CEN/TR 15545:2006

SLOVENSKI STANDARD
01-april-2007
Vodilo za uporabo standarda EN 545
Guide to the use of EN 545
Anleitung zur Anwendung der Norm EN 545
Guide d'utilisation de l'EN 545
Ta slovenski standard je istoveten z: CEN/TR 15545:2006
ICS:
23.040.10 Železne in jeklene cevi Iron and steel pipes
23.040.40 Kovinski fitingi Metal fittings
91.140.60 Sistemi za oskrbo z vodo Water supply systems
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

TECHNICAL REPORT
CEN/TR 15545
RAPPORT TECHNIQUE
TECHNISCHER BERICHT
December 2006
ICS 23.040.10; 23.040.40
English Version
Guide to the use of EN 545
Guide d'utilisation de l'EN 545 Anleitung zur Anwendung der Norm EN 545
This Technical Report was approved by CEN on 28 August 2006. It has been drawn up by the Technical Committee CEN/TC 203.
CEN members are the national standards bodies of Austria, Belgium, Cyprus, Czech Republic, Denmark, Estonia, Finland, France,
Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania,
Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre: rue de Stassart, 36  B-1050 Brussels
© 2006 CEN All rights of exploitation in any form and by any means reserved Ref. No. CEN/TR 15545:2006: E
worldwide for CEN national Members.

Contents Page
Foreword.3
1 Scope .4
4.1.4  Materials in contact with water intended for human consumption.4
6.6 Zinc mass .4
7 Performance test methods .5
7.1 Compressive strength of the cement mortar lining .5
7.2 Leak tightness of flexible joints to positive internal pressure.5
7.3 Leak tightness of flexible joints to negative internal pressure.6
7.4 Leak tightness of flexible push-in joints to positive external pressure.6
7.5 Leak tightness of flexible joints to dynamic internal pressure.6
7.6 Leak tightness and mechanical resistance of flanged joints.6
7.7 Leak tightness and mechanical resistance of screwed and welded flanges .6
Annex F (informative)  Quality assurance.7
F.1 Performance tests .7
F.2 Manufacturing process .7
F.2.1 Quality Control.7
F.2.2 Initial performance testing.7
F.2.3 Factory Production Control System.8
F.2.3.1 Organisation.8
F.2.3.2 Control system.8
F.2.3.3. Document control.10
F.2.3.4 Process control.11
F.2.3.5 Inspection and testing .11
F.2.3.6 Non-conforming products .11
Bibliography .12

Foreword
This document (CEN/TR 15545:2006) has been prepared by Technical Committee CEN/TC 203 “Cast iron
pipes, fittings and their accessories”, the secretariat of which is held by AFNOR.
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights. CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights.
EN 545 deals with components of piping systems for water - pipes, fittings and joints – which, together, form
the part of a water network. Each of these components can be manufactured by a different supplier, which is
often the reality; the performances and the tests required by EN 545, although perfectly comprehensive, are
not always formulated with enough accuracy to be easily used in every real situation occurring the market.
In regard to quality assurance, the attestations and certifications of conformity to the standards available on
the markets:
 attestation of compliance to the performance tests;
 certification of conformity of the products of a batch;
 certification of conformity to EN ISO 9001 of the supplier;
 national quality or conformity marks;
 third party certification of conformity of products to a standard,
 self-declaration of conformity to a standard by the supplier for products that he sells,
have different meanings for the customer, who generally needs all products to be fully in compliance with this
standard.
1 Scope
EN 545 specifies the requirements and associated test methods applicable to ductile iron pipes, fittings,
accessories and their joints for the construction of pipelines:
 to convey water (e.g. potable water);
 with or without pressure;
 to be installed below or above ground.
In respect to potential adverse effects on the quality of water intended for human consumption, caused by the
product covered by this standard:
 this standard provides no information as to whether the product may be used without restriction in any of
the member states of the EU or EFTA;
 it should be noted that, while awaiting the adoption of verifiable European criteria, existing national
regulations concerning the use and/or the characteristics of this product remain in force.
This technical report:
— explains in more detail the process of testing for the performance tests;
— explains in more detail the definitions of the different types/levels of attestation to enable customers to
ensure their requirements are fulfilled;
— explains in more detail the ways of certification of conformity with EN 545 for a reliable evaluation of the
performance of the products.
In order to make the use of this Technical Report easier, the clauses of this document refer to the
corresponding clause numbers in EN 545.
4.1.4  Materials in contact with water intended for human consumption
A comprehensive potability regulation concerning components of pipes systems means:
 regulatory obligation ( i.e.: decree, law….);
 technical specifications;
 tests methods to verify the compliance with the technical specifications;
 directory of approved laboratories able to carry out these tests.
st
On October the 1 2005, there was a national regulation in the following countries: Austria, France, Germany,
Italy, Netherlands, Switzerland and United Kingdom.
In all cases, the national regulations remain in force and must be followed.
6.6 Zinc mass
EN 545 states that a rectangular token of known weight per unit area shall be attached longitudinally along the
axis of the pipe before passing through the coating equipment. After zinc coating and trimming, the size of the
token shall be 500 mm x 50 mm. It shall be weighed on a scale having an error limit of ± 0,01g. The mean
mass is then determined in accordance with the remainder of clause 6.6.
As this test can only be carried out in the factory, conformity certification using this test method can only be
acquired and granted in the factory during the manufacturing process and not on a batch of finished products.
7 Performance test methods
7.1 Compressive strength of the cement mortar lining
This test should be carried out using the actual constituents used in the manufacture of the cement mortar for
the pipes. As such the sand, cement and water should be sampled from the dispensing/holding facilities in the
factory. Similarly, the sand/cement/water ratios should be identical to those used in the manufacturing process
(in the case of the sprayed mortar process, these ratios are identical to the ratio in the mortar mixer, whereas
for the centrifugal process, these ratios are those found in the compacted lining after centrifugal spinning).
Third party accreditation can thus only be granted once these strict conditions have been established and it is
for this reason that it is recommended that these tests be only carried out in the factory.
7.2 Leak tightness of flexible joints to positive internal pressure
The test shall be carried out in accordance with clause 7.2 of EN 545 on an assembled joint comprising two
pipe sections, each at least 1 m long. It shall be carried out separately for other components such as fittings if
their socket differs from that of the spun pipes. For such a test a flange-socket fitting (see 8.3.1 of EN 545)
shall be bolted to a flanged pipe of sufficient length to satisfy the requirements of clause 7.2. Tests shall be
carried out on both unrestrained and restrained joints as necessary.
 Short and long term characteristics of the rubber for the gaskets shall be shown to be in compliance with
EN 681-1.
 Relevant designs of socket and gasket throughout all possible tolerance combinations shall:
 ensure leak tightness at minimum compression under shear and/or angular deflection;
 ensure both leak tightness and satisfactory anchorage under shear and/or angular deflection.
 The short and long term characteristics of the rubber for the gaskets shall be shown to be in compliance
with EN 681-1.
 Using an established gasket, the relevant designs of sockets/spigots shall be shown to be compatible
throughout all possible tolerance combinations (see clause 7.2.3) and shall:
 ensure leak tightness at minimum compression under shear and/or angular deflection;
 ensure both leak tightness and satisfactory anchorage (restrained joint) under shear and/or angular
deflection – especially important where different suppliers of pipes/fittings and gaskets are involved.
The following joint parameters are considered vital to the performance of a joint and shall be checked to be in
accordance with the relevant specifications:
 wall thickness;
 external diameter of spigot;
 socket internal functional diameters;
 depth of socket;
 gasket diameters and thicknesses.
7.3 Leak tightness of flexible joints to negative internal pressure
See 7.2
7.4 Leak tightness of flexible push-in joints to positive external pressure
See 7.2
7.5 Leak tightness of flexible joints to dynamic internal pressure
See 7.2
7.6 Leak tightness and mechanical resistance of flanged joints
This test shall be carried out in accordance with clause 7.6 of EN 545 on an assembly comprising two pipes or
fittings with identical flanges, together with a relevant gasket and bolts recommended by the manufacturer. It
is important that rubber gaskets shall be shown to have the short and long term properties as defined in EN
681-1, in particular that the hardness (IRHD) is within specification. Similarly it is important that the
manufacturers jointing instructions are followed for each particular gasket/material in regard to torque values
and lubrication for the bolts. The sealing of flange joints depends on many factors and the manufacturer
should have written specifications for:
 flange joint faces – surface finish, flatness, permissible irregularities;
 flange jointing materials – bolt lengths/grades, recommended gasket materials;
 jointing instructions – bolt torques, lubrication, bolt tightening sequence.
7.7 Leak tightness and mechanical resistance of screwed and welded flanges
This test shall be carried out in accordance with clause 7.7 of EN 545 on an assembly comprising two pipes
with identical flanges together with a relevant gasket and bolts. This test is primarily a strength test for the
weld/screwed connection and as such is very demanding – twice the working pressure (PFA) combined with
four times the design bending moment. The test is carried out on a pipe purposely machined to its minimum
thickness. The pipes must be of sufficient length to allow the imposition of the high bending moment: minimum
6 DN or 4 000 mm, whichever is the smallest. Because the elevated pressures and bending moments, applied
in the test, result in loadings well in excess of normal service, special gaskets and/or bolts may be used for the
test in order to attain the high stress on the weld/screwed connection.
Because this is a specialist test on pipes that can only be welded/screwed by the
...