Why vitrified clay

The material vitrified clay

Vitrified clay pipes and fittings are produced from the raw materials clay, grog (chamotte) and water. The glaze applied to the products before firing consists of mainly the same basic components plus metallic oxides for colour. During drying at a temperature of approx. 110C most of the water necessary for shaping is extracted. The subsequent firing at temperatures rising up to 1200C creates a completely new material by sintering. This vitrified clay has exceptional properties in respect to chemical resistance, mechanical strength, impermeability and hardness. Highly developed manufacturing and preparation techniques have made it possible to upgrade an already proven product, the consistency is guaranteed by quality control. Vitrified clay pipes are designed for sewers operating on gravity in municipal and industrial applications. The most important properties which might be required for calculation purposes are listed in the following table: Specific weight Bending tensile strength Mohs hardness Modulus of elasticity Coefficient of thermal expansion Thermal conductivity KN/m3 N/mm2 N/mm2 1/K W/m.K 22 15 - 40 8 50.000 5.10-6 1,2

The Standard EN 295

Steinzeug | Keramo pipes and fittings are manufactured to a harmonised European standard EN 295, which specifies requirements for vitrified clay pipes and fittings with flexible mechanical joints for drains and sewers. National reference can still be recognised by two letters indicating the country (e.g. BS EN 295 stands for British Standard EN 295; whereas DIN EN 295 is the translation of EN 295 into the German language). EN 295 consists today of 8 parts : EN 295-1 = Requirements EN 295-2 = Quality control & sampling EN 295-3 = Test methods EN 295-4 = Special fittings, adapters, accessories EN 295-5 = Perforated pipes & fittings EN 295-6 = Manholes EN 295-7 = Jacking pipes EN 295-10 = Performance requirements

Quality control

Pipes and fittings meet the requirements of the relevant clauses of EN 295 in all respects. Compliance wit the requirements is monitored and recorded by the internal quality management system to ISO 9001 of each manufacturing plant. Quality supervision may also be carried out by national certification bodies, such as MA39 (Austria), AFNOR (France) BENOR (Belgium) and DIN CERTCO (Germany). Batch test certificates for specific product supplier are provided upon request.

Properties of vitrified clay

Chemical resistance Vitrified clay pipes and fittings to the specification of EN 295 are resistant to chemical attack in a pH-range from 0 - 14. For special circumstances or application, the chemical resistance may be determined by the use of the test in clause 10 of EN 295-3.

Biological induced H2S-corrosion The formation of H2S in sewage is a consequence of the natural biological decomposition of sulphur containing organic and inorganic matter (proteins, sulphates). H2S mainly forms under anaerobic conditions by sulphate reducing bacteria (desulfovibrio desulfuricans) in the slime of a matured sewer and to a lesser extent by bacteriological processes in the sewage. In gravity sewers the formation of H2S commences after the oxygen originally present in the sewage has been consumed by manifold biological processes. This is followed by the anaerobic decomposition with an ever increasing formation of H2S, which slowly escapes into the sewer atmosphere. Turbulence in the sewage stream increases the escape of the gaseous H2S. The formation of H2S is supported by long sewage flows, low flow velocities and high sewage temperatures. The formation of H2S and the oxidation into H2SO by bacteria (e.g. thiobacillus thiooxidans) living on the moist surface of the sewer occurs not only in gravity sewers, but also and more severely in pressure pipe lines, where, due to the absence of an atmosphere, continuously ideal conditions for the sulphate reducing bacteria prevail. The biological induced H2S-corrosion has its effects only above the surface level of the sewage stream, where the sulphuric acid reacts with the lime content of cement-bound pipe materials. On concrete pipes which contain limestone as the aggregate the effects of biological H2S-corrosion show later than on those having quartzistic aggregate. In general a progression in corrosion of concrete sewers having a constant presence of hydrogen sulphide in the sewer atmosphere can be expected with 3 - 6 mm/y. Vitrified clay pipes are immune to sulphuric acid

H 2S H 2S SO4

H2SO 4

Mechanical resistance The mechanical resistance of vitrified clay has developed enormously during the last decades. Nowadays, a vitrified clay pipe up till DN 600 has the same mechanical strength as reinforced concrete pipes from the series 135. Normally, the installation is done on a sand bedding of 90 (EN 295, chapter 2.9). If there is any doubt to this respect, Steinzeug | Keramo offer a static calculation establishing the most economic and reliable installation method, free of charge.

Resistance to high-pressure cleaning The requirement included in the ZPWN 295 standard is met (resistance with regard to a standardized maintenance cleaning test at 120 bar and a deblocking test at 340 bar). Here again, vitrified clay scores considerably better than many other types of material.

Hydraulic capacity Vitrified clay pipes have and hold a smooth inner surface (wall roughness between 0,02 and 0,05 mm). Especially in the case of limited slopes, this offers quite some advantages. Because of the high erosion resistance, vitrified clay can even be used for slopes up to 10 m/sec., without any danger of material deterioration (for concrete e.g. the maximum slope is only 3 m/sec.). See also EN 295, chapter 2.16.

Durability The vitrified life cycle is calculated to be 80 up to 100 years (LAWA directive A 250), even in the hardest conditions. Furthermore, vitrified clay is the only material that resists regular rinsing and unclogging by means of high water pressure techniques. This means that vitrified clay pipe canals can be written down over a longer period and that maintenance, renovation and replacement costs can be limited to a much lower level.

High abrasion resistance Vitrified clay has high abrasion resistance, which is equally true for the glaze and the rest of the wall. Abrasion values encountered in the tests are approximately 0,08 mm, which is much lower than the typical abrasion values of 0,2 mm to 0,5 mm after 100 000 load cycles measured using the Darmstadt test as specified in the EN 295 standard or the maximum value of 0,25 mm in the ZPWN1 295 standard. Abrasion does not accelerate even with extended load cycles, such as up to 400 000, in contrast to what is often suggested in data sheets for competitive materials. The depth of abrasion remains limited to 0,3-0,8 mm after 400 000 cycles. Compared with the large wall thicknesses of vitrified clay jacking pipes, that represents a negligible loss of wall thickness.
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ZPWN 295 is an internal manufacturer standard of STEINZEUG | KERAMO

Corrosion resistance Vitrified clay material is resistant to all types of chemicals over the entire wall thickness. The resistance of the vitrified clay material and seals is tested using chemicals, including sulphuric acid at pH 0 and NaOH at pH 14, in conformance with EN 295 and ZPWN 295.

Temperature resistance Vitrified clay has a low heat expansion coefficient. Compensating measures are superfluous. In case of sudden temperature shocks, it can be necessary to take protective measures (such as a cold water buffer). In the latter case, or in any case of doubt, you should please contact our technical advisor. See also EN 295, Part I, Chapters 3.8 and 3.9.

Environmental friendly The raw materials for manufacturing vitrified clay pipe are clay and recycled materials from the ceramic industry. Mining of the raw materials and subsequent restoration of a natural environment take place in an environmentally friendly manner. In addition, the environmental impact of manufacturing of vitrified clay is relatively small compared with most other types of sewer materials. The long service life of vitrified clay is an additional decisive factor in this regard. No polluting products are generated at the end of the life cycle.
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Economic consideration The management of domestic and industrial waste water transport, infrastructure and treatment is most often a local government issue. The authority is obliged to pay particular attention to the economic aspects. These include the one-off cost for construction of the sewer line and the operation and maintenance cost (subsequent cost). The cost for construction of a sewer line is determined largely by the location and the type of construction. A line laid through a green field will cost less than a sewer along a major street. In both cases, however, the cost of the pipe material is only a fraction of the entire cost of the project. The operating and maintenance cost are the basis of the charges levied for use of the sewer. These costs represent a constant expense. The calculation of the anticipated magnitude of these expenses is therefore even more important than that of the construction cost. These running costs include: - Capital expenditure - Maintenance - Depreciation - Administration

It can be assumed that the estimated cost for maintenance and administration will be the same for all sewers. With regard to the capital expenditure (interest and amortization) and the rate of depreciation, a different cost must be anticipated, depending on the pipe material. Features such as resistance to corrosion and chemical attack, abrasion, temperature, as well as their impermeability, sewers constructed from vitrified clay have an above-average life-span. The higher cost for interest on the capital required to the purchase of vitrified clay pipes as the chosen material as opposed to cheaper less permanent materials is therefore more than compensated.

Economic viability

Share of pipe material cost in pipe laying

Soil excavation and sheeting 49% Destruction and road re-building 20%

Lowering groundwater level 9%

manholes 11%

Pipe material: Delivery, installation and embedment 11%

Steinzeug | Keramo Paalsteenstraat 36 3500 Hasselt

Service life

Composition of the municipal sewage charges

Source: DUDEY. J., PECHER R., ATV - Survey: Sewage Charges

Products

1. Vitrified clay socket pipes for open trench

The joints It is imperative that tight flexible joints are formed when individual pipes and fittings are assembled to form sewers. The pipe and joint are part of a unique system that together ensures easy assembly, reliability and long service life. For this reason sealing elements are factory installed. Joint L to jointing system F (EN 295) Joint K to jointing system C (EN 295) Joint S to jointing system C (EN 295)
Jointing systems C and F to EN 295

Assemblies These shall remain watertight when tested at internal or external pressures of 5 kPa (0,05 bar) and 50 kPa (0,5 bar). The joint under such internal or external pressure must not show any visible leakage when further be subjected to: Angular deflection: (after 5 mm draw) Nominal size (DN) 100 - 200 250 - 500 600 - 800 > 800 Deflection per meter of deflected pipe length 80 mm 30 mm 20 mm 10 mm

Pipes and fittings of the same jointing system, of the same nominal size and the same pipe class are directly interchangeable. Uniformity of pipe class during installation is a prerequisite. For all applications it must be observed, that joint assemblies are guaranteed to withstand cyclic temperature changes of -10C to +70C and chemical attacks from normal sewage and other harmful effluents in concentrations from pH 0 (sulphuric acid) to pH 14 (caustic soda). Structural design Buried pipe lines can be stressed by backfill and traffic loads. In special applications additional risk may result from temperature influences and internal pressures. Instructions for the calculation of the load bearing capacity of sewers have been published by the Abwassertechnische Vereinigung ((ATV) German Sewage Engineering Society) in ATV-A 127 (Worksheet 127). When carrying out the calculation, a basic distinction must be made between the two available types of pipes. Flexible pipes permit close interactions between load, deformation of the cross section and load distribution. The computation of the likely deformation risk is decisive in the choice of material suitability. Rigid pipes do not deform under load and interaction between deformation and stress distribution do not occur. The stress computation set against the permissible rupture stress is decisive for the suitability. Vitrified clay pipes are rigid pipes.
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Calculating the reserves for stress bearing the identification of the following details is essential: Type of soil, specific weight, angle of internal friction Traffic loads Superimposed loads (e.g. buildings) Designed slope of trench walls Type of trench shoring Trench width at pipe crown Depth of cover Pipe diameter, strength, etc.

The result of the computation gives the factor of safety. In general applications a safety factor of 2,2 is required for vitrified clay pipes. Laying Laying commences at the lowest point of the line. Make sure that socket and spigots are clean, apply the recommended lubricant to the sealing element(s) and push the spigot fully home into the socket manually with the aid of a crowbar and a wooden timber or mechanically with the aid of an approved assembly device. The type of bedding required is determined by a structural analysis. On supplying the necessary details (e.g. type of soil; trench design; loads; life loads; additional loads) we can perform such structural analysis with our recommendations for pipe bedding and pipe strength class free of charge. It is important to ensure that the soil around the base of the pipe is firm. Loose soil should be well compacted mechanically. Soft soil should be removed and replaced by non-cohesive soil. The bed at the base of the trench should be prepared in such a way that the pipe, when laid, is supported along the length of its barrel. Recesses should be formed to accommodate the sockets. In order to avoid point or linear loading vitrified clay pipes should not be laid on stony soil or directly on rock.

Direction of flow

Flexible manhole connections

Tightness: testing with water (W) or air (L) Water test to EN 295 When pipes or pipe sections are tested with water at ambient temperature, the water addition W15 to maintain the pressure of 0,5 bar shall not exceed 0,07 l/m of internal surface without leakage. Water test to EN 1610 The following table contains the values for the permissible water addition (l/m) at an allowance of 0,15 l/m during the test period of 30 minutes.
DN 100 125 150 200 250 300 350 Water addition 0,05 l/m 0,06 l/m 0,07 l/m 0,09 l/m 0,12 l/m 0,14 l/m 0,17 l/m DN 400 450 500 600 700 800 1000 Water addition 0,19 l/m 0,21 l/m 0,24 l/m 0,28 l/m 0,33 l/m 0,38 l/m 0,50 l/m
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Air Test to EN 1610 The air test is a convenient alternative to the usual water test. Pipelines can only be deemed faulty after the unsuccessful completion of a water test. For performing an air test on a line made from Steinzeug | Keramo products, we recommend the following procedure: - Apply a pressure equivalent to 100 mbar (ensure adequate safety measures are implemented) - Observe the period for the air test with an intitial pressure approximately 10% in excess of the required test pressure of pO to settle 5 min. for DN 500; DN/100 in min. for > DN 500 - During the following test periods the air pressure must not drop more than 15 mbar
DN 100 125 150 200 250 300 350 Test period 3,0 min. 3,0 min. 3,0 min. 3,0 min. 3,5 min. 4,0 min. 5,0 min. DN 400 450 500 600 700 800 1000 Test period 5,5 min. 6,0 min. 7,0 min. 8,0 min. 10,0 min. 11,0 min. 14,0 min.

2. Vitrified clay jacking pipes for pipe jacking or microtunnelling

2.1 Economical and ecological advantages Microtunnelling takes place beneath existing service lines. The safeguarding or diversion of these is either minimal or unnecessary and road surfaces arent damaged. Ability to construct sewers without problems and in a cost-effective manner near buildings or historic areas since settlement of the soil is avoided and expensive trench sheeting is not required. Once jacked, the sewer is bedded in ideal circumstances and thanks to the important wall thickness, can take very high loads. The amount of soil to be excavated, transported and dumped is restricted to the volume of the sewer line. There are important cost advantages in contaminated soils, in water-catchment areas, in soils with a high water table and weak soils. Since the greater part of the work of laying a sewer takes place underground and as the space required at ground level is small, life and commerce can go on virtually undisturbed. Pipe-jacking results in significantly lower lost sales for merchants than the open-trench method of pipe laying, which impairs or prevents access to their businesses. Noise, dirt and smell are minimized. The jacking doesnt depend on weather conditions. As a rule traffic can continue to flow when microtunnelling is being employed since the site facilities in the region of the start shaft can be kept compact and target and intermediate shafts can be covered after construction. Major traffic rerouting due to open-trench construction causes significant amounts of time to be lost due to detoured traffic and time spent on the detour route. That is accompanied by high additional costs in terms of work hours, fuel, road surface wear, environmental damage, accidents, and material damage to vehicles.
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 Microtunnelling will not harm existing vegetation. Roots in the line of the sewer are only cut away in the region of the cross-section of the cutter head. In addition measures to lower the level of the ground water are not needed provided suitable construction techniques are employed. In groundwater collection areas and soils with subsidence risks, pipe-jacking provides additional benefits.

2.2 Additional properties High longitudinal resistance Vitrified clay jacking pipes generally have greater wall thicknesses than corresponding standard vitrified clay sewer pipes. That results in high crown pressure ratings and high resistance to ground and traffic loads. Strength in the length direction is the most important factor for jacking pipes, because they must withstand the high jacking forces necessary to overcome the resistance of the cutting face and the external pipe surface. According to the EN 295 standard, the longitudinal compressive strength of the surfaces that transfer the force between pipe sections must be at least 75 N/mm. Steinzeug | Keramo guarantees a value of at least 100 N/mm. That is higher than the values stated for other types of current jacking material. It allows very high jacking forces to be used, although this capability is only partially utilized in practice. The glazed outer surface of the pipe strongly reduces friction between the pipe and the surrounding soil.

Long service life After being properly installed, vitrified clay pipe requires very little maintenance. As vitrified clay scores very high with respect to all the requirements that must be imposed on sewer pipes, vitrified clay pipes attain very long service lives. The important properties mentioned above do not degrade over time. Thats especially true for jacking pipes, because they are structurally overdesigned for their subsequent use and optimally bedded in the ground.

Jacking under railways Steinzeug | Keramo jacking pipes are manufactured and inspected in accordance with internal and external control procedures. They are described in the EN 295 standard and the ZPWN 295 standard, which contains a number of more severe requirements. Certificates of approval for jacking under railway lines are also available for these vitrified clay pipes. They confirm that the pipes meet the requirements of organizations such as the Deutsche Bundesbahn (German Federal Railways), and the certification process include cyclic tests to demonstrate resistance to fatigue phenomena in the presence of alternating loads.

The couplings DN150: GRP Coupling The coupling consists of glass-fibre reinforced polypropylene. Vitrified clay DN 150 jacking pipes can be connected to Steinzeug | Keramo standard pipes directly with the jacking coupling or via the metal banded M couplings (spigot-spigot).
e bk

d1 d3 dM dk

l1 Direction of jacking

DN200-500: stainless steel coupling type 1 The coupling for pipes in these diameters consists of a contoured stainless steel ring, V4A type EN 1.4571, with an integrated moulded rubber seal. The ring has a high chrome and nickel content and a relatively significant molybdenum content. The packing ring, which transmits the jacking force, is integrated and forms a unit with the moulded sealing ring. For diameters up to DN 300 the packing ring is made from rubber elastomer and for DN 400 - DN 500 from fibreboard. The sealing rubber contours not only guarantee tightness, but ensure full protection from the ingress of soil and groundwater during the jacking.
e bK

Dz for DN 400 to 500 d1 d3 dM dK

packing ring in rubber elastomer for DN 200 to 300, in particle board

l1

Sk Direction of jacking

DN600- 1200: stainless steel coupling type 2 and pre-stressing ring Steinzeug | Keramo jacking pipes DN 600 - DN 1200 are delivered with a stainless steel (V4A type EN 1.4571) coupling with a high chrome and nickel content and a relatively significant molybdenum content. The packing ring for transferring the jacking force is made from particle board and is prefitted to the coupling. A pre-stressing ring is fitted at each spigot end. These rings provide additional protection during transport and in case of relatively poorly controlled steering motions during jacking. At the same time, this has increased the permissible jacking forces.
Profiled ring e bk

Dz d1 dM d3 dk

Particle board

l1

sk

Direction of jacking

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Assemblies These shall remain watertight when tested at internal or external pressures of 5 kPa (0,05 bar) and 50 kPa (0,5 bar). The joint under such internal or external pressure must not show any visible leakage when further be subjected to: Angular deflection (after 5 mm draw) Nominal size (DN) DN 800 > DN 800 Deflection per meter of deflected pipe length 20 10

The joints are tested in accordance with EN 295, which means that they are guaranteed to be leak-tight at 0.5 bar, including the angular deflections and radial loads specified in the standard. They are also tested in accordance with ZPWN 295(1) and ATV A142, with guaranteed leak-tightness at 2.4 bar. Leak-tightness is also tested at an external pressure of 6 bar, which provides a high level of security against penetration of soil slurries and bentonite.

Structural design Steinzeug | Keramo advises on the loads and stresses that occur during and after pipe installation by jacking. Specific advice is given as to the pipe capability regarding all factors. The calculations are done in accordance with the ATV guideline A161. Precisely what stresses will in fact be inflicted relies on the expertise of the contractor. These stresses can depend on the soil type, and also on a series of additional factors that determine the friction on the boring shield and on the pipe body. When jacking the results of the static calculations must be respected. Additional guidelines for the correct execution of jacking work can be found in: - the European standard EN 12889 with the criteria for pre-investigations, design and execution, and a description of tests to be conducted after insertion, - guidelines from the administration granting the commission, - instructions from the designer or the engineering consultancy, - manuals and recommendations from the manufacturer.

Trenchless construction Different methods can be used for the construction of underground sewers. Steinzeug | Keramo publishes a brochure with the principal characteristics and dimensions of the various types of jacking pipes in vitrified clay. This free brochure is available on request. We also offer a checklist in order to make sure that you will not forget anything.

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Keramo Steinzeug N.V. Paalsteenstraat 36 . B-3500 Hasselt

02-008-0308

STEINZEUG Abwassersysteme GmbH Alfred-Nobel-Str. 17 . D-50226 Frechen Telephone +49 22 34 5 07-0 Telefax +49 22 34 5 07-2 07 E-Mail: info@steinzeug.com Internet: www.steinzeug-keramo.com

Telephone +32 11 21 02 32 Telefax +32 11 21 09 44 E-Mail: info@keramo-steinzeug.be Internet: www.steinzeug-keramo.com