated by the numerous stages in our

towards the development of our products can reduceor even prevent environmental impact during thelifetime of the product. We are convinced that ser-vices and products which are in accordance with theenvironment, are also an important factor for ourcustomers. We have come to recognise, that as acompany we can contribute significantly to environ-mental protection, for example, by saving energy andwater and reducing industrial effluents and waste. In

efforts to protect the environment were recognizedby means of the NEN-EN-ISO 14001 certificate,issued by Gastec Certification B.V.

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1.3 Terms and definitionsTerms and definitions used throughout this technicalmanual comply (as much as possible) with the latestterms and definitions used in European standards.

Allowable operating pressure (PFA)Internal pressure, exclusive of surge that a compo-nent can safely withstand in permanent service (seeEN 805), often referred to as working pressure.

Allowable test pressure (PEA)Maximum hydrostatic pressure that a newly installedcomponent can withstand for a relatively short dura-tion, when either fixed above ground level or laid andbackfilled underground in order to measure the inte-grity and tightness of the pipeline (see EN 805), oftenreferred to as test pressure.

Note:This test pressure is different from the system testpressure (STP), which is related to the design pres-sure of the pipeline, and is intended to ensure the in-tegrity and leak tightness of a certain fitting installed.

Depth of engagementMinimum distance between any point of the spigotend and the internal face of the joint gasket.

Ductile ironCast iron used for pipes, fittings and accessories inwhich graphite is present, mainly in spheroidal form.

FittingCasting other than a pipe, which allows pipeline de-viation, change of direction or bore. In additionflanged socket pieces, flanged spigot pieces andcollars are also classified as fittings.

Flange

Flat circular end of a fitting or pipe extending per-pendicular to its axis, with bolt holes equally spacedin a circle.

Note:A flange may be fixed (e.g. integrally cast or welded-on) or adjustable; an adjustable flange comprises ofa ring, in one or several parts assembled together,which bears on an end joint hub and can be freelyrotated around the axis before jointing (see EN 545).

Flanged joint

Flexible joint both during and after installation and which canaccept a slight offset of the centreline.

GasketSealing component of a joint.

JointConnection between the ends of two pipes and/orfittings in which a gasket is used to effect a seal.

Joint angular deflectionAngle between the axis of two connected pipe com-ponents, which a flexible joint can accommodate.

Joint gapMaximum axial distance between any point of the

spigot ends of the pipes to be connected (coupling),or, maximum axial distance between any point ofthe spigot end of the pipe and the flange face (flangeadaptor).

Large tolerance couplingFitting intended for use with pipes of various mate-rials which:

ween two spigots of pipes, fittings or valves, .....,and,

to facilitate easy assembly.

Large tolerance flange adaptorFitting intended for use with pipes of various mate-rials which:

a spigot of a pipe or a fitting and the flange ofanother component of the pipeline (e.g. pipe,fitting, valve, .....), and,

to facilitate easy assembly.

Large tolerance stepped or reducer coupling components of different nominal sizes.

Mechanical flexible jointFlexible joint in which sealing is obtained by applyingpressure to the gasket by mechanical means, e.g. agland.

Nominal pressure (PN)Numerical designation expressed by a number,which is used for reference purposes.

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Nominal size (DN, for diameter nominal)Numerical designation of size, which is common toall components in a piping system. It is a convenientround number for reference purposes and is onlyloosely related to manufacturing dimensions (seeEN ISO 6708).

Outside diameter (OD)Outside diameter of the pipe(s) to be connected.

Performance testProof of design test, which is done once and is re-peated only after changing the design.

Restraint flexible jointFlexible joint in which a means is provided to preventseparation of the assembled joint.

SocketFemale end of a pipe or fitting to make the connec-tion with the spigot of the next component.

SpigotMale end of a pipe or fitting.

Restraint (pull out resistant) symbol used by

Georg Fischer Waga N.V., indicating that the

product comes with a self-anchoring system.

1.4 Dimensions and unitsDimensions are indicated in mm and/or inches andare specified as nominal or standard sizes.

We reserve the right to alter design of fittings.

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1.5 Conversion table

To convert to multiple by

Area0.1550 sq. inch (in2) sq. centimetre (cm2) 6.451610.764 sq. feet (ft2) sq. metre (m2) 0.09290Density

0.062428 pound/foot (UK) kilogram/metre3(kg/m3) 16.01850.010022 pound/gal (UK) kilogram/metre3 (kg/m3) 99.77610-3 gram/centimetre3(g/cm3) kilogram/ metre3(kg/m3) 10000.160544 pound/gal (UK) pound/foot3(lb/ft3) 6.22884Dynamic viscosity103 centipoises (cP) Pascal second (Pa s) 10-32.419 pound/ft hr (lb/ft h) centipoises (cP) 0.41341.000 gram/metre sec (g/m s) centipoises (cP) 1.000Length0.0393701 inch (in) millimetre (mm) 25.40

0.28084 feet (ft) metre (m) 0.30481.090361 yard (yd) metre (m) 0.9144001010 angstrom (A) metre (m) 10-10Mass0.035274 ounce (oz) gram (g) 28.34952.20462 pound (lb) kilogram (kg) 0.4535920.96207 ton UK (long ton) tonne (t) 1.01605Pressure and stress9.869*10-3 atmosphere (atm) kilopascal (kPa) 101.300.1450 pound-force/in2(psi) kilopascal (kPa) 6.894760.01020 kilogram force/cm2(kgf/cm2) kilopascal (kPa) 98.0665

0.06804 atmosphere (atm) pound-force/in2(psi) 14.7020.89 pound-force/ft2(lbf/ft2) kilopascal (kPa) 0.0478810.000 milibar (mbar) kilopascal (kPa) 0.100033.86 milibar (mbar) inches mercury (in Hg) 0.0295368.95 milibar (mbar) pound-force/in2(psi) 0.014504.015 inches water (in H

2O) kilopascal (kPa) 0.2491

Power and Heat Flow rate3.41210.85981.0001.818x10-3Torque0.737613.90.1020

Multiply by to convert

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1.6 Pipe outside diametersPipe OD of most commonly used pipes

Coupling Steel Steel PVC/PE PVC/PE Ductile Grey cast AC cl. 6/12DN metric imp. iron cl. 18 iron British

50 60.3 60.3/66 63 60.3 66 68 -65 76.1 76.1 75 76.1 82 - -80 88.9 88.9 90 88.9 98 95 -100 114.3 108 110/125 114.3 118 122 124125 139.7 133 140 139.7 144 148 149/151150 168.3 159 160/180 168.3 170 174 174200 219.1 211/216 225 219.1 222 228 228225 244.5 241 250 244.5 248 257 -250 273 267 280 273 274 284 268/280300 323.9 316/318 315/355 323.9 326 337 334350 355.6 368 355 355.6 378 - -

400 406.4 419 400 406.4 429 - -450 457 464/470 - 457 480 - -500 508 514/521 500 508 532 - -550 559 559 - - 558 548 550600 609.6 622 630 609.0 632 635 -

Coupling AC cl. 10 AC cl. 10 AC cl. 12 AC cl. 12 AC cl. 18 AC cl. 24DN rough approx. rough.approx.

50 68 - - - - -65 - 72 74 78 86 8680 98 102 104 - - -100 120 124 124 108/128 106/126 106/126125 145 149 149 153 153 -150 176 180 180 184 178 157/184200 - - - - - -225 232 236 238 242 234 244250 284 288 292 296 288 296

300 340 346 350 356 344 354350 - - 350 356 - 354400 - 402 410 416 402 414450 452 460 468 476 456 468500 510 518 522 530 508 522550 568 576 580 - 564 578600 - - - - - -

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2 Material specifications

2.1 Metal

2.1.1 GGG 40 ductile cast ironConforming to DIN 1693 (ISO R 1083). Generaldescription: cast iron (used for pipes, fittings andaccessories) in which graphite is present mainly inspheroidal form.

MechanicalpropertiesGGG 40

DIN 1693 ISO R 1083

Hardness,BrinellTensilestrength, ulti-mate

Tensilestrength, yieldElongation atbreakModulus ofelasticity

140-190 HB

min. 400 N/mm2

250 N/mm2

minimum 15%

-

150-200 HB

min. 420 N/mm2

280 N/mm2

minimum 12%

GPa typical forsteel

2.1.2 GGG 45 ductile cast iron description: cast iron (used for pipes, fittings and

accessories) in which graphite is present mainly inspheroidal form.

Mechanical propertiesGGG45

EN 1563:1997

SymbolNumberTensile strength R

m

0,2% Proof Stress Rp0,2

Elongation at breakModulus at elasticityPredominant structure

min. 450 N/mm2

min. 310 N/mm2

min. 10%169 GN/mm2

Ferrite

2.1.3 Steel 37-2, ASTM A108Conforming to DIN 1.0112, BS 970 080A17. Generaldescription: medium low-carbon steel with a goodweldability and slightly better machine-ability.

Mechanical properties ISO R 1083

Hardness, BrinellTensile strength,

ultimateTensile strength, yieldElongation at breakModulus of elasticity

126140 N/mm2

370 N/mm2

15% in 50 mm205 GPa typical for steel

2.1.4 Stainless steel

2.1.4.1 AISI 304, A2 quality X 5CrNi 189Conforming to DIN 1.4301, ISO 683/13 11.General description: austenitic CR-Ni stainless steel.High ductility, excellent drawing, forming and spin-ning properties. Essentially non-magnetic, becomesslightly magnetic when cold worked.Chemical resistance: resists most oxidizing acids bide precipiation in the heat-affected zone duringwelding and a lower susceptibility to intergranularcorrosion.

Mechanical propertiesAISI 304

Hardness, Brinell

Tensile strength,ultimateTensile strength, yieldElongation at break

123 converted fromRockwell B hardness

565 N/mm2

310 N/mm2

70% in 50 mm

Thermal properties

CTE, linear 20 C

Modulus of elasticity

17.3 m/m- C from0-100 C193-200 GPa

2.1.4.2 AISI 316, A4 quality X 5CrNiMo 17122Conforming to DIN 1.4401, ISO 6931.General description: molybdenum content increasesresistance to marine environments. High creepstrength at elevated temperatures and good heat re-sistance. Biocompatible. Fabrication characteristicsare similar to types 304.

Mechanical properties

AISI 316Hardness, BrinellTensile strength,ultimateTensile strength, yieldElongation at breakModulus of elasticity

190620 N/mm2

415 N/mm2

45% in 50 mm193 GPa

Thermal properties

CTE, linear 20 C 17.3 m/m- C from0-100 C

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2.2 RubberRubbers are available in many shapes and qualities.Rubbers are an essential component of fittings andvalves in pipeline constructions. Depending on thetransported media and temperature, a choice has tobe made for a sealing material. All the different ma-terials have their own specific quality and applications.

Rubber, the basic understandingsThere still exists some confusion regarding the ma-terial rubber and the methods by which products aremanufactured of it. Natural or synthetic rubber iscombined with several chemicals through mixingand rolling, resulting in the so-called non-vulcanisedrubber mixture.The added chemicals are often moreimportant than the rubber raw material, for charac-teristics of the final product. Such a rubber mixture,a viscous, plastic mass, will be processed further into

the required product, by a variety of methods. To formthe product to its final shape, moulds are required toshape the material either by transfer moulding ma-chines or compression presses. The rubber mixtureis introduced in the mould under pressure, at a tem-perature of about 150 C, resulting in a chemical re-action, which transforms the mixture into a formed,elastic product. One should be fully aware of the re-quired quality standard, in order to decide on thecompound to be used.

2.2.1 NBRNitrile Butadiene Rubber.Rubber seals should conform to certain require-ments, such as:NEN 5601 Hardness with shore ANEN-ISO 37 Determination tension and stress

propertiesNEN-ISO 48 Hardness with 1 RHDNEN-ISO 188 Tests for accelerated ageingNEN-ISO 815 Determination of permanent

deformationNEN-ISO 816 Determination of abrasionstrength

NEN-ISO 1431 Determination of ozone resistanceEN-ISO 1817 Determination of resistance

against fluidsNEN-ISO 2285 Determination of permanent

stretch at temperature

NBR rubber is eminently resistant against gas, oil,grease, petrol and solvents. The resistance is

strongly dependent on the Acrylonitril percentage;the best results are achieved with high percenta-ges. However the elasticity, the resistance againstpermanent transformation and the low temperature

resistance will decrease. The material is sensitiveto corrosion by ozone. At lower temperatures, NBRwill stiffen. Depending on the mixture, the maximumtemperature for use can be up to around 90 C. Bycomplete immersion in for example oil, NBR can beused up to around 120 C. NBR is also suitable foruse in drinking- and waste water systems. All NBRseals used by Georg Fischer Waga N.V. meet therequirements of EN 682 GB (DIN 3535/3) for gas ap-plications, and are suitable for use in drinking watersystems.

Application NBR Gas-, drinking- andwaste water systems

TemperatureHardness

-5 C to +50 C60 to 70 IRHD

2.2.2 EPDM

Ethylene-propylene-diene-monomer rubber.By co-polymerisation of ethane and propane, anelastomer arises without double bindings, that canonly be vulcanised with peroxides. If with polymeri-sation a third monomer is built in, the elastomer canbe vulcanised with sulphur (EPDM). EPDM is verywell resistant against weather influences in gene-ral and ozone especially. Besides that, the materialis excellently resistant against high temperatures,hardly sensitive to corrosion, and resistant against

free-basing, acid and solvents. Depending on themixture and type of vulcanisation, the maximumtemperature for use of EPDM is around 120 C.All EPDM seals used by Georg Fischer Waga N.V.meet the requirements of BS 2494/W and EN 681-1/WA.

Application NBR Drinking water

TemperatureHardness

0 C to +50 C70 IRHD

2.2.3 PerbunanAll Perbunan seals used by Georg Fischer Waga N.V.meet the requirements of EN 682 (DIN 3535/3) forgas applications and are suitable for use in drinkingwater systems.

Application Perbunan Gas-, drinking- and

waste water systemsTemperatureHardness

-30 C to +100 Capprox. 60 shore A

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2.2.4 Guidance on storage of rubber sealsIn case there is any doubt about the suitability of therubber sealing for certain applications, please con-tact us.The rubber seals should:

preferably below 15 C,

light and artificial light with a high ultra-violetcontent,

ble of generating ozone, e.g. Mercury vapourlamps, high voltage electrical equipment, whichmay give rise to electrical sparks or silent elec-trical discharges,

compression or other deformation,

2.4 Plastics (Nakam GPM)Nakam GPM has excellent properties for under- andabove ground application. Nakam GPM is a materialwhich has been especially developed for GeorgFischer, is approved by the American Food andDrugs Administration and is perfectly suitable foruse in water & gas.

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3 Coatings & lubricants

3.1 Coating for corrosion protectionTo ensure a durable, high quality corrosion protec-tion of castings (and other metals), coatings must beresistant to temperature changes and the effects ofweather and other environmental influences such asmoisture, industrial gases etc., which stress the cas-ting. The coating must ensure a completely sealedsurface without porous areas. A protective coatingprevents corrosion and the formation of corrosionproducts which, when carried along the pipeline,could lead to disruption at other points. A smoothsurface reduces friction between the transportedmedium and the fitting. Encrustation by salts ororganic materials is avoided.

3.1.1 Epoxy coatings

Coatings on the basis of epoxy resin are the best wayof protecting castings. Epoxy powder coatings offerlong-term reliability. The coating protects the entiresurface area, with a film thickness of minimum 250m. It has no pinholes, tested with 3 kV. The epoxyresin technology uses less energy compared to othercoating processes, as the parts are only heated upto approximately 200 C. The application processesof epoxy coatings, Fluidised Bed Coating or Electro-static Spray Application, allow automatic manufac-turing processes and result in a homogeneous layer

thickness inside and outside of the fittings, formedby one material without discontinuity. Consequentlyit offers excellent edge coverage. We were one of thefirst coupling manufacturers who started to havetheir product protected with an epoxy coating ever.Since we introduced the epoxy-coated couplings inthe beginning of 1987, we have built up a lot of expe-rience and know-how. Within the European Standardwork groups, the tendency is very clearly towardsepoxy coatings instead of other coatings. As a mem-

ber of GSK, Georg Fischer Waga N.V. contributes tolifting the standards for epoxy coating used in the(utility) market.

GSKThe GSK, Quality Association for HeavyDuty Corrosion Protection of PowderCoated Valves and Fittings, was founded in 1993 inorder to fulfil the growing quality requirements forpipelines in many European countries. Today the

GSK has 27 members, all leading European manu-facturers of fittings and valves, engineering compa-nies and producers of fusion bonded epoxy powdercoatings. The epoxy powder coating of valves and fit-

tings is the ideal technology for long-term corrosionprotection and involves the highest levels of qualitycontrol in their manufacture. GSK is recognised by Quality Marks) and sets the quality and testing stan-dards for machinery, materials, processes and qual-ity assurance in the epoxy coatings technology. Theregulations of the GSK not only meet the require-ments of the relevant national and internationalstandards (e.g. DIN, ISO) but also exceed them. Thefixed quality level serves as a reliable standard forbuilders, engineers, construction workers andmanufacturers. A safe and consistent quality fulfilshigh demands. The quality is controlled by an inde-pendent test laboratory: MPA Germany.

3.1.1.1 RESICOATRT 9000 R4 (red)RESICOAThas a very high durability. It shows very

high impact resistance and offers a good electricalinsulation.

Typical technical data RESICOAT RT 9000 R4 (red)

Minimum thickness

ColourBasisImpact resistant

PorosityElasticity

Flexibility

Pressure resistance

Hardness

Adhesion

Salt spray test

Maximum temperature

Edge coverageCD-properties

Chemical resistanceBreakdown voltage

250 m according toGSK Epoxy resin20 joule at 23 C accor-ding to DIN 306710 (zero) 3 kV test5% at 23 C accordingto DIN 30671 and DIN30677-2511% at 23 C accordingto ASTM 522100 at 90 C accordingto DIN 30671Shore D 98 / > 100 accor-ding to EN ISO 2815

> 20 N/mm2

according toDIN 53232 and > 16 MPaaccording to DIN ISO4624> 720 hours according toASTM B 117135 C according to VDE0368ExcellentExcellent at 30 days,23 C

pH 2 up to pH 13> 3 kV at 250 m accor-ding to ISO 8130-2

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Water absorption

Water immersion (fiveyears)Cathodic disbandmenttest

100 days, 23 C < 2% ac-cording to DIN 53495100 days, 65 C < 3% ac-cording to DIN 53495no blisters ISO 7253

at 23 C < 10 mm DIN30677-2

Values measured on blast cleaned cast iron.

3.1.1.2 ApprovalsA wide range of approvals assures the suitability incontact with gas and drinking water. The tests inclu-de water purity and bacterial attack. Furthermorethe coating meets the requirements specified for usein waste water and gas pipe systems. The coating

also meets the requirements of Kest SFW 2.0. TheRESICOAT R4 epoxy resin carries over 80 drinkingwater approvals.Some of these include: Belgaqua(Belgium), DGS (France), KWT (Germany), KIWA(the Netherlands), NSF Standard 61 (USA), WRAS(United Kingdom) as well as drinking water approv-als in Austria, Switzerland and the Czech Republic.And last but not least the RESICOATR4 meets therequirements of DIN 30677, 30677 T1 + T2, DIN 3476and passes the GSK standard.

Coating application processBefore the fittings are coated, they are cleaned, andthen grid-blasted according to class SA 2 . Bothapplication techniques, Fluidised Bed Coating orElectrostatic Spray Application, are used to apply thecoating to our fittings.

Fluidized bed coatingThe powder melts onto the pre-heated grid-blastedfitting and excessive powder falls off, helped by

movement of the coated part.

Electrostatic spray applicationThe powder is applied by an electrostatic spray gun,either manually or by a robot.

3.2 Anti Friction coatingGalling or fretting is a severe form of adhesive wear,which occurs during sliding contact of one surfacerelative to another. Clumps of one part may stick tothe mating part and break away from the surface.

This is also the case with stainless steel. To preventthis problem, anti friction coatings can be used. Bluecoloured coating indicates that the bolts are stain-less steel A2 and black coloured coating indicates

that the bolts are stainless steel A4.

3.2.1 Teflon coating (PTFE)In order to prevent friction, the stainless steel boltsand nuts are spray-coated with fluoro-carbon coa-ting, a low friction coating applied to threads. Thisanti friction coating is a dry lubricant consisting ofsuspensions of the solid lubricant PTFE. This coa-ting has the property of reducing the torque-tensionscatter during tightening. This type of coating is alsoused to prevent problems caused by weld splatterobstructing the threads of weld nuts during theirplacement and it eliminates the need for masking orcleaning when painted, since paint will not adhere tothe coating. The Teflon coating can be supplied in awide variety of different colours.

3.3 Lubricants

3.3.1 Silicone lubricants (rubber parts)As a standard Georg Fischer Waga N.V. applies CFSsilicone spray, a colourless silicone fluid for oil andgrease free lubrication between the rubber and thefitting. Because the silicone will vaporise in time, it

is advised to check for adher-ence between the aforemen-tioned parts, and subsequentlyrelubricate if necessary. Thislubrication provides a friction

free installation, leading to lesstension in the rubber, which willcontribute to a longer lifeexpectancy of the fitting.

3.3.2 Passivated nutsAnother anti friction measure is the use of passiva-ted nuts. Here, another zinc layer lubricates thethread reducing friction.

Main ingredientSecondary ingredientColourTemperature range Corrosive protection

Pure silicone oilTeflonColourless/transparant-50 C - +200 CExcellentGood

Approvals

for use in products, that are in contact with foods.If another type of lubricant is used, check if the lu-bricant does not contain elements that affect the

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ru er. or use n pota e water systems t s a v seto use a lubricant, which is approved for such use.

3.3.3 Anti-Seize CompoundsAnti-seize compounds are used on the threads ofasteners. t prevents ga ng o mat ng sur aces on

especially the stainless steel fasteners. Furthermoreit can provide a barrier to water penetration sincethe threads are sealed by use of the compound. Ont e stee asteners t t ere ore a so mproves t ecorrosion resistance to allow the parts to be subse-quently disassembled even under adverse envi-ronmental conditions. We advise to use a lubricantcontaining molybdenum disulphide or copper, suchas Molykote Cu-7439 plus copper past or equivalent.

his solid lubricant acts as a high pressure resistantfilm. It can be used by itself as a dry lubricant as wellas in other solid lubricants and in oils and greases.

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4 Technical specifications for flanges

Flanged connections are one of the oldest methodsof connecting pipes and/or fitting together. One ofthe first flanged connections dates from the 17thcentury and was described in a standard for the firsttime in 1882. In 1926 the first material indepedentstandard for mating dimension of flanges was publi-shed. These standard sizes made it possible to con-nect two flanges, independent of type, within thesame DN (nominal size) and PN (pressure class)together regardless the material of which the flangewas made from.

4.1 Flange mating dimensionsThe mating dimensions describe the interchange-ability between flanges within the same DN and PN.The mating dimensions are described by:

The mating dimensions, which are used in ourproducts, are standard PN 10 or PN 16 according EN1092-2, ISO 2531, DIN 2501, DIN 28604 / 28605 andother EN-ISO-DIN orientated standards. This secu-res the interchangeability with BS 4504: Section3.2:1989 up to DN 300.

Drilling patterns(e.g. mating dimensions) of other standards can besupplied as long as they are allowed within the phy-sical dimensions of the flange.

4.2 Physical dimensionsOther physical dimensions of the flange determinethe strength of the flange. This strength is dependingon the type of material of which the flange is madeof.

Physical dimensions are:

facing,

The flanges used in our products are all dimen-sioned type B (raised face) according to EN 1092-2.

4.3 Flange facingAll flange facings in our cast iron product lines arestandard equipped with concentrically grooves.These grooves, opposite to flat facings, give a ring

tightening force to the flange gasket rather than afaced tightening. This ensures a heavy-duty perfor-mance with high life expectancy in combination withrubber flange gasket

18


19/68

4.4 Flange mating dimensions overview

19


20/68

5 Insert stiffeners

In this chapter, the need of using insert stiffeners(also called support liners) in general is explained.Also the specific guideline of using inserts in combi-nation with the Georg Fischer Waga N.V. products ismentioned.

5.1 Mechanical pipe joints on plastic pipesPlastic materials suffer from material relaxation,resulting in a change of shape over time. This phe-nomenon is known as stress relaxation. Especiallywhen installing a mechanical coupling on plasticpipes, tightening of the bolts results in an increasedsurface pressure of the joint onto the plastic pipewall. This extra pressure in most cases leads to adeformation of the pipe wall (picture 1), enhancingthe relaxation process. In case of restraint mecha-

3007 Family,the forces of the restraining mechanism broughtonto the pipe are often much higher than the forcesof the sealing mechanism. These higher stresslevels will therefore result in a higher creep defor-mation and might cause a higher risk of joint failure.

By inserting a stainless steel insert stiffener into theplastic pipe end, the pipe is reinforced from the in-side, ensuring that the pipe wall cannot be deformed(picture 2). This will result in the best possible con-

nection on plastic pipes.

1. 2.

Mechanical pipe joints

3. 4.

Residual stress and bending torques

5.2 Bending torquesAnother reason for using the stainless steel insert

stiffeners is to avoid bending torques. A plastic pipealways tends to knick exactly at the spot of the sealingarea when bending torques act on the pipe (picture 3.).This might result in leakages of the fitting. When using

an insert stiffener, the bending point is diverted awayfrom the sealing area, resulting in a long-lasting leakfree connection (picture 4.)

5.3 Use of insert stiffenersIn order to guarantee the best possible performanceof the Georg Fischer Waga N.V. fittings on plasticpipes, we set the following directive:

Use of an insert stiffener (approved by Georg FischerWaga N.V.) is mandatory on all plastic pipes, bothfor restraint and non restraint connections, both forpermanent and temporary connections.

Exceptions:No insert stiffeners need to be used for temporary(< 5 years) non-restraint connections on:- PP-B, PB and HD-PE (80/100) pipes with

SDR-class 11 or smaller- PVC pipes with SDR-class 21 or smaller

Remark:In theory, the pressure inside the pipe is an im-portant factor to determine if an insert stiffener isrequired or not. The inside pressure could take overthe function of an insert stiffener, but only whenthis pressure would be constantly present and neverdrop. In practice, a constantly present pressure isnever the case. Therefore, Georg Fischer Waga N.V.

always requires the use of insert stiffeners accordingto the above.

5.4 Design and propertiesGeorg Fischer Waga N.V. offers two types of insertstiffeners for different applications. Depending onthe application the right choice has to be made. Toguarantee the correct support to the spigot, insertstiffeners must be designed according the intendeduse for plastic piping systems. Therefore insert stif-

feners must conform to the following properties toguarantee its function.The insert stiffener must:

installation

support

the joint area plus 0,2 x the outside diameter

on by the sealing and restraining mechanism

20


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5.4.1 Insert Economyhe Insert Economy is designed for (PE, PB, PVC

etc.) pipes dimensioned according to DIN 8074. Theinsert can be installed in these pipes as long asthey are within the allowed production tolerances.n or er to secure a su c ent support to t e p pe,

the (nominal) diameter of the insert is just belowthe nominal inside diameter of the pipe. This meansthat when the pipe is produced at its biggest toler- the pipe is produced at its lowest tolerance, you needsome extra force to put in the insert. But this extraforce should be no more than can be achieved with ahammer. The Insert Economy is available for variousSDR-sizes. To guarantee the correct working of theinsert, the use is limited to pipes up to DN300. Abovethis dimension, the production tolerances becomesuch, that sufficient support is no longer guaran-

teed. For inserts bigger than DN300, we offer theinserts with wedge.

5.4.2 Insert with wedgehe insert with wedge is intended for pipes with

larger production tolerances and pipes producedaccording to unknown standards, and is available

p to DN800. The wedge construction offers a smalltolerance, overcoming minor dimension differencesof the pipe. After positioning the insert, the wedge ishammered in, to fix the insert. After that the top-endo t e rema n ng we ge as to e sawe o .

21


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6.3 Fiksers

To get the best possible end-load resistance on diffe-rent pipe materials without any compromise, twotypes of Fiksers 3000:

Multi/Fikser

for the best restraint performance on hard pipematerials like steel, grey cast iron, ductile cast iron,stainless steel, PVC, etc.

Poly/Fikser:for the best restraint performance on polyolefinepipes like PE, PB, etc.

6.4 Body and glandThe length of the body determines the insertionsdepth or joint gap possible. Because the insertiondepth complies, and even exceeds, the dimensionsgiven in ISO 2531, large joint gaps can be covered.Secondly the design of the body and gland are suchthat losses in tension, which will occur in time, arecompensate y t e ex ty o t e ears.

6.5 Pressure/Performance

See table in the user manual on page 38-39.

6.6 Joint gapMaximum axial distance between any point of thespigot ends of the pipes to be connected coupling ,or, maximum axial distance between any point ofthe spigot end of the pipe and the flange face flangeadaptor).

6.7 Depth of engagementMinimum distance between any point of the spigot

end and the internal face of the joint gasket. The ma-nufacturer shall declare the maximum joint gap, andit should be nog less than the values given in table 3.

6 MULTI JOINT3000

For all pipe materials and pipe sizes from DN 50 upto and including DN 300, we not only offer a largerange of up to 43 mm, but also a stepless range upto DN 250. This, combined with a large variety of dif-ferent types and a working pressure of 25 bar non-

3000 fittingsthe most versatile couplings in the market combines wide range with end-loadresistance by using metal grippers Fiksers .

6.1 Variofleks ring 3000 is an in-

novative, patented system, consisting of a specialsegmented plastic ring combined with a thin rubbergas et. s com nat on s ca e t e ar o e s

ring. The segmented ring ensures the tolerance,

where the gasket ensures the leak tightness. Thisseparation of functions prevents gasket over-stressing and results in an expected leak and trou-ble free functioning of the coupling for 50 years, forevery pipe outside diameter within the couplingrange.

.6.2 Variofiks ringWhen inserting metal grippers Fiksers inside theVariofleks sealing system is

pgra e to an en - oa res stant sea ng an gr pping ring (Variofiksring). This combination of large-tolerance and end-load resistance makes the 3000 system unique in the world.

22


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Maximum OD or DN tobe connected

Coupling Flangeadaptor

OD (mm) DN (mm) (mm)

OD 110110


24/68

24


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6.8 Angularity 3000 family has on each side anominal angularity at installation of 8 on a flexibleconnection and approximately 4 on a restraint con-nection.

6.9 Temperature 3000 has different parts, whichresist different temperatures.

NBR EPDM

VariosealRESICOAT RT9000 R4FlekscoresMaximum al-lowed for joint

-5 / +50 C+60 C

+70 C-5 / +50 C

0 / 100 C+60 C

+70 C0 / +60 C

6.10 Certified quality

3000 family is both tested inter-nally as well as externally by independent laborato-ries. All performed tests comply with the inter-national standard requirements such as ISO 2531.

25


26/68

506580

100125

150200225250300

MULTI/JOINTtype 3000 & 3007 couplingmaximum allowable working pressure: non-restraint - water up to 25 bar, gas up to 8 bar *

: restraint - water up to 16 bar, gas up to 8 bar *

DN

[mm] 1 [mm]connection

3 [mm]a

[mm]b

[mm]ed

[mm]kg

164186204236264

304354386432490

46-7169-90

84-105104-132132-155

154-192192-232232-257267-310315-356

10095

115110120

120140145170170

4.85.67.29.4

12.0

14.828.633.440.051.5

46-7169-90

84-105104-132132-155

154-192192-232232-257267-310315-356

220-250209-233234-262230-268246-282

242-298297-351342-404354-424356-426

3xM123xM123xM123xM164xM16


506580

100125

150200225250300

DN

[mm] NBR

code

709 307 210709 307 212709 307 214709 307 216709 307 218

709 307 220709 307 224709 307 226709 307 228709 307 232

709 309 214709 309 216709 309 218

709 309 220709 309 224709 309 226709 309 228709 309 232

709 300 210709 300 212709 300 214709 300 216709 300 218

709 300 220709 300 224709 300 226709 300 228709 300 232

EPDM

restraint

type 3007 with Fiksers

non-restraint

type 3000

multi/fikser poly/fikser

restraint


non-restraint

type 3000


709 307 610709 307 612709 307 614709 307 616709 307 618

709 307 620709 307 624709 307 626709 307 628709 307 632

709 309 614709 309 616709 309 618

709 309 620709 309 624709 309 626709 309 628709 309 632

709 300 610709 300 612709 300 614709 300 616709 300 618

709 300 620709 300 624709 300 626709 300 628709 300 632

Note: Multi/Fikser x Poly/Fikser on request

* For detailed information about the PFA (working pressure) please check the user manual

6.11 Products

26


27/68

50x6565x80

80x100100x125100x150

125x150150x200200x225225x250250x300

MULTI/JOINTtype 3100 & 3107 reduced couplingmaximum allowable working pressure: non-restraint - water up to 25 bar, gas up to 8 bar *


DN


3 [mm]a

[mm]b

[mm]ed

[mm]kg

186204236264304

304354386432490

46-7169-9084-105

104-132132-155

132-155154-192192-232232-257267-310

95115110120120

120120145170170

5.56.78.3

11.113.8

14.422.031.936.249.0

242-268242-268232-265238-275276-323

276-322265-321340-398385-424356-426

3xM12/3xM123xM12/3xM123xM12/3xM163xM16/4xM163xM16/4xM16

4xM16/4xM164xM16/6xM206xM20/6xM206xM20/6xM206xM20/8xM20

50x6565x80

80x100100x125100x150

125x150150x200200x225225x250250x300

DN

[mm] NBR

code

709 407 218709 407 220709 407 224709 407 232709 407 236

709 407 238709 407 248709 407 278709 407 282709 407 286

709 409 224709 409 232709 409 236

709 409 238709 409 248709 409 278709 409 282709 409 286

709 400 218709 400 220709 400 224709 400 232709 400 236

709 400 238709 400 248709 400 278709 400 282709 400 286

EPDM

restraint


non-restraint

type 3100


restraint


non-restraint

type 3100


69-9084-105

104-132132-155154-192

154-192192-232232-257267-310315-356

709 407 618709 407 620709 407 624709 407 632709 407 636

709 407 638709 407 648709 407 678709 407 682709 407 686

709 409 624709 409 632709 409 636

709 409 638709 409 648709 409 678709 409 682709 409 686

709 400 618709 400 620709 400 624709 400 632709 400 636

709 400 638709 400 648709 400 678709 400 682709 400 686

Note: Multi/Fikser x Poly/Fikser on request* For detailed information about the PFA (working pressure) please check the user manual

27


28/68

506580

100125150

200200250250300300

MULTI/JOINTtype 3050 & 3057 flange adaptormaximum allowable working pressure: non-restraint - water up to 25 bar, gas up to 8 bar *


DN


3 [mm]a

[mm]b

[mm]ed

[mm]kg

164186204236264304

354354432432490490

46-7169-90

84-105104-132132-155154-192

192-232192-232267-310267-310315-356315-356

10095

115110120120

140140170170170170

5.66.56.58.6

13.014.0

21.721.731.131.140.540.5

50fl/PN1660-65fl/PN16

80fl/PN16100fl/PN16125fl/PN16150fl/PN16

200fl/PN10200fl/PN16250fl/PN10250fl/PN16300fl/PN10300fl/PN16

179-194187-198183-197181-200196-214194-222

224-251224-251260-295260-295283-318283-318

3xM123xM123xM123xM164xM164xM16

6xM206xM206xM206xM208xM208xM20

DN

[mm] NBR

code

709 357 210709 357 212709 357 214709 357 216709 357 218709 357 220

709 357 224709 357 225709 357 228709 357 229709 357 232709 357 233

EPDMrestraint


non-restraint

type 3050


restraint


non-restraint

type 3050


506580

100125150

200200250250300300

--

709 359 214709 359 216709 359 218709 359 220

709 359 224709 359 225709 359 228709 359 229709 359 232709 359 233

709 350 210709 350 212709 350 214709 350 216709 350 218709 350 220

709 350 224709 350 225709 350 228709 350 229709 350 232709 350 233

709 357 610709 357 612709 357 614709 357 616709 357 618709 357 620

709 357 624709 357 625709 357 628709 357 629709 357 632709 357 633

--

709 359 614709 359 616709 359 618709 359 620

709 359 624709 359 625709 359 628709 359 629709 359 632709 359 633

709 350 610709 350 612709 350 614709 350 616709 350 618709 350 620

709 350 624709 350 625709 350 628709 350 629709 350 632709 350 633



28


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50x40fl65x80fl

100x80fl125x100fl125x150fl

225x200fl225x200fl225x250fl225x250fl

MULTI/JOINTtype 3150 & 3157 reduced flange adaptormaximum allowable working pressure: non-restraint - water up to 25 bar, gas up to 8 bar *


DN


3 [mm]a

[mm]b

[mm]ed

[mm]kg

164186236264264

386386386386

46-7169-90

104-132132-155132-155

232-257232-257232-257232-257

10095

115110120

190190130130

5.06.79.1

11.813.2

29.729.727.727.7

40fl/PN1680fl/PN1680fl/PN16

100fl/PN16150fl/PN16

200fl/PN10200fl/PN16250fl/PN10250fl/PN16

185-200198-210196-215197-215276-294

274-301274-301212-239212-239


6xM206xM206xM206xM20

DN

[mm] NBR

code

709 457 208709 457 218709 457 224709 457 232709 457 238

709 457 278

709 457 279709 457 280709 457 281

EPDM

restraint


non-restraint

type 3150


restraint


non-restraint

type 3150


50x40fl65x80fl

100x80fl125x100fl125x150fl

225x200fl

225x200fl225x250fl225x250fl

--

709 459 224709 459 232709 459 238

709 459 278

709 459 279709 459 280709 459 281

709 450 208709 450 218709 450 224709 450 232709 450 238

709 450 278

709 450 279709 450 280709 450 281

709 457 608709 457 618709 457 624709 457 632709 457 638

709 457 678

709 457 679709 457 680709 457 681

--

709 459 624709 459 632709 459 638

709 459 678

709 459 679709 459 680709 459 681

709 450 608709 450 618709 450 624709 450 632709 450 638

709 450 678

709 450 679709 450 680709 450 681

Note: Multi/Fikser x Poly/Fikser on request* For detailed information about the PFA (working pressure) please check the user manual

29


30/68

80100150

MULTI/JOINTtype 3400 & 3407 bendmaximum allowable working pressure: non-restraint - water up to 25 bar, gas up to 8 bar *


DN


3 [mm]a

[mm]b

[mm]ed

[mm]f

[mm]

204236304

84-105104-132154-192

115110120

100125175

291-315246-365417-445

3xM123xM164xM16

DN

[mm] NBR

code

709 477 214709 477 216709 477 220

EPDM

restraint


non-restraint

type 3400


restraint


non-restraint

type 3400


80100150

kg

10.213.626.3

84-105104-132154-192

709 479 214709 479 216709 479 220

709 470 214709 470 216709 470 220

709 477 614709 477 616709 477 620

709 479 614709 479 616709 479 620

709 470 614709 470 616709 470 620

100150

MULTI/JOINTtype 3750 & 3757 T-piecemaximum allowable working pressure: non-restraint - water up to 25 bar, gas up to 8 bar *


DN


3 [mm]a

[mm]b

[mm]ed

[mm]h

[mm]

236304

104-132154-192

110120

169184

400-438412-468

3xM164xM16

DN

[mm] NBR

code

709 507 226709 507 234

EPDM

restrainttype 3757 with Fiksers non-restrainttype 3750


restrainttype 3757 with Fiksers non-restrainttype 3750


100150

104-132154-192

709 509 226709 509 234

709 500 226709 500 234

kg

15.823.7

2 [mm]

80fl80fl

709 507 226709 507 234

709 509 226709 509 234

709 500 226709 500 234

30


31/68

80100

MULTI/JOINTtype 3450 & 3457 1) duckfootmaximum allowable working pressure: non-restraint - water up to 25 bar, gas up to 8 bar *


DN


3 [mm]a

[mm]b

[mm]ed

[mm]f

[mm]

204236

84-105104-132

115110

165167

380-394393-412

3xM123xM16

DN

[mm] NBR

code

709 487 214709 487 216

EPDM

restraint


non-restraint

type 3450


restraint


non-restraint

type 3450


80100

80fl/PN16100fl/PN16

709 489 214709 489 216

709 480 214709 480 216

709 487 614709 487 616

709 489 614709 489 616

709 480 614709 480 616

kg

15.515.6

h1

[mm]

108135

h2

[mm]

180180


* For detailed information about the PFA (working pressure) please check the user manual1)

50x80fl100x80fl

150x100fl

MULTI/JOINTtype 3550 & 3557 1) reduced duckfootmaximum allowable working pressure: non-restraint - water up to 25 bar, gas up to 8 bar *


DN


3 [mm]a

[mm]b

[mm]ed

[mm]f

[mm]

164236304

46-71104-132154-192

100110120

140190169

356-371408-426400-428

3xM123xM124xM16

DN

[mm] NBR

code

709 197 213709 497 224709 497 238

EPDM

restraint


non-restraint

type 3550


restraint


non-restraint

type 3550


50x80fl100x80fl

150x100fl


-709 499 224709 499 238

709 490 213709 490 224709 490 238

kg

12.717.621.1

h1

[mm]

90135160

h2

[mm]

174184180

709 497 613709 497 624709 497 638

-709 499 624709 499 638

709 490 613709 490 624709 490 638

31


32/68

Note: Multi/Fikser x Poly/Fikser on request* For detailed information about the PFA (working pressure) please check the user manual1)

50100150200

MULTI/JOINTtype 3080 & 3087 spigot endmaximum allowable working pressure: non-restraint - water up to 25 bar, gas up to 8 bar *


DN


s [mm]a

[mm]b

[mm]ed

[mm]l

[mm]

164269304354

46-71104-132154-192192-232

100110120140

75120135145

204-219258-277289-317335-362

3xM123xM164xM166xM20

DN

[mm] NBR

code

709 337 210709 337 216709 337 220709 337 229

EPDM

restraint


non-restraint

type 3080


restraint


non-restraint

type 3080


50100150200

kg

3.47.4

11.621.1

63110160200

-709 339 216709 339 220709 339 229

709 330 210709 330 216709 330 220709 330 229

709 337 610709 337 616709 337 620709 337 629

-709 339 616709 339 620709 339 629

709 330 610709 330 616709 330 620709 330 629

80

MULTI/JOINTtype 3180 & 3187 reduced spigot endmaximum allowable working pressure: non-restraint - water up to 25 bar, gas up to 8 bar *


DN


s [mm]a

[mm]b

[mm]ed

[mm]l

[mm]

20484-105 115 120240-254 3xM12

DN

[mm] NBR

code

709 337 224

EPDM

restraint


non-restraint

type 3180


restraint


non-restraint

type 3180


80

110

709 339 224 709 330 224 709 337 624 709 339 624 709 330 624

kg

5.7

32


33/68

5065

80100125

150200225250300

MULTI/JOINTtype 3200 & 3207 end-cap blindmaximum allowable working pressure: non-restraint - water up to 25 bar, gas up to 8 bar *


DN


3 [mm]a

[mm]b

[mm]ed

[mm]kg

164186

204236264

304354386432490

46-7169-90

84-105104-132132-155

154-192192-232232-257267-310315-356

10095

115110120

120140145170170

3.54.1

5.16.57.8

9.618.320.927.134.4

blindblind

blindblindblind

blindblindblindblindblind

115-130145-157

142-156144-163151-169

149-177180-207211-242214-249219-254

3xM123xM12

3xM123xM164xM16


506580

100125

150200225

250300

DN

[mm] NBR

code

709 377 210709 377 212709 377 214709 377 216709 377 218

709 377 220709 377 224709 377 226

709 377 228709 377 232

709 379 214709 379 216709 379 218

709 379 220709 379 224709 379 226

709 379 228709 379 232

709 370 210709 370 212709 370 214709 370 216709 370 218

709 370 220709 370 224709 370 226

709 370 228709 370 232

EPDM

restrainttype 3207 with Fiksers

non-restrainttype 3200


restrainttype 3207 with Fiksers

non-restrainttype 3200


709 377 610709 377 612709 377 614709 377 616709 377 618

709 377 620709 377 624709 377 626

709 377 628709 377 632

709 379 614709 379 616709 379 618

709 379 620709 379 624709 379 626

709 379 628709 379 632

709 370 610709 370 612709 370 614709 370 616709 370 618

709 370 620709 370 624709 370 626

709 370 628709 370 632

5065

80100125

150200225250300

MULTI/JOINTtype 3200 & 3207 1) end-cap threadmaximum allowable working pressure: non-restraint - water up to 25 bar, gas up to 8 bar *


DN


3 [mm]a

[mm]b

[mm]ed

[mm]kg

164186

204236264

304354386432490

46-7169-90

84-105104-132132-155

154-192192-232232-257267-310315-356

10095

115110120

120140145170170

3.54.1

5.16.57.8

9.618.320.927.134.4

115-130145-157

142-156144-163151-169

149-177180-207211-242214-249219-254

3xM123xM12

3xM123xM164xM16



* For detailed information about the PFA (working pressure) please check the user manual1)

33


34/68

506580

100125

150200225250300

506580

100

125150200225250300

506580

100125

150200225250300

506580

100125

150

200225250300

506580

100125

150200

225250300

DN

[mm] NBR

code

709 387 204709 387 209709 387 214

709 387 219709 387 224

709 387 229709 387 234709 387 249709 387 239709 387 244

709 387 205709 387 210709 387 215709 387 220

709 387 225709 387 230709 387 235709 387 250709 387 240709 387 245

709 387 206709 387 211709 387 216709 387 221709 387 226

709 387 231709 387 236709 387 251709 387 241709 387 246

709 387 207709 387 212709 387 217709 387 222709 387 227

709 387 232

709 387 237709 387 252709 387 242709 387 247

709 387 208709 387 213709 387 218709 387 223709 387 228

709 387 233709 387 238

709 387 253709 387 243709 387 248

EPDM

restraint


non-restraint

type 3200


restraint


non-restraint

type 3200


Rp

[inch]

709 389 214

709 389 219709 389 224

709 389 229709 389 234709 389 249709 389 239709 389 244

709 389 215709 389 220

709 389 225709 389 230709 389 235709 389 250709 389 240709 389 245

709 389 216709 389 221709 389 226

709 389 231709 389 236709 389 251709 389 241709 389 246

709 389 217709 389 222709 389 227

709 389 232

709 389 237709 389 252709 389 242709 389 247

709 389 218709 389 223709 389 228

709 389 233709 389 238

709 389 253709 389 243709 389 248

709 380 204709 380 209709 380 214

709 380 219709 380 224

709 380 229709 380 234709 380 249709 380 239709 380 244

709 380 205709 380 210709 380 215709 380 220

709 380 225709 380 230709 380 235709 380 250709 380 240709 380 245

709 380 206709 380 211709 380 216709 380 221709 380 226

709 380 231709 380 236709 380 251709 380 241709 380 246

709 380 207709 380 212709 380 217709 380 222709 380 227

709 380 232

709 380 237709 380 252709 380 242709 380 247

709 380 208709 380 213709 380 218709 380 223709 380 228

709 380 233709 380 238

709 380 253709 380 243709 380 248

709 387 604709 387 609709 387 614

709 387 619709 387 624

709 387 629709 387 634709 387 649709 387 639709 387 644

709 387 605709 387 610709 387 615709 387 620

709 387 625709 387 630709 387 635709 387 650709 387 640709 387 645

709 387 606709 387 611709 387 616709 387 621709 387 626

709 387 631709 387 636709 387 651709 387 641709 387 646

709 387 607709 387 612709 387 617709 387 622709 387 627

709 387 632

709 387 637709 387 652709 387 642709 387 647

709 387 608709 387 613709 387 618709 387 623709 387 628

709 387 633709 387 638

709 387 653709 387 643709 387 648

709 389 614

709 389 619709 389 624

709 389 629709 389 634709 389 649709 389 639709 389 644

709 389 615709 389 620

709 389 625709 389 630709 389 635709 389 650709 389 640709 389 645

709 389 616709 389 621709 389 626

709 389 631709 389 636709 389 651709 389 641709 389 646

709 389 617709 389 622709 389 627

709 389 632

709 389 637709 389 652709 389 642709 389 647

709 389 618709 389 623709 389 628

709 389 633709 389 638

709 389 653709 389 643709 389 648

709 380 604709 380 609709 380 614

709 380 619709 380 624

709 380 629709 380 634709 380 649709 380 639709 380 644

709 380 605709 380 610709 380 615709 380 620

709 380 625709 380 630709 380 635709 380 650709 380 640709 380 645

709 380 606709 380 611709 380 616709 380 621709 380 626

709 380 631709 380 636709 380 651709 380 641709 380 646

709 380 607709 380 612709 380 617709 380 622709 380 627

709 380 632

709 380 637709 380 652709 380 642709 380 647

709 380 608709 380 613709 380 618709 380 623709 380 628

709 380 633709 380 638

709 380 653709 380 643709 380 648

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6.12 User manual MULTI/JOINT 3000 Family

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7 MULTI JOINTXL

For bigger pipes from DN 300 up to and including DN

rance solution with ranges up to 32 mm. This, com-bined with a huge insertion depth and the fact that fittings are completely made of

t e o v ous c o ce w en you are oo ng or ong-lasting quality and reliability.

.1 Sealing rings

has a double conical shape with a triple radius fea-ture, reducing the amount of stress on the gasket.

range sealing system, meaning that when in restingposition, the gasket dimension is exactly in themiddle of the coupling range picture 1 . When thepipe to be connected has an outside diameter whichis in the upper or lower part of the range, the gasket

is slightly stretched, respectively slightly compres-sed.

cture

hese unique features assure a minimum of stressn the gasket, resulting in an expected life expec-

tancy of 50 years.

7.2 Body and glandThe length of the body determines the insertionsdepth or joint gap possible. Because the insertiondepth complies, and even exceeds, the dimensionsgiven in ISO 2531, large joint gaps can be covered.

Secondly the design of the body and gland are suchthat losses in tension, which will occur in time, arecompensated by the flexibility of the ears. The highmodulus of GGG 40 ductile cast iron guarantees asufficient, durable pressure on the rubber ring.

7.3 Performance data

7.3.1 Pressure/performanceAll sizes, all types on all pipe materials:PFA water 10 barPFA gas 4 bar

7.3.2 Insertion depthFor all sizes 200 mm per socket.

7.3.3 Angularity angularity of 4.

7.3.4 Temperature resist different temperatures.

NBR EPDM

RESICOAT RT9000 R4

ax mum alowed for joint

-5 / +50 C+60 C

-5 / +50 C ot ava a e

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350

400450500600

MULTI/JOINTXL type 2500 couplingmaximum allowable working pressure: non-restraint - water 10 bar, gas 4 bar

DN


3 [mm]a

[mm]b

[mm]ed

[mm]kg

551

600653720820

356-380

400-429450-482500-532605-637

240

240240240240

99.0

115.0122.0149.0178.0

356-380

400-429450-482500-532605-637

520

520520520520

8xM16

10xM1610xM1610xM2012xM20

350400450500

600

DN

[mm]code

709 006 200709 006 205709 006 207709 006 210

709 006 215

709 006 600709 006 605709 006 607709 006 610

709 006 615

NBR

non-restraint

EPDM

non-restraint

300x350400x450

500x550

MULTI/JOINTXL type 2600 reduced couplingmaximum allowable working pressure: non-restraint - water 10 bar, gas 4 bar

DN

[mm]b

[mm]ed

[mm]kg

551653

765

240240

240

102.0125.0

160.0

8xM16/8xM1610xM16/10xM16

12xM20/12xM20

300x350400x450500x550

DN

[mm]code

709 007 205709 007 210709 007 215

709 007 605709 007 610709 007 615

NBR

non-restraint

EPDM

non-restraint

1 [mm]connection

3 [mm]a

[mm]

315-337400-429

500-532

520520

520

356-380450-482

548-580


7.1 Products

40


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350x350fl

400x400fl500x500fl600x600fl

MULTI/JOINTXL type 2550 flange adaptormaximum allowable working pressure: non-restraint - water 10 bar, gas 4 bar

DN


3 [mm]a

[mm]b

[mm]ed

[mm]kg

551

600720820

356-380

400-429500-532605-637

240

240240240

77.0

88.0120.0142.0

350fl/PN10


360

360360360

8xM16

10xM1610xM2012xM20

350x350fl400x400fl500x500fl600x600fl

DN

[mm]code

709 008 255709 008 260709 008 264709 008 270

NBR

non-restraint

EPDM

non-restraint

709 008 655709 008 660709 008 664709 008 670

350x300fl450x400fl

550x500fl

MULTI/JOINTXL type 2650 reduced flange adaptormaximum allowable working pressure: non-restraint - water 10 bar, gas 4 bar

DN


3 [mm]a

[mm]b

[mm]ed

[mm]kg

551653

765

356-380450-482

548-580

240240

240

78.094.0

128.0

300fl/PN10400fl/PN10

500fl/PN10

360360

360

8xM1610xM16

12xM20

350x300fl450x400fl550x500fl

DN

[mm]code

709 008 250709 008 262709 008 266

NBR

non-restraint

EPDM

non-restraint

709 008 650709 008 662709 008 666


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7.2 User Manual MULTI/JOINTXL

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WA4013/1107/GB Georg Fischer Waga N.V.2007, printed in the Netherlands

ConnectingMULTI/JOINT

ST-systemDraw-Lock

FGR, Stainless steel couplingsPlast/Joint

Repairing

WAL/V, Bell joint leak clampsMulti/Clamp, Stainless steelrepair clamps

Tapping

Multi/Clamp, threaded / flangedsaddlesMulti/Saddle PlusDrilling device W400

Additional products and spare parts

Street coversInsert stiffenersHydrantsValvesRatchet spanners

Assuring a reliable and safe connection

for dimensions DN25-2800 and allkinds of pipe materialsfor pressure ratings upto and inclu-ding 48 barconnection to pumps, housings andmoreintegration in existing pipelines

Temporary or long term maintenance

of the pipe

for all pipe materials in utility, indus-trial systems, shipbuilding, etc.under pressure or pressurelessrepairunder pressure repair of bell-joints,AC pipes and more

Under pressure or pressureless tapping

to install house connectionsno interruption of supplyfor installations of valves, hydrantsand service lines

The technical data are not binding and notexpressly warranted characteristics of the goods.They are subject to change. Please consult ourGeneral Conditions of Supply.

Georg Fischer Waga N .V.Lange Veenteweg 19, 8161 PA /P.O. Box 290, 8160 AG Epe, the Netherland sT +31 (0) 578 678 378 / F +31 (0) 578 620 [email protected] / www.waga.nl

Product range overview

Georg Fischer Waga N.V. is the jointing technology specialist, of fering a com-plete range of products that have been used in the water & gas market formany years. No matter how complicated your connection problem is, we canoffer you a solution when it comes to:

Local distributor

Georg

W

sadd

Instr

1.

2. 3.

4. 5.

6. 7.

46


47/68

8. 11.

13.

14. 15.

9. 10.

47


48/68



ST-systemDraw-Lock


Repairing

WAL/V, Bell joint leak clampsMulti/Clamp, Stainless steelrepair clamps

Tapping


Additional products and spare partsStreet coversInsert stiffenersHydrantsValvesRatchet spanners



Temporary or long term maintenanceof the pipe

for all pipe materials in utility, indus-trial systems, shipbuilding, etc.under pressure or pressurelessrepairunder pressure repair of b ell-joints,AC pipes and more



The technical data are not binding and notexpressly warranted characteristics of the goods.They are subject to change. Please consult our

General Conditions of Supply.


Lange Veenteweg 19, 8161 PA /P.O. Box 290, 8160 AG Epe, the NetherlandsT +31 (0) 578 678 378 / F +31 (0) 578 620 848

[email protected] / www.waga.nl


Georg Fischer Waga N.V. is the jointing technology specialist, offering a com-plete range of products that have been used in the water & gas market formany years. No matter how complicated your connection problem is, we canoffer you a solution when it comes to:

Local distributor

Georg Fi

Wid

saddle

with inte

ry shu

Instru

1.

2. 3.

4. 5.

6. 7.

48


49/68

8. 10. 12.

14.

16. 17.

9.

15.

11.

49


50/68


Connecting

MULTI/JOINT

ST-systemDraw-Lock


RepairingWAL/V, Bell joint leak clampsMulti/Clamp, Stainless steelrepair clamps

TappingMulti/Clamp, threaded / flangedsaddlesMulti/Saddle PlusDrilling device W400










Georg Fischer Waga N.V.Lange Veenteweg 19, 8161 PA /

P.O. Box 290, 8160 AG Epe, the Netherlan dsT +31 (0) 578 678 378 / F +31 (0) 578 620 [email protected] / www.waga.nl



Local distributor

Georg F

W

saddl

with int

ry shu

Instr

1.

2. 3.

4. 5.

6. 7.

50


51/68

8. 9. 11.

13.

16. 17. 114. 15.

10.

51


52/68

User Manual W400 D

eorg sc er aga . .. . ox ,

T: +31 0 578 678 378 F: +31 0 578 620 848: [email protected] http://www.waga.nlWA4004/0606/GB

218

A1

32 4 5 6 7 8 10 11 12 13 15

6 9 14

1. Scopehis user manual is applicable for the W400 Dr

r ng. e can e equ ppe w t cup rsuitable for all kinds of pipe materials.Usage of the W400 Drilling Device should be capersonne on y.

his user manual is part of the technical handboIt contains information about storage and the uso app cat on. e n ormat on n t s ocumentmore eta e n ormaton on spec c app catonhandbook, which is available on request.

his manual must be read in full before using thre ecte y ncorrect or un ust usage o t s prouture re erence.

2. Description basic machinehe W400 Drilling Device consists of a basic drillin

accessories and adapters can be ordered separat

a ety screw

0 Jointing part

A1 Threaded adapteran re w t tte p ot r

A3 Cup drill

o e saw cutter

A2 709701260 till 261 ole saw mandrel

A1 709702001 till 006 hreaded adapter

x one t screw

18 709703000 atchet

17 709700010 rill shaft

en soc et screw

15 709700005 O-ring709700016 us va ve

craper

12 709700004 O-ring

ear ng us

10 709700002 ointing part

9 700619552 Safety screw

raverse / Feed part

7 709700011 rust bearing

709700012 Spring

ear ng us

4 709700009 Spring load indicator

nap r ng

2 709700008 Clamp parts 1 709700007 Clamp bush

5. Accessories, additional parts and spare parts

52


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54/68


Connecting

MULTI/JOINT

ST-systemDraw-Lock



Tapping







for all pipe materials in utility, indus-trial systems, shipbuilding, etc.

under pressure or pressurelessrepairunder pressure repair of bell-joints,AC pipes and more




Georg Fischer Waga N.V.Lange Veenteweg 19, 8161 PA /P.O. Box 290, 8160 AG Epe, the Netherl andsT +31 (0) 578 678 378 / F +31 (0) 578 620 [email protected] / www.waga.nl



Local distributor

Georg F

The

under

on bell

Instr

54


55/68

1. Check all the parts 2. Cleaning 3. Rinsing 4. Cutting

6. Assembly 7. Mounting segment rings 8. Tighten the leak clamp 9. Setting of the leak cla

Clean and grind the pipe in such

a way that dirt and corrosion are

thoroughly removed. Clean the

area where seal will be appliedand remove all rust and loose or

flaking surface material, material

damages and burs.

Check if all the parts are

supplied.

Remove or hammer in any lead

which may have come out.

Cut the rubber gasket under a

angle of 45 to make sure it fit

the diameter of the pipe (pay

attention: this is a precise job

Assemble the rings close to

the bell joint (the closer, the

better) and tighten the segment

rings to make sure they will keep

the desired diameter.

Line-up all parts and make sure

that the stapled or glued rubber

gasket remains mounted pro-

perly. Install the clamping bolts

and handtighten them.

Tighten the bolts (cross-wise)

keeping the distance between

the segment rings equally at a

torque of 50 Nm.

After tightening the bolts at

50 Nm, gently hammer the rin

closer to the pipe. This will spe

up the setting of the rubber

gasket.

55


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ST-systemDraw-Lock



TappingMulti/Clamp, threaded / flangedsaddlesMulti/Saddle PlusDrilling device W400



Assuring a reliable and safe connectionfor dimensions DN25-2800 and allkinds of pipe materialsfor pressure ratings upto and inclu-ding 48 barconnection to pumps, housings andmoreintegration in existing pipelines







Lange Veentewe g 19, 8161 PA /

P.O. Box 290, 8160 AG Epe, the Netherlands

T +31 (0) 578 678 378 / F +31 (0) 578 620 848

[email protected] / www.waga.nl



Local distributor

Georg Fis

Y

Instruc

56


57/68

1. Check all the parts 3. Cleaning 2. Mark the insertion depth

5. Installation 6. Tighten the nut

Check if all the parts are supplied and if theconfiguration is suitable for the application.Plast/Jointis suitable for:- plastic pipe materials such as: PE, PB

PVC-U, PEX, ABS and PP- 16 bar PFA water- 8 bar MOP gas- temperatures between -5C and +50C

Mark the insertion depth on the pipe(see table at point 9).

- Loosen the nut to the end of the bolt, donot remove the nut.

- Use a suitable lubricant to lubricate thepipe end(s) for an easier installation.

- Insert the pipe into the coupling up to theinsertion depth mark.

Tighten the nut with the following torqueper bolt size:- M12 60 - 100 Nm- M16 80 - 120 Nm- M20 100 - 140 Nm

Clean the pipe end up to the insertion depth:- the sharp edge of the pipe should be

removed by chamfering- for gas applications it is advised to scrape

the pipe with a rotary peeler

7. Integrity test

- In order to check the correct installationof the coupling, test the installationbefore closing the installation site, withat least the intended working pressure.

- The maximum allowable working pres-sure is indicated in PFA (Pression deFonctionnement Admissible). The testpressure should never exceed 1,5 x PFA.

- If the coupling does not perform in accor-dance with the values, the coupling shouldbe removed according to point 8, restartingthe installation from point 2.

This user manual is part of the technical handbook of Georg Fischer Waga N.V., and is distributed with each product. It contains information about the installation and disassembling of the product. The information in this docu-ment is generalized. For higher performances, nuances or more detailed information on specific applications please consult your supplier.

57


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9 Tender Specifications

9.1 Tender specification MULTI/JOINTforuse in water

For large tolerance fittings for use in fluidslike potable water and sewage & waste

water: Georg Fischer WAGA MULTI/JOINT

or equal.

ScopeThis tender specification specifies the requirementsfor large tolerance couplings, flange adaptors andother fittings (hereinafter called mechanical joints),restrained or non-restrained, sized DN 50 up to andincluding DN 300, for conveying fluids like potablewater, waste water and cooling water, suitable for

to be installed under and above ground, and insideand outside buildings. The mechanical joints shall beconstructed in conformity with ISO 2531.

RangesThe mechanical joints shall be suitable for all pipematerials, both metal and non-metal, like PE, PVC,GRP, PB, asbestos cement, copper, steel, galvanizedsteel, stainless steel 304 and 316, grey cast iron,ductile cast iron and concrete. Mechanical jointsshall be designed to cover following pipe outside

diameters per nominal diameter:

DN size Mini-mumrange(mm)

Maxi-mumrange(mm)

Mini-mumlengthcoupling(mm)

Mini-mumlengthflangeadaptor(mm)

5065

80100125150200225250300

4669

84104132154192232267315

7190

105132155192232257310356

220209

234230246242297342354356

179187

183181196194224

260283

Separated bolt sets

Couplings shall have separate bolt sets for eachsocket end, enabling connecting one pipe end at atime and ensuring optimal bolt torque at each pipeend.

Possibility of changing configuration on thespotThe mechanical joint shall offer the possibility ofchanging the configuration from restrained to non-restrained or vice versa at the time of installation, byeither inserting or removing gripping elements onthe spot.

Material specificationsBody & clamp rings: Ductile cast iron in conformity Coating: Coating shall be a RESICOATRT9000R4epoxy powder coating or equal, with a minimumlayer thickness of 250 micron and chemical resis-tance of pH 2 up to pH 13. Coating shall be approvedby an internationally accepted institute for potablewater or other fluids (e.g. WRc, KIWA, DVGW) andshall fulfill the requirements of GSK (Gtegemein-

schaft Schwerer Korrosionsschutz).Bolts, nuts and washers: Bolts, nuts and washersshall be made of stainless steel A2-70 or A4-80.Bolts shall have an anti friction Teflon coating to pre-vent cold-welding due to fretting. Nuts shall be yel-low passivatedRubber gasket: EPDM according to EN 681-1, for thetype WA for cold potable water supply up to 50 C.NBR according to EN 682 (GB) for cold non-potablewater supply, drainage, sewerage and rainwater pi-pes (continuous flow up to 45 C.) with oil resistance.

Gripping elements: Gripping elements shall be madeof stainless steel A4 (AISI 316).Flanges: Flanges shall be constructed in such a way -sions and tolerances comply with EN1092-2. Flangeface shall have concentrical grooves.Pressures:Non-restrained: max. working pressure:25 bar, restrained: max. working pressur

2012 - waga technical manual

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