INSTA_SBC_EN_13589-2_Sep_2009

INSTA SBC EN 13598-2:2009 September 2009

Specific rules for Nordic certification in accordance with EN 13598-2:2009 Plastics piping systems for non-pressure underground drainage and sewerage Unplasticized poly (vinyl chloride) (PVC-U), polypropylene (PP) and polyethylene (PE) Part 2 : Specifications for manholes and inspection chambers in traffic areas and deep underground installations

INSTA SBC EN 13598-2:2009 Specific rules for certification in accordance with EN 13598-2 Foreword EN 13598-2 is a product standard that specifies the definitions and requirements for buried manholes and inspection chambers installed to a maximum depth of 6 m from ground level to the invert of the main chamber and manufactured from unplasticized poly(vinyl chloride) (PVC-U), polypropylene (PP), polypropylene with mineral modifier (PP-MD) or polyethylene (PE). The following modifications are made in this version of this document: Certification licence

References INSTA-CERT GRC EN 13598-2

A clarification regarding ground water depth and ring stiffness for risers are made.

General Rules for the services provided by INSTA-CERT Product certification Plastics piping systems for non-pressure underground drainage and sewerage — unplasticized poly(vinyl chloride) (PVC-U), polypropylene (PP) and polyethylene (PE) — Part 2: Specifications for manholes and inspection chambers in traffic areas and deep underground installations

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INSTA SBC EN 13598-2:2009 1

CONDITIONS FOR CERTIFICATION

The issuing of a certification license requires that the applicant commits himself to follow the ”General Rules for the services provided by INSTA-CERT Product certification” (hereafter INSTA-CERT GRC) and this INSTA SBC and to make sure that the products mentioned fulfils the requirements in EN 13598-2.

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APPLICATION FOR A CERTIFICATION LICENSE

The applicant is free to choose at which certification body, partner of INSTA-CERT, he wants to apply for a licence to be issued. The licence is valid in all 4 countries (Denmark, Finland, Norway and Sweden). The application shall be in writing on a separate form, available at the certification body chosen. The application form should include information concerning the applicant as well as information about dimensions of manholes and inspection chambers. The application shall include: - reports covering type tests (testing and inspection) according to clause 4.1. and description of each component intended to be covered in the certificate. When appropriate, technical specifications or drawings can be used. The type test report or any other test reports should be presented in any of the Nordic languages or in English. the type test report or any other test reports should be presented in any of the Nordic languages or in English. The age of the reports should preferably not exceed two years. - information concerning the material in manholes and inspection chambers stating the name of the manufacturer of raw material and information of the raw material. - If applicable information concerning manufacturer and type of the sealing rings, together with documentation that the sealing ring material meet the requirements in the relevant standard, EN 681-1 or -2, either as a valid accredited certificate or as accredited test reports as required in the standard. - description of the manufacturers internal control system and instructions for quality assurance of relevant product according to clause 4.1.2. - proposal for marking according to clause 5 and Annex B. If the applicant is the seller/importer, the application must be signed also by the manufacturer at the relevant place of production. If the applicant is not the manufacturer it is the responsibility of the applicant to ensure that the manufacturer has valid versions of these specific rules (SBC) and those documents referred to in this SBC.

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CERTIFICATION LICENSE

The certification license can be issued, when the reports from the type testing proves that the requirements in EN 13598-2 and this SBC are fulfilled and other application initiatives according to item 2 are approved. A certification licence covers only one manufacturer and products from one place of production. For a manufacturer extending his scope of certification to another production site with similar products one of the following alternatives may be followed 1. Type testing is carried out by an approved test laboratory according to Tables 13-16, Audit test. A licence may be issued, when the approved results are available for short time tests. 2. The manufacturer carries out a preliminary type test (PTT) according to Tables 13-16, Audit test. The licence may be issued as soon as approved results are available for all tests and manholes or inspection chambers are sent for testing at an approved test laboratory.

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INSTA SBC EN 13598-2:2009 The scopes of certification are chambers and manholes having a minimum depth of 3 m of groundwater above invert of the main chamber and risers with a ring stiffness of ≥ 4 kN/m2. Chambers and manholes are divided in size groups according to Table 1. Table 1 Size groups for chambers and manholes connection pipes. Nominal diameter DN/OD ≥ 110 ≤ 200 > 200 ≤ 500 > 500 ≤ 1000

Nominal diameter DN/ID ≥ 100 ≤ 180 > 180 ≤ 560 > 560 ≤ 1000

Size group 1 2 3

3.1 Grouping for bases: Material and design Riser shaft dimensions and design Flow channel directions Connection size and type (solid, structured-wall) 3.2 Grouping for risers: Dimensions Design Material Stepladders Cones 3.3 Definitions: 3.3.1 Base group Bases produced from the same material, using the same production process, e.g. injection moulding; - having the same riser shaft dimension; - being within the same connection size group - including various flow channel directions - including various joint designs 3.3.2 Flow channel directions The direction of the flow channels between the inlet pipe connection(s) and the outlet pipe connection(s), e.g. straight through, Y, bend. 3.3.3 Connection size The dimensions of the socket(s) and/or spigot(s) integrated in the chamber base for the connection of inlet/outlet waste water carrying pipes. 3.3.4 Joint design Various designs of sockets and or spigots intended to connect solid-wall and/or structured-wall pipes of different plastics or non-plastics materials to the base. 3.3.5 Riser dimension Circular risers: the diameter, wall-construction and material of the riser to be connected to the base. Non-circular risers: The cross sectional dimensions, wall-construction and material of the riser to be connected to the base. 3.3.5 Cone Centric or excentric adaptor allowing connection between the base and riser or riser/telescopic part to the near surface component.

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INSTA SBC EN 13598-2:2009

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TESTING AND INSPECTION

Testing and inspection include:

4.1

type testing and inspection, 4.1 factory production control (BRT, PVT), 4.2 audit testing (AT) and inspection, 4.3 other testing and/or inspection, 4.4 testing and/or inspection at change of production conditions, 4.5

Type testing and inspection

Material in these specific rules means specification of raw material type, additives and their mixture ratios as described in 8.1.1. 4.1.1 Type testing Type testing is carried out on products, which are included in the application and to the extent stated in Tables 2-5. On request by the applicant the type test is carried out by an approved testing laboratory according to Annex A to this SBC. The type test report shall confirm that all requirements are fulfilled with regard to the manholes and inspection chambers. The type test report shall state the designation of material and sealing rings, used in the tested manholes and inspection chambers. Sealing rings, which are not product certified, shall be tested and fulfil all requirements in clause 4.4 in EN 13598-2. 4.1.2 Initial inspection The initial inspection shall be carried out by an approved inspection body according to Annex A to this SBC. The initial inspection forms part of the type test and shall verify that the manufacturers system for quality assurance for relevant products comply with the below notes and clause 4.2.1. Documented routines shall cover: - disposition of responsibility - documentation (manual or document shall refer to INSTA-CERT GRC, SBC and valid standards for actual products and to be found accessible for the personnel in question). - purchase, receiving inspection and stocking of raw material - factory production control - recording of the results from the internal inspection including handling of records in electronic form - deviations and corrective actions - calibration of measuring and testing equipment with traceability to accredited calibrated instruments - final inspection of finished product - handling of finished product (stocking, packaging and delivery) to prevent damages - claims - traceability from products to internal records In case the applicant has a valid INSTA-CERT licence for similar products this shall be taken in consideration when deciding in the extent of initial inspection. At the initial inspection it shall be evaluated if the resources of the manufacturer are sufficient to ensure a satisfactory quality level of the products and to carry out internal testing according to clause 4.2.1.

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INSTA SBC EN 13598-2:2009 4.2

Factory production control

4.2.1 Internal testing The manufacturer is responsible for demonstrating through described procedures and written instructions that INSTA-CERT marked manholes and inspection chambers included in the certification licence fulfil the requirements in EN 13598-2 and this SBC. The internal testing is carried out partly as batch release test, BRT, with the minor extension stated in Tables 7-9, and as process verification test, PVT, carried out according to Tables 10-12. Documentation from the testing should be kept for 5 years. The licensee/manufacturer is responsible for ensuring that the instructions concerning the internal quality inspection is available for the personnel in the language of the manufacturer country concerned. Records of the internal testing shall be signed, dated and available for the external inspector according to clause 4.3.1. The records shall include information of - or traceability to -

Type of raw material Certificate of raw material Recipe identification / designation Batch number Date of production

If the tested manholes and inspection chambers do not fulfil the requirements, the manufacturer/the licensee must immediately initiate the necessary corrective actions to ensure that the products fulfil the requirements, see clause 8.2 batch release tests in this SBC. Sales of defective conformity marked products shall be prevented. 4.3

Audit testing and inspection

Audit testing and inspection of manholes and inspection chambers shall be carried out twice a year by an approved inspection body and testing laboratory according to Annex A to this SBC (see 4.3.3). 4.3.1 Inspection The inspection includes -

review of the manufacturer’s documentation of the internal control according to clause 4.2.1 including inspection of records as well as inspection of the manufacturer’s testing equipment and calibration of measuring and testing equipment used. storage, packing and delivery of final products. In addition also random surveillance of the quality insurance routines is made according to clause 4.1.2. manholes and inspection chambers are sampled from the manufacturer’s stock for testing according to clause 4.3.2.

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INSTA SBC EN 13598-2:2009 4.3.2 Audit testing Testing is carried out according to Tables 13-16 covering manholes and inspection chambers with sizes representative for the manufacturer’s production. All test results shall be documented in a report stating the designation of material and sealing rings used in tested manholes and inspection chambers. Certified sealing rings do not need a separate testing. 4.3.3 Results from inspection and testing If the requirements are not fulfilled the certification body decides, if necessary in consent with the inspection body/test laboratory, which actions shall be taken. Deficiencies in the results of external or internal testing or inspection may cause withdrawal of the right to use the conformity mark until sufficient actions to ensure the quality have been taken. The certification body may additionally increase the number of external inspections for a certain period of time. 4.4

Other testing and inspection

Other control may be carried out under the conditions stated in INSTA-CERT GRC. 4.5

Control at change of material, design or production conditions

The licensee shall inform in advance the certification body of all changes in recipes and production methods. Table 2 describes the extent of the testing, which is caused by the change. The licensee is not allowed to mark any changed product with the conformity mark without a written permission from the certification body.

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MARKING

Manholes and inspection chambers included in the certification licence shall at least be marked with: 1. The conformity mark, see Annex B 2. Information according to EN 13598-2 clause 10 2. If relevant, an assigned identity number Marking according to items 1 to 3 shall be approved by the certification body. Any additional marking shall not be in conflict with the marking according to items 1 to 3.

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FEES

Application- and annual fees according to INSTA-CERT homepage www.insta-cert.com. The costs for type testing and inspection as well as audit testing and inspection shall be paid by the applicant/licensee directly to the inspection body/testing laboratory. Costs related to other kind of testing and/or inspection shall be paid according to the conditions stated in INSTA-CERT GRC.

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REGISTER

Register of approved manholes and inspection chambers according to EN 13598-2 can be found on the INSTACERT homepage www.insta-cert.com.

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INSTA SBC EN 13598-2:2009 8

TESTING EXTENT

8.1

Type testing

Relevant type testing according to Tables 2-6 shall be carried out for each base material used, PVC-U, PP or PE, and when changes in construction, changes in material and/or production method are taking place. Characteristics with given frequency are tested by an approved testing laboratory.

8.1.1

Material specification, PVC-U

For the purpose of this SBC the material specification consists of a recipe/compound which defines types of PVC-U and additives and their dosage level or within an agreed specification in accordance with CEN/TS 14541. The dosage levels of ingredients shall not exceed the tolerance bands given in table 2. If any level exceeds the dosage band or if a type is changed, this variation in formulation constitutes a change in material. Lead stabiliser systems is not included in Table 2 in this SBC since it is not permitted to import and sell lead stabilised PVC products in Denmark and Sweden. In Norway and Finland there is not (yet) a ban, but lead stabilisation are not used in those countries in practice. Table 2

Compound of raw material mixture, PVC-U Component

Type

Range

PVC content

K value: +/- 3 units

X1 = 100 parts

Type of stabilizer or master batch

Ca-Zn

X1: + 25 %

Sn Ca-Sn Other Lubricants

All

X2: + 50 % if X2 < 0,2 X2: + 0,1 part if X2 > 0,2

Fillers

CaCo3

X3: + 6 parts

Others

X4: + 50 %

Impact modifiers

All

X5:+ 1 part

Flow agents

All

X6 + 25 % if X 6 < 2 X6: + 0,5 part if X6 > 2

Pigments

no requirements

Other components

According to manufacturer’s announcement

X7…n: + 25 %

With an agreed specification

< X8

2)

< X9

3)

External reprocessable and recyclable material

1)

External reprocessable and recyclable material

Without an agreed specification

1)

The specifications shall be declared by the manufacturer to the certification body.

2)

See restrictions in standard prEN 13476-1, clause B.2

3)

See restrictions in standard prEN 13476-1, clause B.3

The manufacturer defines the mixture.

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INSTA SBC EN 13598-2:2009 8.1.2

Material specification, PP

For the purpose of this SBC the material specification consists of a recipe/compound having a polypropylene with specific product name (grade) and additives with known dosage level or within an agreed specification in accordance with CEN/TS 14541. Change of colour is not considered as a change of material.

8.1.3

Material specification, PE

For the purpose of this SBC the material specification consists of a recipe/compound having a polyethylene with specific product name (grade) and additives with known dosage level or within an agreed specification in accordance with CEN/TS 14541. Change of colour is not considered as a change of material.

8.2 Characteristics that require type testing Table 3 General Characteristic Reference to clauses and New tables of EN 13598-2

3rd part type testing frequency Change of design

Change of material

Extension (new base group)

Number of test pieces

Number of measurements per test piece

Material

4

Once/material

Once/material

3

1

Durabilty

4

Once/material, one arbitrary base

Once/material, one arbitrary base

1

1

K-value EN 922:1994 Min. 65

Once/ material

Once/ material

1

1

PVC content, table 2

One calculation/ material

One calculation/ material

General (appearance)

5.1

Products used Products used Products used Products used for third part for third part for third part for third part type test type test type test type test

1

1

Colour

5.2

Products used Products used Products used Products used for third part for third part for third part for third part type test type test type test type test

1

1

Dimensions

6.1

Products used Products used Products used Products used for third part for third part for third part for third part type test type test type test type test

1

1

Sealing ring

4.4

Marking

10

Check of documentation Inform Inform certification certification and inspection and inspection body about body the intended about the marking intended marking

1

1

Check of documentation

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INSTA SBC EN 13598-2:2009 Table 4 Bases Characteristic Reference to clauses and tables of EN 13598-2 New

3rd part type testing frequency

Change of design

Structural integrity H > = 3 meter

7, Table 3

Impact resistance, falling object

7, Table 3

Once/base group

Once/base group

Impact resistance, -10 °C, drop test

7, Table 3

Once/base group

Effect of heating, only PVC Mass of rotationmoulded component

8, Table 5

Once/base group

9.2

Change of material

Once/base Once/changed Once/base group, base group, group, primarily primarily primarily straight straight straight through flow through flow through flow channel channel channel

Number of test pieces

Extension (new base group)

Number of measurements per test piece

Once/new base group, primarily straight through flow channel

1

1

Once/base group

Once/new base group

1

1

Once/base group

Once/base group

Once/new base group

1

1

Once/base group

Once/base group

Once/new base group

1

1

1

1

Products used Products used Products used Products used for third part for third part for third part for third part type test type test type test type test

Table 5 Risers, telescopic parts and ladders Characteristic Reference to 3rd part type testing frequency clauses and New Change of Change of Extension tables of design material EN 13598-2 Dimensions of 6.2.2 Once/design Once/new ladder steps, design when relevant

Number of test pieces 1

Number of measurements per test piece 1

Ring stiffness, riser 2 > = 4 kN/m

7, Table 4

Once/size/ type

Once/size/ type

Once/material Once/new size

3

1

Ladder steps Vertical load, when relevant

7, Table 4

Once/design

Once/new design

Once/material

1

1

Ladder steps Horizontal pull out, when relevant

7, Table 4

Once/design

Once/new design

Once/material

1

1

Once/size

Once/size

Once/material Once/new size

min 20

1

Impact resistance riser -10 °C EN 1411 H50 ≥ 1 m Not for > 630

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INSTA SBC EN 13598-2:2009 Table 6 Fitness for purpose Characteristic Reference to 3rd part type testing frequency clauses and New Change of Change of Extension tables of design material EN 13598-2 Tightness 9, Table 6 Once/base Once/base Once/new pipe/base group/joint group/joint base design design group/joint design

Number of test pieces

1

Number of measurements per test piece 1

Tightness riser

9, Table 6

Once/size

Once/size

Once/new size

1

1

Tightness telescopic joint (H > 0,5 m)

9, Table 6

Once/size

Once/size

Once/new size

1

1

Tightness cone

9, Table 6

Once/size

Once/size

Once/new size

1

1

Load bearing capacity cone

9, Table 6

Once/design

Once/new design

1

1

a

Once/material

a

once/cone design using the highest specified load class and the cover solution with the smallest load distribution area as test parameters

8.3

Batch Release Test, BRT

Batch release testing is carried out by the producer and includes determination of the characteristics listed in tables 7-9 with the specified minimum sampling frequencies. A batch may only be released when BRT shows conformity with the requirements of EN 13598-2 and this SBC. If a product is rejected due to any lack of quality stated in Tables 7-9 the batch shall be scrapped or a re-test procedure shall be carried out for the specific character/part of the product that has been rejected. The following procedures shall then be carried out. − The latest product which fulfils all requirements specified in EN 13598-2 shall be traced. Release all products which have been produced before this date and reject the products which have been produced after this date. − Routines for handling deviating products shall be described in the manufacturer’s quality plan. Characteristics of chambers and manholes and minimum sampling frequencies for BRT Table 7 General Characteristic

General (appearance)

Reference to Sampling procedure (minimum sampling) clauses and tables of EN 13598-2 5.1 At start up and change of material and/or colour. Then every 8 h.

Colour

5.2

At start up and change of material and/or colour. Then every 8 h.

Dimensions

6.1

At start up and every 8 h

Marking

10

At start up. Then every 8 h.

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INSTA SBC EN 13598-2:2009 Table 8 Bases Characteristic

Effect of heating, only PVC Mass of rotation-moulded component Tightness pipe/base

Reference to Sampling procedure (minimum sampling) clauses and tables of EN 13598-2 8, Table 5 At start up and every week 9.2 9, Table 6

At start up and every 8 h At the first production of a new connection size

Table 9 Risers, telescopic parts and ladders Characteristic

Dimensions of ladder steps, when relevant Ring stiffness, riser 2 > = 4 kN/m

7, Table 4

Impact resistance riser, 0 °C EN 744 TIR ≤ 10 %

8.4

Reference to Sampling procedure (minimum sampling) clauses and tables of EN 13598-2 6.2.2 At start up and every week. At start up and /week At start up and /week

Process Verification Test, PVT

Process verification testing is carried out by the producer and includes determination of the characteristics listed in table 10-12 with the specified minimum sampling frequencies. For products which have been audit tested in the same period the process verification test does not need to be repeated. If the product does not conform to the requirements in respect of any characteristic in tables 10-12 the retest procedures detailed in the manufacturer’s quality plan shall be performed. If the retest procedure does not show conformity of the product to the requirements, then the process shall be investigated and corrected in accordance with the procedures in the manufacturer’s quality plan. Characteristics and minimum sampling frequencies for PVT Table 10 General Characteristic

Material

Reference to Sampling procedure clauses and (minimum sampling) tables of EN 13598-2 4.1.1, 4.1.2 Once/year/material

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INSTA SBC EN 13598-2:2009 Table 11 Risers, telescopic parts and ladder steps Characteristic

Ladder steps Vertical load, when relevant Ladder steps Horizontal pull out, when relevant

Reference to Sampling procedure clauses and (minimum sampling) tables of EN 13598-2 7, Table 4 Once/design/year 7, Table 4

Once/design/year

Table 12 Fitness for purpose Characteristic

Tightness pipe/base

Reference to Sampling procedure clauses and (minimum sampling) tables of EN 13598-2 9, Table 6 Once/size/2 years

Tightness riser

9, Table 6

Once/size/2 years

Tightness telescopic part > 0,5 m

9, Table 6

Once/design/size/2 years

Tightness cone

9, Table 6

Once/design/size/2 years

8.5

Audit test, AT

Audit testing shall be carried out by the testing laboratory on behalf of the certification body and includes determination of the characteristics listed in table 13-16 with the specified minimum sampling frequencies. Characteristics and minimum sampling frequencies for AT Table 13 General Characteristic

Material

Reference to Sampling procedure clauses and (minimum sampling) tables of EN 13598-2 4.1.1, 4.1.2 One material/year

K-value EN 922:1994 Min. 65

Once / year / material (check of documentation)

PVC content, table 2

Once / year / material (check of recipe)

General (appearance)

5.1

Products selected for AT

Colour

5.2

Products selected for AT

Dimensions

6.1

Products selected for AT

Sealing ring

4.4

Check of documentation

Marking

10

Products selected for AT

a) To be tested in pipe form.

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INSTA SBC EN 13598-2:2009 Table 14 Bases Characteristic

Structural integrity H > = 3 meter

Reference to Sampling procedure clauses and (minimum sampling) tables of EN 13598-2 7, Table 3 One sample/year, varying base groups

Impact resistance, falling objects

7, Table 3

One sample/base group/year

Impact resistance, -10 °C, drop test

7, Table 3

One sample/base group/year

Effect of heating, only PVC

8, Table 5

One sample/year, varying base groups

Mass of rotationmoulded component

9.2

Products selected for AT

Table 15 Risers, telescopic parts and ladder steps Characteristic

Dimensions steps and ladders, when relevant

Reference to Sampling procedure Reference to (minimum sampling) clauses and tables of EN 13598-2 6.2.2 Products selected for AT

Ring stiffness, riser 2 > = 4 kN/m

7, Table 4

Once/design/year

Ladder steps Vertical load, when relevant

7, Table 4

Once/design/year

Ladder steps Horizontal pull out, when relevant

7, Table 4

Once/design/year

Impact resistance riser -10 °C EN 1411 H≥1m Not for > 630

Once/design/year

Table 16 Fitness for purpose Characteristic

Tightness pipe/base connection

Reference to Sampling procedure clauses and (minimum sampling) tables of EN 13598-2 9, Table 6 One base/year, varying base groups

Tightness riser

9, Table 6

One assembly/year

Tightness telescopic part > 0,5 m

9, Table 6

Once/design/year

Tightness cone

9, Table 6

One assembly/design/year

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ANNEXES

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INSTA SBC EN 13598-2:2009 Annex A Annex B

Body for inspection and testing Nordic marking

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INSTA SBC EN 13598-2:2009 ANNEX A This annex forms part of the Specific Rules.

INSPECTION BODIES AND TESTING LABORATORIES 1

Inspection Body

An inspection body, which fulfils the requirements stated in EN 45 004, shall assess the manufacturer’s internal quality control of his products, which are to be certified/are certified. The certification body is responsible for the evaluation of the inspection body. 2

Testing laboratory

Testing of plastics chambers and manholes for certification in conformity with the requirements in EN 13598-2 and by external control shall be carried out by a testing laboratory accredited according to ISO 17025. The accreditation shall include the testing standards stated in EN 13589-2. 3

Bodies approved for inspection (I) and testing (P): Nemko AS Postboks 73 Blindern NO-0314 Oslo Tel.: + 47 22 96 03 30 Fax: + 47 22 96 05 50

(I)

Inspecta Certification P.O. Box 94 Miestentie 3 FI-02151 Espoo Tel.: +358 10 521 6720 Fax.: +358 10 521 6750

(I)

SP Certifiering Box 857 SE-515 15 Borås Tel.: +46 10 516 50 00 Fax.: +46 10 516 56 10

(I)

DS Certificering Kollegievej 6 DK-2920 Charlottenlund Tel.: +45 72 24 59 00 Fax.: +45 72 24 59 02

(I)

SP-Sveriges Tekniska Forskningsinstitut (P/I) Box 24036 SE-400 22 Göteborg Tel.: + 46 10 516 50 00 Fax: + 46 31 16 12 95

VTT Byggnadsteknik P.O. Box 1000 FI-02044 VTT Tel.: + 358 20 722 111 Fax: + 358 20 722 7001

(P/I)

FORCE Instituttet Dantest Park Allé 345 DK-2605 Brøndby Tel.: + 45 43 267 000 Fax: + 45 43 267 011

Danish Technological Institute, Industry and Energy (P/I) VA testing and inspection Kongsvang Alle 29 DK-8000 ÅRHUS C Tef.: + 45 72 20 12 10 Fax: + 45 72 20 12 12

(P/I)

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INSTA SBC EN 13598-2:2009

ANNEX B This annex forms part of the Specific Rules.

Below please find the conformity mark for products according to the present INSTA-CERT SBC.

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