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WSAA Product Appraisal 1611 1

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Iplex Pipelines Australia Pty Ltd PRODUCT APPRAISAL REPORT 1611 Issue 2 Crevet Irontite® Ductile Iron Pipes AS/NZS 2280:2014 Ductile iron pipes and fittings Publication Date: 27 March 2018

WSAA Product Appraisal 1611 Issue 2

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Document History

The following information indicates the changes made to this document.

Date Version

16 February 2011 PA10/08

23 August 2016 Peer Review

28 September 2016 Published

13 February 2018 Client Review Issue 2

26 March 2018 Peer Review

27 March 2018 Published Issue 2

29 July 2018 Published Issue 2_0

Peer Reviewers

Name/Title Organisation Date

Product Appraisal Technical Advisory Group WSAA 28 September 2016

WSAA Expert Panel WSAA 28 September 2016

Peter Pittard, WSAA Consultant WSAA 23 August 2016

Carl Radford, Product Appraisal Manager WSAA 28 September 2016

Peter Pittard, WSAA Consultant WSAA 1 February 2018

Product Appraisal Technical Advisory Group WSAA 26 March 2018

WSAA Expert Panel WSAA 26 March 2018

Carl Radford, Product Appraisal Manager WSAA 27 March 2018


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Overview of WSAA The Water Services Association of Australia (WSAA) is the peak industry body representing the urban water industry. Our members provide water and sewerage services to over 20 million customers in Australia and New Zealand and many of Australia's largest industrial and commercial enterprises. Based around our vision of 'customer driven, enriching life', WSAA facilitates collaboration, knowledge sharing, networking and cooperation within the urban water industry. We are proud of the collegiate attitude of our members which has led to industry-wide approaches to national water issues. WSAA can demonstrate success in the standardisation of industry performance monitoring and benchmarking, as well as many research outcomes of national significance. The WSAA Executive retains strong links with policy makers and legislative bodies and their influencers, to monitor emerging issues of importance to the urban water industry.

WSAA was formed in 1995 as a non-profit organisation to foster the exchange of information between industry, government and the community, and to promote sustainable water resource management. The urban water industry is committed to anchoring its services to customers' values, and to enrich communities where water services have broad economic, environmental and social values. In line with this our main activities focus on four areas:

1. influencing national and state policies on the provision of urban water services and sustainable water resource management

2. promoting debate on environmentally sustainable development and management of water resources and the community health requirements of public water supplies

3. improving industry performance and establishing benchmarks and industry leading practices for water service processes; and

4. fostering the exchange of information on education, training, research, water and wastewater management and treatment and other matters of common interest.

Copyright

This document is copyrighted. Apart from any use as permitted under the Copyright Act 1968, no part of this document may be reproduced or transmitted in any form or by any means, electronically or mechanical, for any purpose, without the express written permission of Water Services Association of Australia Limited. © Copyright 2018 by WATER SERVICES ASSOCIATION of Australia Limited All rights reserved.


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CONTENTS

1 EXECUTIVE SUMMARY ...................................................................................................................... 6 1.1 Recommendations ......................................................................................................................... 6

2 THE APPLICANT ................................................................................................................................. 6 2.1 The Supplier .................................................................................................................................. 6 2.2 The Manufacturer........................................................................................................................... 7

3 THE PRODUCT ................................................................................................................................... 7 4 SCOPE OF THE APPRAISAL .............................................................................................................. 9 5 APPRAISAL CRITERIA ........................................................................................................................ 9

5.1 Quality Assurance Requirements.................................................................................................... 9 5.2 Performance Requirements ............................................................................................................ 9

6 COMPLIANCE WITH APPRAISAL CRITERIA ....................................................................................... 9 6.1 Compliance with Quality Assurance Requirements .......................................................................... 9 6.2 Compliance with Performance Requirements ................................................................................ 10

6.2.1 Ductile iron ............................................................................................................................ 10 6.2.2 Elastomeric joints .................................................................................................................. 10 6.2.3 Linings .................................................................................................................................. 10

6.2.3.1 Cement mortar lining ....................................................................................................... 10 6.2.3.2 Seal coating .................................................................................................................... 10 6.2.3.3 Polyurethane lining .......................................................................................................... 11

6.2.4 Coatings ................................................................................................................................ 11 6.2.5 Polyethylene sleeving ............................................................................................................ 11 6.2.6 Joint deflection ...................................................................................................................... 12 6.2.7 Contact with drinking water .................................................................................................... 12 6.2.8 Flange gaskets ...................................................................................................................... 12

7 FITTING INSTRUCTIONS, TRAINING AND INSTALLATION .............................................................. 12 7.1 Installation instructions ................................................................................................................. 12 7.2 Fittings and flanged Pipe .............................................................................................................. 12 7.3 Tapped Connections .................................................................................................................... 13

8 PRODUCT MARKING ........................................................................................................................ 13 9 PACKAGING AND TRANSPORTATION ............................................................................................. 13 10 PRODUCT WARRANTY................................................................................................................... 14 11 WATER AGENCY EXPERIENCE WITH THE PRODUCT OR FIELD TESTING REPORT................... 14 12 OUTCOMES OF EXPERT PANEL PRODUCT REVIEW.................................................................... 14 13 LIFE EXPECTANCY OF DI PIPE ...................................................................................................... 14

13.1 Linings ....................................................................................................................................... 14 13.2 Coatings .................................................................................................................................... 15

14 FUTURE WORKS ............................................................................................................................ 16 15 DISCLAIMER ................................................................................................................................... 16

15.1 Issue of Report .......................................................................................................................... 16 15.2 Limits on Reliance on Information and Recommendations ........................................................... 17

15.2.1 Disclaimer of liability ............................................................................................................ 17 15.2.3 Need for independent assessment ....................................................................................... 17

15.3 No Updating............................................................................................................................... 18 15.4 No Warranty .............................................................................................................................. 18

APPENDIX A – PRODUCT LITERATURE ............................................................................................. 19 APPENDIX B - QUALITY CERTIFICATIONS ......................................................................................... 24 APPENDIX C - WSA PRODUCT SPECIFICATION ................................................................................ 38


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APPENDIX D - ESTIMATED LIFE EXPECTANCY ................................................................................. 40 APPENDIX E - SUPPLIER CONTACTS................................................................................................. 41


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1 EXECUTIVE SUMMARY Northern Iron & Brass Foundry Pty Ltd (NIBF) and Crevet Pipelines Pty Ltd are subsidiaries of Iplex Pipelines Australia Pty Ltd, which in turn is a member of the Building Products Division of Fletcher Building Ltd.

NIBF is located at 22 Meyer Avenue, Innisfail, Queensland and is the licensee of StandardsMark product certification for ductile iron pipes manufactured to AS/NZS 2280:2014 Ductile iron pipes and fittings. This Issue 2 includes a range of PN 25 ductile iron pipes, an option for a zinc-aluminium-rare-earth alloy coating with a blue coloured finishing layer and an option for polyurethane lining.

Xinxing Ductile Iron Pipes Company Ltd is the manufacturer and Iplex Pipelines Pty Ltd markets the pipe under the trademark Crevet Irontite®. The ductile iron pipes, with spigot and socket elastomeric joints, are manufactured in nominal sizes from DN 300 to DN 750 with PN25 pressure classification, DN 100 to DN 750 with PN 35 classification and DN 100 to DN 750 in Flange Class.

The pipes are either internally lined with general purpose Portland cement mortar (GP), for transport of drinking or recycled water, calcium aluminate cement mortar (CA) or polyurethane (PU) for transport of sewerage and aggressive non-drinking waters with pH >4<12. A bituminous seal coat (SC) is provided on GP cement mortar linings for all pipe sizes up to DN 300 and is optional for sizes larger than DN 300.

The external coating options are metallic zinc (Zn) or zinc-aluminium-rare earth alloy (XINAL 400+), with a two-part epoxy finishing layer; black for zinc coated GP lined pipes, blue for XINAL 400+ GP lined pipes and red for CA or PU lined pipes. Crevet Irontite® ductile iron pipes manufactured by Xinxing are deemed to satisfy the quality assurance and performance requirements of AS/NZS 2280 and WSAA Product Specification WSA PS 200 – Ductile Iron Pipes (CIOD) for Pressure Applications - Water Supply and Sewerage. NOTE: Iplex Pipelines Pty Ltd have a trade facilitation arrangement with the Australia China Metal Corporation Pty Ltd (ACMC) for importing Crevet Irontite® pipes manufactured by Xinxing. ACMC is not a participant in assuring conformance of Crevet Irontite® pipe to technical requirements. ACMC is not joined with Iplex Pipelines or NIBF in this appraisal.

1.1 Recommendations It is recommended that WSAA members, subject to any specific requirements of the member, accept or authorise the Crevet Irontite® range of ductile iron pipes ("Product") for pressure pipelines as detailed in this report, for use in water supply and sewerage applications, subject to any relevant conditions relating to the design, installation and acceptance testing are in accordance with the relevant WSAA Codes and manufacturer’s requirements.

2 THE APPLICANT 2.1 The Supplier Northern Iron & Brass Foundry Pty Limited is a subsidiary of Iplex Pipelines Australia Pty Ltd, which in turn is a member of the Building Products Division of Fletcher Building Ltd.

Iplex Pipelines was established in Australia in 1938 and has grown to become a recognised leader in the supply of pipeline products to the water and gas industries. The company is a wholly owned division of Fletcher Building Ltd with fourteen manufacturing sites located across Australia and New Zealand. Iplex Pipelines has a long established history of supplying pipeline solutions to civil/infrastructure, irrigation, mining and telecommunication customers.


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Crevet is a brand of Iplex Pipelines and Crevet Irontite® is their range of ductile iron pipe. Its range of products include ductile iron pipe and fittings, PVC pipe, valves, hydrants, couplings and other pipeline components.

Northern Iron & Brass Foundry Pty Ltd manufactures a range of ductile iron fittings and other specialty castings at its Innisfail foundry and is the licensee of the StandardsMark Licence for Crevet Irontite® ductile iron pipes, manufactured by Xinxing Ductile Iron Pipes Co Ltd. 2.2 The Manufacturer Xinxing Ductile Iron Pipes Co Ltd is the largest manufacturer of ductile iron pipe in the world with a capability of 1.8 million tonnes per annum. The company exports around 30% of its production to more than 100 countries around the world and boasts a domestic market share of 45%. The pipes may be manufactured at either of two Xinxing pipe plants in China. One is located at Wu’an Town, Handan City, Hebei Province and the other at Huangshi City, Hebei Province.

Xinxing is affiliated to the Chinese State-owned Assets Supervision and Administration Commission of the Chinese State Council. The company was founded in 1971.The registered company trademark is "Xinxing". Further information and company details and capability are provided on the website http://www.xinxingpipes.com.cn.

3 THE PRODUCT This appraisal applies to Crevet Irontite® ductile iron cement mortar lined pipes manufactured to AS/NZS 2280:2014 and as listed on the schedule of certified products. See Appendix B. The pipes are suitable for conveying drinking and recycled water, raw water, bore water, irrigation, slurry and pressure sewerage.

Crevet Irontite® is manufactured in nominal sizes from DN 300 to DN 750 with PN25 pressure classification, DN 100 to DN 750 with PN 35 classification and DN 100 to DN 750 in Flange Class with T-type push-fit elastomeric joints. The effective length is 5.7 metres. The pipes are either internally lined with general purpose Portland cement mortar (GP), for transport of drinking or recycled water, calcium aluminate cement mortar (CA) or polyurethane (PU) for transport of sewerage and aggressive waters with pH >4<12. A bituminous seal coat (SC) is provided on GP cement mortar linings for sizes up to DN 300 and is optional for sizes larger than DN 300. The external coating options are metallic zinc (Zn) or zinc-aluminium-rare earth alloy (XINAL 400+), with a two-part epoxy finishing layer; black for zinc coated GP lined pipes, blue for XINAL 400+ GP lined pipes and red for CA or PU lined pipes.

Flange Class pipe is predominantly used for the manufacture of flanged pipe. Iplex Pipelines offers pipes with end configurations of flange-flange, flange-spigot and flange-socket, manufactured to customer specified lengths up to 5.55 metres long. The Crevet Irontite® ductile iron pipe range is summarised in Table 1 and dimensions detailed in Table 2. Figure 1 depicts a graphic of an Irontite® pipe cross section.


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TABLE 1 IRONTITE® DI PIPE RANGE (SPIGOT-SOCKET)

Nominal Diameter DN Pressure Class

Effective Length

(m)

External Coating Options

Lining Options

300 to 750 PN 25 5.70 Zinc

or

Zinc-Aluminium-Rare Earth Alloy

GP, GP+SC, CA, PU

100 to 300 PN 35 5.70 GP+SC, CA, PU

375 to 750 PN 35 5.70 GP, GP+SC, CA, PU

100 to 750 Flange Class 5.70 GP, GP+SC, CA

TABLE 2 PIPE DIMENSIONS

Nominal diameter DN

PN 25 PN 35 Flange Class Mean

outside diameter

(mm)

Nominal wall

thickness (mm)

Minimum wall

thickness (mm)

Nominal wall

thickness (mm)

Minimum wall

thickness (mm)

Nominal wall

thickness (mm)

Minimum wall

thickness (mm)

100 - - 5 3 7 6 122

150 - - 5 3 8 6 177

200 - - 5 3 8 7 232

225 - - 5.2 3.2 9 7 259

250 - - 5.6 3.6 9 8 286

300 5.2 3.6 6.3 4.3 10 8 345

375 5.4 3.8 7.3 5.3 10 9 426

450 6.2 4.5 8.3 6.3 11 10 507

500 6.8 5.0 9 7 12 10 560

600 7.8 5.9 10.3 8.3 13 11 667

750 9.4 7.3 12.2 10.2 15 13 826

FIGURE 1 – CROSS SECTION OF CREVET IRONTITE® DI PIPE SOCKET WITH LINING AND COATING

Further details of Crevet Irontite® DI pipe, lining options and external pipe coatings are discussed in Clause 6 and provided in product literature in Appendix A.


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4 SCOPE OF THE APPRAISAL This product appraisal covers Crevet Irontite® DI pipe as detailed in Section 3 and listed in the Product Certification Schedule included in Appendix B.

5 APPRAISAL CRITERIA 5.1 Quality Assurance Requirements The WSAA Product Appraisal Technical Advisory Group accepts ductile iron pipes manufactured in compliance with AS/NZS 2280 Ductile iron pipes and fittings and duly certified by means of an ISO Type 5 product certification scheme undertaken by a JAS-ANZ accredited Conformity Assessment Body (CAB) or by an international accreditation system recognised by JAS-ANZ. The manufacturer is generally expected to have a production management and control system that has been duly accredited in accordance with AS/NZS ISO 9001 as a prerequisite to undergoing a product certification audit.

5.2 Performance Requirements Crevet Irontite® (DI) cement mortar lined pipe has been appraised for compliance with AS/NZS 2280:2014/Amdt 1:2015 Ductile iron pipes and fittings. Appraisal criteria are also determined by the WSAA Product Appraisal Technical Advisory Group and regularly reviewed to ensure that the criteria reflect the requirements of WSAA members.

The following Product Specification is also relevant to this application:

WSA PS-200 – Ductile Iron Pipes (CIOD) for Pressure Applications – Water Supply and Sewerage. A copy of the above Product Specification can be found in Appendix C or downloaded from the WSAA website.

6 COMPLIANCE WITH APPRAISAL CRITERIA 6.1 Compliance with Quality Assurance Requirements The following quality assurance certifications have been submitted by Crevet:

• Iplex Pipelines Australia Pty Ltd – ISO9001:2015 Certificate of Registration No. QEC0037 - issued by SAI-Global. Nominated sites include Crevet locations within Australia.

• Northern Iron and Brass Foundry Pty Ltd - ISO 9001:2015 Certificate of Registration No. QEC0104 - issued by SAI-Global.

• Xinxing Ductile Iron Pipes Co Ltd – ISO9001:2008 Certificate No QAC0031001 – issued by Lloyds Register.

• Huangshi Xinxing Pipes Co Ltd – ISO9001:2008 Certificate No QAC0031001/K – issued by Lloyds Register.

• Crownpack Pty Ltd - ISO 9001 Certificate of Registration No 3531 - issued by SCI Qual International.

• Northern Iron and Brass Foundry Pty Ltd - Standards Mark Licence No SMK0950/1 - AS/NZS 2280 - issued by SAI Global.

• Thai Duong Rubber Joint Stock Rubber Company - ApprovalMark No. AMI74510 - AS1646 - issued by ApprovalMark International.

• Thomas Grozier & Son Pty Ltd – WaterMark Certificate of Conformity No. WMKA00103 – BK Lubricant – Issued by SAI-Global.

Refer to Appendix B for copies of primary quality assurance certificates. Copies of certificates not attached are available from WSAA.


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6.2 Compliance with Performance Requirements 6.2.1 Ductile iron AS/NZS 2280 requires DI pipe to conform to a minimum tensile strength of 420 MPa and minimum elongation of 10%. Test results have been submitted to demonstrate compliance.

6.2.2 Elastomeric joints The Crevet Irontite® range of ductile iron pipes incorporate the well-known T-type dual hardness spigot and socket elastomeric joint. The pipes incorporate EPDM “cast iron” gaskets supplied by Hultec and manufactured by Thai Duong, Vietnam, under an AS 1646 ApprovalMark product certification licence.

TABLE 3 ELASTOMERIC SEALS FOR IRONTITE® DI PIPE

Product Description Hardness (IRHD)

Sealing bulb Retaining heel

DN100 to DN750 CI Gasket 55 Shore A ± 3 85 Shore A ± 3

The BK Bactericidal jointing lubricant is supplied by Thomas Grozier & Son Pty Ltd. under WaterMark Licence for compliance with ATS 5200.014-2004 Technical Specifications for plumbing and drainage products – Jointing materials. AS/NZS 2280 Type Test requirements have been submitted for previous editions of this Appraisal and the latest SAI-Global StandardsMark audit report has been submitted to demonstrate compliance. 6.2.3 Linings 6.2.3.1 Cement mortar lining

Crevet Irontite® DI pipes, suitable for the transport of drinking water and recycled water, are cement mortar lined using Type GP Portland cement, complying with AS 3972 General purpose and blended cements.

Pipes suitable for transport of sewerage and aggressive waters with pH >4<12 are cement mortar lined using calcium aluminate cement in compliance with EN 14647 Calcium aluminate cement-composition, specifications and conformity criteria. The materials used for the cement mortar lining are sourced from approved sub-suppliers in China. The cement mortar lining is applied at the manufacturing site by a centrifugal process.

The cement mortar lining thickness for Crevet Irontite® DI pipe is given in Table 4 in compliance with AS/NZS 2280 requirements.

TABLE 4 CML THICKNESS FOR CREVET IRONTITE® DI PIPES TO AS/NZS 2280

DN Nominal (mm) Minimum (mm)

100 to 600 5 3.5

750 6 4.5

6.2.3.2 Seal coating

AS/NZS 2280 provides for seal coating of cement mortar lined DI pipes and fittings subject to compliance with ISO 16132 Ductile iron pipes and fittings – Seal coats for cement mortar linings.


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Iplex Pipelines provides seal coated cement mortar lining on pipes up to DN 300 and offers seal coating as an option for sizes larger than DN 300. The seal coat used is Sika Inertol® BS10, a single component bitumen solution formulated with special fillers and fast-evaporating solvents.

Iplex has submitted Test Report No. XC2962 dated 24/4/09 from CSIRO Manufacturing & Infrastructure Technology Division confirming that the seal coat (Sika Inertol® BS10) complies with the performance test requirements for both short term sealing efficiency and long term durability and routine testing for visual appearance, coating thickness and adhesion, specified in ISO 16132. 6.2.3.3 Polyurethane lining

An alternative polyurethane lining is available for transport of sewerage and aggressive waters with pH >4<12. The lining complies with EN 15655 Ductile iron pipes, fittings and accessories. Internal polyurethane lining for pipes and fittings. Iplex has submitted test certificates from Bureau Veritas to verify that the polyurethane lining conforms to the requirements of EN 15655. 6.2.4 Coatings Crevet Irontite® DI pipe is externally protected with either (a) metallic zinc coating followed by a two-part epoxy resin finishing layer, or (b) 85-15 zinc-aluminium alloy with a rare earth addition (XINAL 400+), followed

by a two-part epoxy resin finishing layer. The coatings are applied by electric arc melting of the zinc or alloy wire sprayed with compressed air on to the ductile iron pipe surface in accordance with ISO 8179-1 Ductile iron pipes, fittings, accessories and valves -External zinc-based coatings. The mean mass of metallic zinc coating applied is 200 g/m2 as specified in AS/NZS 2280. The minimum mass of XINAL 400+ coating applied is 400 g/m2 as specified in EN 545. Iplex Pipelines Australia has submitted Test Report No. XC2960R1 dated 20/5/2010 from CSIRO Manufacturing & Infrastructure Technology Division to demonstrate that the 2-part epoxy coating, H53-01 Part A and H53-01 Part B, has been tested and meets the performance requirements of AS 3750.13:1997 Paints for steel structures - Epoxy primer (two pack). The epoxy finishing layer is coloured black for zinc coated GP lined pipes, blue for XINAL 400+ GP lined pipes and red for CA or PU lined pipes.

Refer to Table 5 for details of the external coatings.

TABLE 5 COATINGS APPLIED TO IRONTITE® DI PIPES

Component Coating material Coating thickness Colour

Metallic Zinc 99.99% Zn Mean mass 200 g/m2 Grey

Zinc-Aluminium-Rare Earth Alloy XINAL 400+

85% Zn 15% Al +rare earth

Minimum mass 400 g/m2 Grey

Epoxy Finishing Layer 2 Part Epoxy Paint to AS/NZS 3750.13 Mean dry film 80 μm

Black for Zn coated GP lined, blue for XINAL 400+ coated GP lined and red for CA and PU lined.

6.2.5 Polyethylene sleeving Polyethylene sleeving is manufactured for Iplex Pipelines by Crownpack Pty Ltd. Crownpack Pty Ltd is a Quality Endorsed Company and holds AS/NZS ISO 9001:2008 Certificate of Registration.


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6.2.6 Joint deflection The elastomeric seal joint deflections recommended by Iplex Pipelines is shown in Table 6 compared to the requirements of AS/NZS 2280.

TABLE 6 ELASTOMERIC SEAL JOINT DEFLECTION

Nominal Size DN AS/NZS2280 Minimum Joint Deflection (degrees)

Irontite Maximum Joint Deflection

100 – 200 3½o 5o

225 – 250 3½o 4o

300 – 375 2½o 4o

450 – 600 2½o 2o

750 1 o 2o

6.2.7 Contact with drinking water AS/NZS 2280 requires all products that are intended for contact with drinking water and recycled water shall comply with AS/NZS 4020 Testing of Products for use in contact with drinking water. Iplex has submitted Test Report No 1518459, dated 21/03/2016, from AMS Laboratories Pty Ltd, to demonstrate AS/NZS 4020 compliance of a DN 100 cement mortar lined ductile iron pipe with 2 part H53-01 epoxy resin coated socket. Iplex has also submitted Test Report No. 1518460, dated 4/2/2016, from AMS Laboratories Pty Ltd, to demonstrate AS/NZS 4020 compliance of a DN 100 Sika Inertol BS10 seal coated ductile iron cement mortar lined pipe. 6.2.8 Flange gaskets Flange gasket materials comply with industry standard WSA-109. Iplex Pipelines supply solid EPDM gaskets 3 mm thick complying with WSA PS 312 Flanged Gaskets and O-rings. For flanges rated at PN 35, 1.5 mm thick fibre gaskets are recommended.

7 FITTING INSTRUCTIONS, TRAINING AND INSTALLATION 7.1 Installation instructions Installation methods for Crevet Irontite® DI pipes are generally in accordance with AS/NZS 2566 Buried flexible pipelines Part 2: ‘Installation’. The standard specifies the requirements for the installation, field testing and commissioning of buried flexible pipelines with structural design in accordance with AS/NZS 2566.1. Iplex Pipelines also offers Crevet Irontite® installer training for pipe layers, at a cost to the contractor, where required.

A product catalogue, Ductile Iron Pipe, Fittings and Accessories, containing product information and handling and installation instructions, as well as structural and hydraulic design tools, are available from the Iplex website at: http://www.iplex.com.au/iplex.php?page=lib&lib=19&sec=195

7.2 Fittings and flanged Pipe A complete range of compatible ductile iron fittings including bends, tees, reducers and connectors etc. and mechanical couplings and repair clamps for maintenance purposes are available from Iplex Pipelines, and other suppliers, in sizes DN 100 to DN 750.


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Crevet Irontite® flanged pipes are manufactured from Flange Class DI pipes. The pipe is cut to the required length and flanges are attached by screwing the pipe and flanges with mating threads. The joints are sealed with an epoxy resin. Flanges comply with either Figure B5 (PN 16) or Figure B6 (PN 35) of AS/NZS 4087 Metallic flanges for waterworks purposes.

7.3 Tapped Connections Crevet Irontite® DI pipe is not recommended for direct tapping and either a tapping band, flanged off take clamp or pre tapped connector, depending on the diameter of the branch, will be required.

Specialist contractors should be used when tapping mains under pressure.

For small diameter service connection off-takes approved tapping bands or pre-tapped connectors should be used.

8 PRODUCT MARKING Crevet Irontite® DI pipes are marked in accordance with AS/NZS 2280. All pipes are permanently and legibly labelled with the following:

• Manufacturers name or mark: CREVET / ACMC / XINXING

• Nominal size: DNxxx

• Pressure classification: PN35

• Standard: AS/NZS 2280

• StandardsMark licence number: aaaaaSMK0950/1

A colour band located on the pipe socket identifies the pipe class. Blue for ‘Flange Class’, Red for PN 35 and Yellow for PN25. See Figure 2.

FIGURE 2 – PIPE MARKED WITH COLOURED BANDS FOR CLASS INDENTIFICATION

9 PACKAGING AND TRANSPORTATION Crevet Irontite® pipes are packaged in the factory to Australian China Metal Corporation (ACMC) standard. The standard requires Crevet Irontite® pipes to be assembled into standard bundle configuration with scalloped timbers in between each layer and timber side supports. The spigot and socket ends are protected from damage using a 6mm thick medium density fibre board. The bundles are secured together using high tensile steel strapping. To protect the pipe's epoxy and zinc coatings from damage, a 75 x 5 mm insertion rubber strip is positioned between the pipe and steel strapping prior to tensioning. The DI pipe packs are transported in containers or stowed for loose cargo discharge and transported to Brisbane. The pipe packs are offloaded and inspected by an


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Iplex Pipelines representative before being transported to the central storage facility located in Brendale, for national distribution via the Iplex distribution centres that are spread strategically around the country. Alternately, where shipment size permits, the containers can be shipped to the nearest port of the project.

FIGURE 3 SHIPPING OF DUCTILE IRON PIPES

Crevet Irontite® DI pipes are packed for road freight on timber bearers to prevent any direct contact with the bottom of the tray. Pipes are secured to the truck with chains/slings to prevent movement during transit. Rubber padding is also used between the chains/slings and outer pipes in the top row for protection against damage.

10 PRODUCT WARRANTY The products are covered by the normal commercial and legal requirements of the Competition and Consumer Act 2010 (Cth), which covers manufacture to the relevant standard, and details of Iplex Pipelines warranty is included in their terms and conditions of sale.

11 WATER AGENCY EXPERIENCE WITH THE PRODUCT OR FIELD TESTING REPORT Ductile Iron pipe has been in common use for many years with most Australian water agencies having utilised the product. Iplex Pipelines introduced Crevet Irontite® pipe in to Australia in 2009 and it has now been used by a large number of Australian Water Agencies. Additional field testing is not proposed for this Appraisal.

12 OUTCOMES OF EXPERT PANEL PRODUCT REVIEW There are no outstanding issues following the expert panel review.

13 LIFE EXPECTANCY OF DI PIPE 13.1 Linings Cement mortar lining is considered to be the default internal protection system for potable and recycled water applications. Seal coating may be applied over cement mortar lining. The intended purpose of a seal coating is to reduce the contact between the cement mortar lining and the contents of the water main, thereby restricting lime leaching and consequent high


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pH levels when conveying soft (i.e. low carbonate alkalinity) water, especially in small diameter pipelines where flow rates are low and residence times are lengthy. AS/NZS 2280 suggests that consideration should be given to the use of seal coatings where the total alkalinity of the water being conveyed is less than 30 mg/L.

Many Australian water utilities specify seal coatings as mandatory for pipes up to and including DN 300. Calcium aluminate cement mortar linings are intended for aggressive water applications and are typically used in gravity and pressure sewerage mediums with pH between 4 and 12. For applications outside of this pH range consideration should be given to polymeric lining systems. Calcium Aluminate Cement is not AS/NZS 4020 compliant and is therefore not suitable for potable water applications.

WSA Technical Note 6 - Guidelines for the use of cement mortar linings in sewerage applications provides details of operating limits for different cements used for the cement mortar lining of DI and steel pipes for sewers. It reviews literature with regard to the use of cement mortar lining for sewerage conveyance and in particular focuses on the prime water chemistry constituents that need to be considered viz. sulphate(SO4), pH, and hydrogen sulphide (H2S) (which can be transformed to sulphuric acid). A copy of WSA Technical Note 6 is available for download from the WSAA website. Polyurethane linings may also be considered for aggressive medium applications.

13.2 Coatings The majority of Australian Water Agencies have adopted a policy of specifying loose polyethylene sleeving (LPS) for all ductile iron pipes as a corrosion protection measure, unless specialised coatings such as polyurethane or polyethylene, for example, are employed. Properly installed LPS provides a high degree of corrosion protection by creating a passive uniform environment around the pipe and limiting oxygen exposure. LPS should be installed in accordance with AS 3681 and only accredited pipe layers trained in the application of sleeving should be utilised.

The need for LPS depends on the type of soil and the required service life of the pipeline. Ductile iron pipes may be buried without extra external protection in soils that are not aggressive. In soils that are aggressive, and where either the time or the cost of soil assessment is prohibitive, LPS is the recommended solution. The application of zinc coatings has not historically been utilised on ductile iron pipes in Australia, although they have been used in Europe for more than 60 years. Zinc coatings are now provided in Australia as a standard offering with 200 g/m2

thickness complete with a finishing layer and are considered to enhance the external corrosion benefits of pipe in buried applications. In some soil applications it is considered acceptable to install zinc coated pipes without polyethylene sleeving. Enhancements to zinc coatings are also available where 85/15 Zinc-Aluminium alloy, copper enhanced Zinc-Aluminium alloy and rare earth element enhanced Zinc-Aluminium alloys are offered with 400 g/m2 thickness complete with a finishing layer. It is reported that these coatings provide improved corrosion protection over standard zinc coating and allows for installation in a wider range of soils, without the need for sleeving. EN 545 nominates that DI pipes with zinc coating of 200 g/m2 thickness and min 100µm thick finishing layer or enhanced zinc alloy coating with 400 g/m2 thickness and min 100µm thick finishing layer can be buried without sleeving except: For Zinc coatings

- soils with a resistivity less than 1500 Ω cm when laid above the water table, or less than 2500 Ω cm when laid below the water table


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- mixed soils i.e. comprising two or more soil natures

- soils with a pH below 6 and a high reserve of acidity

- soils containing refuse, cinders, slags or polluted by wastes or industrial effluents

- areas where there are stray currents

For Zinc-Aluminium or enhanced Zinc-Aluminium alloys

- acidic peaty soils

- soils containing refuse, cinders, slag or polluted by wastes or industrial effluents

- soils below the marine water table with a resistivity lower than 500 Ω cm,

- areas where there are stray currents

EN 545 also advises that evidence of the long-term performance of the above-mentioned solution (e.g. tests and references) should be provided by the manufacturer. It should be noted however that there has been no proven experience or data to support the extrapolation of European experience to Australian conditions and environments. It is considered imperative that testing be undertaken to ensure that the soil environment meets any necessary pre-conditions. Manufacturers should be consulted for life expectancy estimates. Refer to Appendix D for the manufacturers life expectancy estimates for the DI pipe considered in this Appraisal. future works There are no future works items identified for this Appraisal.

14 DISCLAIMER This Product Appraisal Report (Report) is issued by the Water Services Association of Australia Limited on the understanding that: This Report applies to the product(s) as submitted. Any changes to the product(s) either minor or major shall void this Report. To maintain the recommendations of this Report any such changes shall be detailed and notified to the Product Appraisal Manager for consideration and review of the Report and appropriate action. Appraisals and their recommendations will be the subject of continuous review dependent upon the satisfactory performance of products. WSAA reserves the right to undertake random audits of product manufacture and installation. Where products fail to maintain appraised performance requirements the appraisal and its recommendations may be modified and reissued. Appraisal reports will be reviewed and reissued at regular intervals not exceeding five (5) years. The following information explains a number of very important limits on your ability to rely on the information in this Report. Please read it carefully and take it into account when considering the contents of this Report.

Any enquiries regarding this report should be directed to the Program Manager, Carl Radford, Phone: 03 8605 7601 email [email protected]. 14.1 Issue of Report This Report has been published and/or prepared by the Water Services Association of Australia Limited and nominated Project Manager and peer group of technical specialists (the Publishers).


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The Report has been prepared for use within Australia only by technical specialists that have expertise in the function of products such as those appraised in the Report (the Recipients). By accepting this Report, the Recipient acknowledges and represents to the Publisher(s) and each person involved in the preparation of the Report that the Recipient has understood and accepted the terms of this Disclaimer. 14.2 Limits on Reliance on Information and Recommendations 14.2.1 Disclaimer of liability Neither the Publisher(s) nor any person involved in the preparation of the Report accept(s) any liability for any loss or damage suffered by any person however caused (including negligence or the omission by any person to do anything) relating in any way to the Report or the product appraisal criteria underlying it. This includes (without limitation) any liability for any recommendation or information in the Report or any errors or omissions. 14.2.2 Intellectual Property and other rights The Water Services Association of Australia Limited does not undertake any assessment of whether the importation, manufacture, sale or use of the Product the subject of this Report infringes the intellectual property rights or proprietary rights of any person. Recipients of the report should undertake their own assessment of whether (as relevant) the importation, manufacture, sale or use of the relevant Products infringe the intellectual property rights or other proprietary rights of any person. If the Product infringes intellectual property rights or other proprietary rights there is potential for the supply of the Products to be interrupted.

From time to time the Water Services Association of Australia Limited and the other Publishers may receive notice of allegations that the importation, manufacture, sale or use of the Product infringes intellectual property rights or other proprietary rights. The Water Services Association of Australia Limited's policy is to not refer to such allegations in its reports or take any other steps to put Recipients on notice of such allegations, unless and until it is aware that the allegations have been admitted or proved in Court. As such, Recipients acknowledge, agree and accept that the Water Services Association of Australia Limited may have information in its possession about intellectual property rights infringement allegations or other infringement allegations in relation to the Product which are not referred to or disclosed in this Report and which are not otherwise communicated to Recipients.

14.2.3 Need for independent assessment The information and any recommendation contained (expressly or by implication) in this Report are provided in good faith (and subject to the limitations noted in this Report). However, you should treat the information as indicative only. You should not rely on that information or any such recommendation except to the extent that you reach an agreement to the contrary with the Publisher(s).

This Report does not contain all information that a person might require for the purposes of assessing any product discussed or appraised within it (Product). The product appraisal criteria used in preparing this Report may not address all relevant aspects of the Product. Recipients should seek independent evidence of any matter which is material to their decisions in connection with an assessment of the Product and consult their own advisers for any technical information required. Any decision to use the Product should take into account the reliability of that independent evidence obtained by the Recipient regarding the Product.


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Recipients should also independently verify and assess the appropriateness of any recommendation in the Report, especially given that any recommendation will not take into account a Recipient’s particular needs or circumstances. WSAA has not evaluated the extent of the product liability and professional indemnify insurance that the provider of the product maintains. Recipients should ensure that they evaluate the allocation of liability for product defects and any professional advice obtained in relation to the product or its specification including the requirements for product liability and professional indemnity insurance. 14.3 No Updating Neither the Publisher(s) nor any person involved in the preparation of this Report [has] [have] any obligation to notify you of any change in the information contained in this Report or of any new information concerning the Publisher(s) or the Product or any other matter. 14.4 No Warranty The Publisher(s) do[es] not, in any way, warrant that steps have been taken to verify or audit the accuracy or completeness of the information in this Report, or the accuracy, completeness or reasonableness of any recommendation in this Report.


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APPENDIX A – PRODUCT LITERATURE

• Extracts from Product Catalogue

• Additional literature is available at:

http://www.iplex.com.au/iplex.php?page=lib&lib=19&sec=195


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APPENDIX B - QUALITY CERTIFICATIONS Copies of the following Quality Certification Certificates are available for downloading from the WSAA members website.

TABLE B1 IPLEX PIPELINES AUSTRALIA PTY LTD – MANAGEMENT SYSTEMS

Sites: Strathpine, QLD, Chipping Norton, NSW, Thurgoona, NSW, Bohle, QLD, Elizabeth, SA, Reservoir, VIC

Quality Systems Standard ISO 9001:2015

Certification licence no. QEC0037

Certifying agency SAI-Global

First date of certification 3 April 1990

Current date of certification 22 December 2017

Expiry date of certification 9 January 2021

TABLE B2 NORTHERN IRON AND BRASS FOUNDRY PTY LTD

– MANAGEMENT SYSTEMS

22 Meyer Avenue, Innisfail, QLD. 4860


Certification licence no. QEC0104

Certifying agency SAI-Global

First date of certification 10 February 1989

Current date of certification 29 May 2017

Expiry date of certification 2 June 2020

TABLE B3 XINXING DUCTILE IRON PIPES CO LTD– MANAGEMENT SYSTEMS

Wu’an Town, Hebei Province, China


Certification licence no. QAC0031001

Certifying agency Lloyds Register

First date of certification 3 July 2003

Current date of certification 1 August 2015

Expiry date of certification 31 July 2018


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TABLE B3 HUANGSHI XINXING PIPES CO LTD– MANAGEMENT SYSTEMS

169 Xingxialu Street, Huangshi City, Hubei Province, China


Certification licence no. QAC0031001/K

Certifying agency Lloyds Register

First date of certification 15 November 2009

Current date of certification 1 August 2015

Expiry date of certification 31 July 2018

TABLE B4 NORTHERN IRON AND BRASS FOUNDRY PTY LTD

– PRODUCT CERTIFICATION

22 Meyer Avenue, Innisfail, QLD. 4860

Product Standard/Spec. AS/NZS 2280:2014

Certificate No. SMK0950/1

Issuing certification body SAI-Global

First date of certification 25 September 2009

Current date of certification 7 December 2017

Expiry date of certification 24 September 2022


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APPENDIX C - WSA PRODUCT SPECIFICATION


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APPENDIX D - ESTIMATED LIFE EXPECTANCY The following estimated life expectancies have been provided by Iplex. Life expectancy estimates are indicative only and may increase or decrease as a result of the system operating conditions, preventative maintenance programs, operating environment and other geographical and site-specific factors. It should be noted that service life for a pipeline is not necessarily defined as the time to first failure but as the typical service life achievable before major rehabilitation is required.

TABLE D1

ESTIMATED LIFE EXPECTANCY OF DI PIPE – CREVET IRONTITE

COATING AND LINING OPTIONSENVIRONMENT

BENIGN MODERATELY AGGRESSIVE AGGRESSIVE

INTERNAL LINING Portland Cement >100 years >75 years >50 years

Portland Cement + Seal Coat >100 years >75 years >50 years

Calcium Aluminate Cement >100 years >75 years >50 years

EXTERNAL COATING 200g/m² zinc + finishing layer >75 years >50 years >20 years

200g/m² zinc + finishing layer + PE sleeving >100 years >75 years >50 years

400g/m² Zn-Al-RE + finishing layer >100 years >75 years >50 years

400g/m² Zn-Al-RE + finishing layer + PE sleeving >100 years >100 years >75 years


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APPENDIX E - SUPPLIER CONTACTS Iplex National Customer Service Centre Telephone: 13 18 40 Facsimile: 13 18 60 Email: [email protected] New South Wales Sydney Corporate Office Level 4, 68 Waterloo Road Macquarie Park NSW 2113 Locked Bag 3501 North Ryde BC NSW 1670 Sydney Iplex Pipelines Pty Ltd, Crevet Pipelines Pty Ltd Sales, Manufacturing & Distribution 35 Alfred Road Chipping Norton NSW 2170 Private Mail Bag 5 Moorebank NSW 2170 Telephone: (02) 9755 8266 Albury Iplex Pipelines Pty Ltd Sales, Manufacturing & Distribution 31 Terry Court, Thurgoona NSW 2640 P.O. Box 5037 Murray Regional Post Office, NSW 2640 Telephone: (02) 6043 6666 Queensland Brisbane Iplex Pipelines Pty Ltd, Crevet Pipelines Pty Ltd Sales, Manufacturing & Distribution Cnr South Pine & Johnstone Roads Brendale QLD 4500 PO Box 5160 Brendale QLD 4500 Telephone: (07) 3881 9222 Townsville Iplex Pipelines Pty Ltd, Crevet Pipelines Pty Ltd Sales, Manufacturing & Distribution 14 Ronald Court Bohle QLD 4818 Telephone:(07) 4774 5552


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Northern Territory Darwin Iplex Pipelines Pty Ltd, Crevet Pipelines Pty Ltd Sales and Distribution 96B Winnellie Road Winnellie NT 0820 PO Box 39429 Winnellie NT 0821 Telephone: (08) 8947 0466 South Australia Adelaide Iplex Pipelines Pty Ltd, Crevet Pipelines Pty Ltd Sales, Manufacturing & Distribution 169 Philip Highway Elizabeth SA 5112 PO Box 133 Elizabeth SA 5112 Telephone: (08) 8256 2000 Tasmania Launceston Iplex Pipelines Pty Ltd, Crevet Pipelines Pty Ltd Sales & Distribution 244 Georgetown Road Rocherlea TAS 7248 PO Box 42 Mowbray TAS 7248 Telephone: (03) 6326 8031 Victoria Melbourne Iplex Pipelines Pty Ltd, Crevet Pipelines Pty Ltd Sales, Manufacturing & Distribution 7-15 Radford Road Reservoir VIC 3073 PO Box 312 Reservoir VIC 3073 Telephone: (03) 9460 7000 Western Australia Perth Iplex Pipelines Pty Ltd, Crevet Pipelines Pty Ltd Sales, Manufacturing & Distribution 25 King Edward Road Osborne Park WA 6017 PO Box 1194 Osborne Park WA 6917 Telephone: (08) 9340 4888

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Melbourne Office Level 8, 401 Docklands Drive Docklands VIC 3008 Phone: (03) 8605 7666 Sydney Office Level 9, 420 George Street Sydney NSW 2000 GPO Box 915 Sydney NSW 2001 Phone: (02) 9221 5966

www.wsaa.asn.au

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