CI/Sfb (52.6) AUGUST 2018 VortX Timesaver EEZI-FIT Ensign Cast Iron above and below ground gravity drainage systems • Ensign • EEZI-FIT • Timesaver • VortX Saint-Gobain PAM UK specialises in the manufacture of cast iron above and below ground drainage systems, for Commercial, Public and Residential buildings. LEADING DRAINAGE PRODUCTS We lead markets in the supply of: Across each of these categories • C ast iron soil and rainwater systems, we can provide: n and suspended pipework in basements and • Innovative products and processes o car parks and buried under building drainage • Specialist engineering services i ct • D uctile iron water and sewer pipes, fittings, • Total technical support u valves & couplings & adaptors d • D uctile iron access covers & gratings o r t n I INNOVATION With Saint-Gobain PAM UK and the PAM brand, you can be assured of Quality, Innovation and Technical Expertise at all times. QUALITY ASSURANCE All parts of our operation have audited quality management systems and fully satisfy ISO 9001:2008. The majority of products are third-party assessed and approved against all relevant worldwide regulations and standards. SUSTAINABILITY We continually invest time, energy and expertise to create an extensive range of innovative solutions which are easy to install, simple to joint and simply offer better value for money in terms of total life costs. COMPLETE SERVICE GLOBAL EXPERTISE Complete service integration. Saint-Gobain PAM UK is the UK arm of Saint-Gobain PAM, the international pipelines company, which employs around 9000 people and generates annual sales of £1.2 billion in over 120 countries. Together they form part of the Saint-Gobain group, one of the world’s leading multinational organisations. TECHNICAL SUPPORT With the international support of parent company Saint-Gobain, we are able to offer unrivalled technical support, a total solution approach and unparalleled quality and innovation. A UK-based business, with two foundries and a distribution centre in the Midlands, we combine international reach with local, specific solutions across all of our customers. 2 Contents PAM Services ............................................................................................4 PAM quality assurance .......................................................................5 Why specify cast iron above ground ...........................................6 Why specify cast iron below ground .........................................14 Why specify Ensign ............................................................................15 Section 1 – Ensign Soil 17 EEZI-FIT 38 Section 2 – Ensign Drain 43 Pipes and Fittings – Push-fit Sanitary System Pipes and FIttings Below Above Ground BS EN877 BS EN877 Ground BS EN877 n o i t c u d o r t n I Section 3 55 Section 4 65 Section 5 71 Couplings – Technical Brackets – Technical Connections – Technical Section 6 85 Section 7 95 Section 8 103 Buried Drainage – Technical Specifications CAD & BIM Technical Section 9 – VortX 109 Timesaver – 1 136 Timesaver Soil – 2 170 Roof, Floor and Shower Pipes and FIttings Below Pipes and FIttings Above Drains Ground BS437 Ground BS416 3 PAM services Saint-Gobain PAM is the premier supplier of ductile iron and cast iron products to the UK's key utilities, telecoms, highways, civil engineering, construction and housing companies. We lead markets in the supply of: • Ductile iron water and sewer pipes, fittings, valves & couplings & adaptors • Ductile iron access covers & gratings • Cast iron soil and drainage and rainwater systems n o Across each of these categories we can provide: i t c • Innovative products and processes u • Specialist engineering services d o • Total technical support tr n I With Saint-Gobain PAM UK and the PAM brand, you can be assured of Quality, Innovation and Technical Expertise at all times. Technical advisory service Saint-Gobain PAM offer a comprehensive technical advisory service. The team can provide: • Complete CAD drawing take-off detailing a bill of materials • Installation advice • Site support • T ool-box training Telephone hotline: 01952 262529 Fax: 01952 262592 Email: [email protected] Customer collaboration – special fittings At times – specifiers and installers come across difficult or unusual situations that may require special bespoke fittings. PAM is equipped with 3D printer technology that can provide that solution through collaboration, 3D modelling and sampling – from design to concept to casting approval within one week. For further Information contact the technical department: Telephone: 01952 262529 Email: [email protected] Or liaise with your regional technical sales manager. BIM services PAM UK has been developing its BIM Level 2 libraries in Revit for its ranges of soil and drain products. Contact the PAM UK BIM Manager: Matthew Hassall Telephone hotline: 01952 262561 Includes new Ensign and EEZI-FIT manifolds Mobile: 07815 800304 Coupling rotation added Email: [email protected] All families now have "shared" parameters to ease scheduling Sales enquiries All files are lighter and have been purged Telephone hotline: 0115 930 0861 Fax: 0115 930 0648 Email: [email protected] Customer services team Email: [email protected] Website: www.saint-gobain-pam.co.uk 4 PAM quality assurance Environment Standard BS EN ISO 14001:2004/Licence: EMS83973 Saint-Gobain PAM UK manufacturing sites including Sinclair, at Telford, have been awarded the ‘Manufacturing to Environmental Standards’ accreditation BS EN ISO 14001:2004 which was developed to help manufacturers maintain and improve their management of environmental responsibilities and assist them in ensuring compliance with environmental laws and regulations. Saint-Gobain PAM UK operates Integrated Pollution and Preventative Control (IPPC) regulations and have implemented comprehensive environmental management systems throughout the manufacturing sites. n o i Quality assurance t c u BS EN ISO 9001:2008 – Registered No: FM12908 d o The Ensign System is manufactured under the BS EN ISO 9001: 2008 r Quality Assurance Scheme. Continual checks made throughout the year t n by the BSI inspectorate, ensure that the set standards are maintained. I Product certification BS EN 877:1999 A1:2006 Kitemark KM51733 Ensign is the only cast iron system to be tested and awarded Kitemark approval to the product standard in the UK. (See scope below). Ensign EEZI-FIT has been included in Kitemark certificate KM51733 for sanitary gravity applications and 0.5 bar (accidental static water pressure) performance. BS EN 14366:2004 Ensign and EEZI-FIT have been tested to the criteria laid down in BS EN 14366:2004. Laboratory measurement of noise from waste water installations at the IBP laboratory in Stuttgart. A number of test reports are available. CEMARS Certified Emissions Measurement And Reduction Scheme. Certificate Number 2016053J. CEMARS certification demonstrates the Company's commitment to measuring, managing and reducing greenhouse gas emissions in a robust and credible way. BES6001 Responsible Sourcing of Construction Materials. Kitemark Licence: BES600635 Summary of applicable standards STANDARDS European Standard BS EN 877:1999 This Product Standard applies to cast iron pipework elements used for the construction, normally as gravity pipe systems, of discharge systems for buildings and of drains. The range of nominal diameters extends from DN40 to DN600 inclusive. This standard specifies the requirements for the materials, dimensions and tolerances, mechanical properties, appearance and standard coatings for cast iron pipes, fittings and accessories. It also indicates performance specifications for all components, including joints. It covers, above ground soil, waste, rainwater and buried systems and performance requirements in these applications. Product Standards ISO 6594: International standard for socketless drainage systems in cast iron. BS EN 681/ISO 4633: Specification for elastomeric seals for joints in pipework and pipelines. Codes of Practice Standards BS EN 12056-2: Code of practice for gravity drainage systems inside buildings – sanitary pipework. BS EN 12056-3: Code of practice for gravity drainage systems inside buildings – for drainage of roofs. BS EN 752-1: Code of practice for drain and sewer systems outside buildings. 5 Why specify cast iron above ground Fire safety and comfort The following two concepts are applied as regards to fire safety: 1. Reaction to fire Ensign and EEZI-FIT cast iron drainage systems are manufactured to a harmonised European standard BS EN 877 and as such, since July 2013 are required to be CE marked by law. The CE mark, whilst not a quality standard, n is a self declaration of product performance with the exception of reaction to fire, o which requires a mandatory certificate by independent testing at a recognised i ct Euroclasses fire testing centre. u d A1 – – A summary of the Declaration of Performance (DoP) for the Ensign and EEZI-FIT o ranges is shown on page 99 or available from our website www.saint-gobain- r A2 s1 d1 pam.co.uk. The Ensign and EEZI-FIT ranges were tested by Exova Warringtonfire t n A2 s2 to the requirements of BS EN 13501-1 incorporating: BS EN 1182, BS EN 1716, I s3 BS EN 13823 and achieved A1 Euroclass classification rating. s1 d0 B s2 s3 d1 To support the CE mark Saint-Gobain PAM UK cast iron drainage systems carry the BS Kitemark to the product standard: s1 d0 C s2 d1 • Our system complies with all 27 clauses of the standard s3 • We are periodically audited by BSI s1 d0 D s2 • This gives you the ultimate quality guarantee d1 s3 Many buildings are not protected enough against fire hazards. It means that fire Classes other than E-d2 and F can spread rapidly, destroy the building in a short time and, more importantly, jeopardise the lives of the occupants. When a fire breaks out, the first objective Sub-Class SMOKE production is to slow down its spreading both horizontally and vertically. Drainage systems s1: Low smoke production should be selected so that they restrict the passage of fire and do not feed it. s2: Medium smoke production 2. Fire resistance s3: High smoke production It is a construction component’s ability to withstand fire for a given period of time FLAMING DROPLETS and to retain its serviceability in the event of fire. If a fire breaks out, it is essential sub-classification to prevent any early collapse of the structure, and then to limit the extent of the d0: No flaming droplets damage, so as to ensure that occupants can be evacuated and/or the belongings d1: Flaming droplets that persist will be protected. for less than 10 seconds d2: Flaming droplets Compartmental principles Fire Safety Regulation for buildings is based on compartmental principle. Within a building, a compartment is a fire rated space designed to stop fire spreading for a given period of time. Above ground drainage systems as part of the building services (unless in a protected shaft), will pass through the separating wall/floor and as such must comply with the following: • Building Regulations Approved Doc B • Section 10: Protection of openings and fire stopping • 10.5 openings for pipes in conjunction with Table 14 Multi-storey high rise buildings present several unique challenges not found in traditional low rise buildings – in particular longer egress times and distance, influencing evacuation strategies, considerations for accessibility for the fire department, smoke movement and fire control. The multiple floors of high rise buildings can create the cumulative effect of requiring a great number of people to travel great vertical distances in order to evacuate the building. Ensuring maximum fire protection and minimising the generation of toxic smoke has to be one of the highest priorities for the designer – to safe guard the occupants of the building. Therefore when specifying drainage systems for high rise buildings: 1) Specify non-combustible products wherever possible 2) S pecify products which generate minimal smoke when exposed to fire 3) Specify products which will not feed a fire A1 4) S pecify products that will give the occupants maximum time to evacuate the building Classified 5) Specify products which are classified A1 Cast iron meets these requirements 6 Why specify cast iron above ground Fire safety and comfort Waste water drainage systems and fire stopping requirements Drainage systems passing through structures designed to withstand fire, should not provide open breaches. For a given time, specified in the applicable regulations, they should not allow the passage of fire, smoke, heat or combustion products from one compartment to the other. For plastics, the fire-stopping rule consists in “plugging the hole”. This function n Visit: www.saint-gobain-pam.co.uk is achieved by using fire collars recommended by the manufacturers. Plastic o i materials which are highly sensitive to heat will not withstand the fire, and t c will not remain in place, even in the case of a contained fire. u d As shown by the “Burning Question” laboratory tests in Germany, if the o fire collars are not activated (particularly when installed under the fire r t compartment) they could pose a potential risk for fire to spread downwards n in a multi-storey building. Some types of plastic material (eg. HDPE and I Polypropylene) when exposed to fire generate molten droplets, which could potentially spread a fire down through the building. Cast iron systems Building Regs Doc B states the following: alternative A – non-combustible material; maximum nominal internal diameter up to 160mm; 10.6 – provide a propriety sealing system which has been shown by testing to maintain the fire resistance of the wall, floor or cavity barrier. Our systems require only a simple sealing material such as mortar and therefore reduces the need for a secondary process, such as fitting expensive fire collars thereby reducing installation time, labour and overall cost. Key points for fire-stopping detailed in the building regulations are: 10.17b – all pipes openings should be: kept to as few as possible; and kept as small as practicable; and fire-stopped 10.19 – proprietary fire-stopping and sealing systems (including those designed for service penetrations) which have been shown by test to maintain the fire resistance of the wall/floor include: cement mortar and gypsum-based plaster Saint-Gobain PAM has and will continue to periodically test their cast iron drainage systems with standard mortar penetrations and other solutions in order to understand the potential effect of fire on its integrity, resistance and overall performance. Cast iron drainage systems are robust and have a 4 hour structural integrity so should not collapse causing potential danger to evacuating people or fire fighters. The performance level of fire resistance will be influenced by a number of factors: the pipe diameter, the thickness of the floor or wall, size of the penetration void, material used to seal the void and even the stack configuration through the penetration. Considerations for building design – to insurers A report published to insurers entitled “Modern Methods of Construction and Fire Protection Considerations” by the FPA (Fire Protection Association) detail design guidance. Some objectives noted from Table 1: To minimise the effect of fire on the business; To limit the effect of business interruption; To allow a business to be trading within 24 hours of a fire. The report highlights some essential principles Cast Iron • Use building materials which will not make a significant ü contribution to a fire at any stage of its growth • Design a building's structure to have a resistance to ü collapse or excessive deflection in the event of a fire • Construct a building in such a way as to minimise the ü extent of fire and smoke damage in the event of fire At the time of going to print we recognise that fire safety in buildings and fire testing is under review and it is likely that the performance requirements may be revised. Therefore, if you have any questions our technical team can provide guidance and help you select the right configuration for optimal performance tel: 01952 262529 7 Why specify cast iron above ground Acoustics Noise in buildings is considered to be detrimental to health and the quality of life. Efforts have been made in the last 30 years to attenuate the sounds coming from the street, worsening the perception of the sounds emitted within the buildings. Heat insulation policies aiming at reducing energy consumption will also heighten these perceptions. n o Among the priority criteria in the comparative performances of drainage i materials, acoustic performance is considered to be second only to fire t c safety: cast iron pipe systems have intrinsic acoustic properties. Owing u d to its density and the development in accessories equipment, they offer o outstanding performances. r nt Pipe systems and equipment noise I Noise emitted by waste water pipe systems is classified under the regulation in the equipment noises. Noise originating from pipe systems is due to the sound energy produced by water/air turbulence, but mostly by the mechanical effect of the water-flow on the internal pipe walls. FOCUS Noise and regulations requirements Noise is an energy affecting air pressure and is transmitted through vibration. Sound is measured in decibels (dB) using a nonlinear scale. For noise from equipment apparels, the following categories are identified and measured: • Airborne noise: air vibrations that are propagated. In the case of waste water pipe systems, this noise is mainly heard in the room where the pipe is located. When a material is dense and thick, the pipe walls prevent air transmission; as is the case with cast iron which offers intrinsic acoustic properties • Structure-borne noise: vibration of a building’s structure. This noise will be noticed in rooms adjacent to the pipe. When the noise produced in a pipe is not transmitted by the air, the residual noise is transmitted by structural vibrations. Whilst the mass of the cast iron limits the vibratory level, the junctions and fixing to the building will propagate noise. Objective: dampen the vibrations at the connections with the solid structure BS EN 14366:2004 A new standard introduced to provide manufacturers of all drainage materials with a simple testing criteria (see diagram left). The results recorded should be comparable and allow the specifier to make a more informed choice. Ensign was the first UK drainage system to be tested to this new European Standard, carried out on the complete range of Ensign bracketry, providing independent assessed results. EEZI-FIT has also been tested. Pipe internal diameter (mm) 70-80 100-125 150 Conclusion of tests Upper flow rate (l/s) 1 4 8 All brackets within the Ensign range meet the requirements of BS 8233*. For exceptionally low levels of acoustic performance, the standard ductile iron bracket fitted with an acoustic dampener should be used  (see table on page 9). Comparing systems Please note: When comparing Ensign and EEZI-FIT to alternative systems – ensure comparing the same flow rate, and number or brackets used in the tests (eg. 2). For vertical stacks, Ensign often requires only one bracket per 3 metres, therefore acoustic performance will be even better in this instance. *BS8233 – Code of Practice ‘Sound Insulation and Noise Reduction for Buildings’. 8 Why specify cast iron above ground Acoustics Saint-Gobain PAM’s solutions Vibrations transmitted to the building structure are dampened by installing “sound absorbers” and by combining: • Couplings equipped with elastomer sealing gaskets, which reduce metal to metal contact, and prevent the transmission of vibrations n • If required, rubber lined insulating brackets or for exceptional o performance ductile iron brackets fitted with acoustic dampeners i t c Saint-Gobain PAM conducted a series of comparative tests on airborne u d and structure-borne noises in installation conditions, described by standard o BS EN 14366 at the Fraunhofer Institute for Building Physics in Stuttgart. r t n As all manufacturers of waste water pipe systems apply the standard test I protocol, it allows building project managers to compare their results. Test results for the PAM pipe systems, in accordance with standard BS EN 14366 carried out on 100mm diameter pipes: Waste water systems Ensign and EEZI-FIT – (100mm diameter) wall density 220kg/m2 Flow rate l/s AIRBORNE SOUND STRUCTURE-BORNE SOUND 2.0 4.0 8.0 2.0 4.0 8.0 Ensign pipework fitted with two brackets – iron bracket 45 48 54 27 32 34 EF048 Iron bracket fitted with 45 47 54 5 11 19 acoustic dampener EF048AD Ensign EEZI-FIT system fitted with 45 48 51 23 28 36 two brackets – iron bracket EF048 Iron bracket and dampener 45 48 51 4 9 17 EF048D For test results on 150mm Ensign or further details on the tests, please contact Mike Rawlings on 01952 262502, or email [email protected] For installation guidance on acoustic dampeners see page 70. FOCUS Ensign and EEZI-FIT cast iron silences its rivals This exceptionally low level of noise transmission outperforms any other material by up to 10dB(A) for structure-borne noise and 4-5dB(A) for airborne noise. To put this into perspective, 4-5dB(A) equates to noise x 2, or a plasterboard supplier quotes “in order to increase the sound insulation of a solid partition wall by 4-5dB(A) the mass must be doubled”. Material comparisons – THE DIFFERENCE 20 20 15 15 dB(A)1005 Cast iron0 8DB12-9 HDPE 10(silent) Stainless steel Standard HDPE Cast iron using acoustic brackets EF048AD Ensign avoids the hidden costs When comparing costs of drainage materials, we have always stressed the need to factor in the total installed costs – when it comes to acoustic performance it becomes even more important. Specifying Ensign means there is significantly more opportunity to save money on acoustic insulation and, more importantly, all other systems require a significantly greater amount of insulation to match the performance of Ensign. 9 Why specify cast iron above ground Robustness and mechanical strength Pipe system components must withstand hazards before they reach the job site, such as accidental impact before and during installation, during storage, handling and transit. In service, outdoor exposed pipes may be damaged by accidental impacts or vandalism. Impact strength and crush resistance n o Cast iron is well-known for its robustness. The quality of PAM products is i ensured by careful control of both metal composition and manufacturing t c process. The spinning of pipes in the De Lavaud process, followed by heat u d treatment, gives these products outstanding mechanical properties. o r Key mechanical characteristics required by the standard EN 877 are nt controlled by three tests, carried out on pipes when coming out of the I heat treatment furnace to assess tensile strength, ring crush resistance and hardness. In addition, operators have opted to maintain a further test which gives a good indication of the quality of heat treatment: the guillotine impact test. FOCUS De Lavaud process In this process, a constant flow of molten metal at a perfectly controlled temperature and composition is gradually input into a steel mould rotating at high speed. The external wall of the mould is cooled by circulating water and the evenly distributed molten metal cools on contact with the wall before extraction. The process is characterised by its quick cooling that gives a finer solidification and thus, a more homogeneous metallurgical structure. Heat treatment The spun pipes are placed and rotated in a heat treatment furnace at 950°C and then gradually cooled again. This step is essential to the process as it transforms the cast iron’s metallurgical structure. The reduction of iron carbides and the increase of ferrite content considerably improve the mechanical properties of cast iron and reduce its surface hardness. The graphite of the cast iron resulting from the Saint-Gobain PAM process forms clustered graphite, halfway between lamellar and ductile iron. The pipes PAM pipes BS EN 877 Tensile Strength on samples in MPa (average value) 300 200 min Ring Crush Strength in MPa (average value, DN100 pipes) 470 350 min Brinnell Surface Hardness in HB degree (average value) 205 260 max These results demonstrate: • Greater resistance to impact • Greater resistance to crushing • Easier to cut on site, making it easier to install than other cast iron systems 10