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 BRITISH STANDARD BS EN
448:1995

Preinsulated bonded
pipe systems for
underground hot
water networks —
Fitting assemblies of
steel service pipes,
polyurethane thermal
Licensed Copy: Akin Koksal, Bechtel Ltd, 12 December 2002, Uncontrolled Copy, (c) BSI

insulation and outer

casing of polyethylene

The European Standard EN 448:1994 has the status of a

British Standard
 BS EN 448:1995

Cooperating organizations

The European Committee for Standardization (CEN), under whose supervision

this European Standard was prepared, comprises the national standards
organizations of the following countries:

Austria Oesterreichisches Normungsinstitut

Belgium Institut belge de normalisation
Denmark Dansk Standard
Finland Suomen Standardisoimisliito, r.y.
France Association française de normalisation
Germany Deutsches Institut für Normung e.V.
Greece Hellenic Organization for Standardization
Iceland Technological Institute of Iceland
Ireland National Standards Authority of Ireland
Italy Ente Nazionale Italiano di Unificazione
Luxembourg Inspection du Travail et des Mines
Netherlands Nederlands Normalisatie-instituut
Norway Norges Standardiseringsforbund
Portugal Instituto Portuguès da Qualidade
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Spain Asociación Española de Normalización y Certificación

Sweden Standardiseringskommissionen i Sverige
Switzerland Association suisse de normalisation
United Kingdom British Standards Institution

This British Standard, having

been prepared under the
direction of the Refrigeration,
Heating and Air Conditioning
Standards Policy Committee,
was published under the
authority of the Standards
Board and comes into effect on Amendments issued since publication
15 March 1995

© BSI 01-2000
Amd. No. Date Comments

The following BSI references

relate to the work on this
standard:
Committee reference RHE/9
Draft for comment 91/71640 DC

ISBN 0 580 23370 7

 BS EN 448:1995

Contents

Page
Cooperating organizations Inside front cover
National foreword ii
Foreword 2
Text of EN 448 3
National annex NA (informative) Committees responsible Inside back cover
National annex NB (informative) Cross-references Inside back cover
Licensed Copy: Akin Koksal, Bechtel Ltd, 12 December 2002, Uncontrolled Copy, (c) BSI

© BSI 01-2000 i
 BS EN 448:1995

National foreword

This British Standard has been prepared under the direction of the Refrigeration,
Heating and Air Conditioning Standards Policy Committee and is the English
language version of EN 448:1994 Preinsulated bonded pipe systems for
underground hot water networks — Fitting assemblies of steel service pipes,
polyurethane thermal insulation and outer casing of high density polyethylene,
published by the European Committee for Standardization (CEN).
EN 448 was produced as a result of international discussion in which the UK took
an active part.
A British Standard does not purport to include all the necessary provisions of a
contract. Users of British Standards are responsible for their correct application.

Compliance with a British Standard does not of itself confer immunity

from legal obligations.
Licensed Copy: Akin Koksal, Bechtel Ltd, 12 December 2002, Uncontrolled Copy, (c) BSI

Summary of pages
This document comprises a front cover, an inside front cover, pages i and ii,
the EN title page, pages 2 to 14, an inside back cover and a back cover.
This standard has been updated (see copyright date) and may have had
amendments incorporated. This will be indicated in the amendment table on the
inside front cover.

ii © BSI 01-2000
 EUROPEAN STANDARD EN 448
NORME EUROPÉENNE
October 1994
EUROPÄISCHE NORM

ICS 23.040.90

Descriptors: Water pipelines, buried pipes, hot water, heating water pipes, pipe fittings, steels, thermal insulation, thermal insulation
materials, polyurethane, polyethylene, specifications, tests, marking

English version

Preinsulated bonded pipe systems for underground hot

water networks —
Fitting assemblies of steel service pipes, polyurethane
thermal insulation and outer casing of polyethylene

Systèmes bloqués de tuyaux préisolés pour Werkmäßig gedämmte

les réseaux enterrés d’eau chaude — Verbundmantelrohrsysteme für erdverlegte
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Raccords préisolés, tubes de service en acier, Fernwärmenetze — Verbund-Formstücke

isolation thermique polyuréthane et tube de bestehend aus Stahl-Mediumrohr,
protection en polyéthylène Polyurethan-Wärmedämmung und
Außenmantel aus Polyethylen

This European Standard was approved by CEN on 1994-10-14. CEN members

are bound to comply with the CEN/CENELEC Internal Regulations which
stipulate the conditions for giving this European Standard the status of a
national standard without any alteration.
Up-to-date lists and bibliographical references concerning such national
standards may be obtained on application to the Central Secretariat or to any
CEN member.
This European Standard exists in three official versions (English, French,
German). A version in any other language made by translation under the
responsibility of a CEN member into its own language and notified to the
Central Secretariat has the same status as the official versions.
CEN members are the national standards bodies of Austria, Belgium,
Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy,
Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and
United Kingdom.

CEN
European Committee for Standardization
Comité Européen de Normalisation
Europäisches Komitee für Normung
Central Secretariat: rue de Stassart 36, B-1050 Brussels

© 1994 Copyright reserved to CEN members

Ref. No. EN 448:1994 E
 EN 448:1994

Foreword Contents
This European Standard was drawn up by Page
CEN/TC 107/WG 5, Fittings, under the Technical Foreword 2
Committee CEN/TC 107, Prefabricated district
1 Scope 3
heating pipe systems, the Secretariat of which is
held by the Danish Standards Association. 2 Normative references 3
This European Standard shall be given the status of 3 Definitions 3
a national standard, either by publication of an 4 Requirements 3
identical text or by endorsement, at the latest by 4.1 Steel parts 3
April 1995, and conflicting national standards shall
be withdrawn at the latest by April 1995. 4.2 Casing pipes 5
This specification is part of the standards for bonded 4.3 Polyurethane rigid foam insulation (PUR) 6
systems using polyurethane foam thermal 4.4 Fitting assemblies 6
insulation applied by injecting (pouring), to bond to 5 Test methods 7
a steel service pipe and a polyethylene casing pipe. 5.1 Test specimens 7
The other standards from TC 107 are: 5.2 Steel parts 8
EN 253:1994, Pipes. 5.3 Casing pipes 8
EN 488:1994, Valves. 5.4 Polyurethane rigid foam insulation (PUR) 8
Licensed Copy: Akin Koksal, Bechtel Ltd, 12 December 2002, Uncontrolled Copy, (c) BSI

EN 489:1994, Joints. 5.5 Fitting assemblies 8

In compiling this document WG 5 has made use of 6 Marking 9
results of research carried out by system
manufacturers, raw material suppliers, users, 6.1 Casing pipes 9
universities and research institutes. 6.2 Fitting assemblies 9
In accordance with the CEN/CENELEC Common Annex A (informative) Guidelines for inspection 10
Rules, the following CEN members are bound to Annex B (informative) Guidelines for
implement this European Standard: Austria, welding polyethylene casing 12
Belgium, Denmark, Finland, France, Germany, Annex C (informative) Bibliography 13
Greece, Iceland, Ireland, Italy, Luxemburg,
Netherlands, Norway, Portugal, Spain, Sweden, Figure 1 — Examples 4
Switzerland and United Kingdom. Figure 2 — Adaption of inside diameter 5
Figure 3 — Preparations of set-on branches 6
Figure 4 — Segmental casing pipe bends 7
Figure 5 — Main fitting dimensions 9
Table 1 — Tolerances 4
Table 2 — Centre line deviation 7
Table 3 — Main dimensions tolerances 8
Table A.1 — Steel parts inspection 11
Table A.2 — Polyethylene casing,
polyurethane and fitting assembly inspection 12

2 © BSI 01-2000
 EN 448:1994

1 Scope ISO 6761:1981, Steel tubes — Preparation of ends of

tubes and fittings for welding.
This European Standard specifies requirements and
test methods for fittings of prefabricated thermally INTERNATIONAL INSTITUTE OF WELDING
insulated pipe-in-pipe assemblies, comprising a (IIW) Collection of reference radiographs of welds
steel service fitting from DN 20 to DN 600, rigid
polyurethane foam insulation and an outer casing of 3 Definitions
polyethylene. However the quality requirements For the purposes of this standard, the following
can be applied for larger dimensions. definitions apply, together with the definitions
In this standard, fittings are defined as bends, given in EN 253.
T-pieces, reducers and anchors. 3.1
This standard applies only to injected (poured) cold formed bend
insulated fitting assemblies for continuous manufactured by cold bending of steel pipes
operation with hot water at various temperatures in
accordance with clause 1 of EN 253:1994. 3.2
butt welding bend
The estimation of expected life with continuous
operation at various temperatures is outlined in manufactured either by hot bending of steel pipes or
Annex B of EN 253. by hot forming of steel plates which are
subsequently welded together
Guidelines for quality inspection are given in
Annex A of this standard. 3.3
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Guidelines for PE-HD-welding are given in Annex B bending angle-µ

of this standard. the deviation in direction of the steel pipe centre
NOTE This standard does not include rules for calculation of lines
loads and stresses in the prefabricated thermally insulated 3.4
pipe-in-pipe assemblies.
forged T-piece
2 Normative references manufactured by hot forming of either steel pipes or
This European Standard incorporates by dated or steel plates which are subsequently welded together
undated reference, provisions from other 3.5
publications. These normative references are cited welding saddle
at the appropriate places in the text and the a butt welding fitting to be welded into the main
publications are listed hereafter. For dated pipe for the welded connection between the main
references, subsequent amendments to or revisions pipe and the branch pipe in a T-piece
of any of these publications apply to this European
Standard only when incorporated in it by 3.6
amendment or revision. For undated references the welded T-piece
latest edition of the publication referred to applies. manufactured by welding together pieces of steel
EN 253:1994, Preinsulated bonded pipe systems for pipes with or without the use of a welding saddle or
underground hot water networks — Pipe assembly of a drawn collar on the main pipe
steel service pipes, polyurethane thermal insulation 3.7
and outer casing of polyethylene. reducer
EN 287-1:1992, Approval testing of welders — a butt welding fitting to be welded between two steel
Fusion welding — Part 1: Steels. pipes of different diameters
EN 288-1:1992, Specification and qualification of 3.8
welding procedures for fusion welding — anchor
Part 1: General rules.
a steel construction used to transfer the axial load
EN 25817:1992, Arc-welded joints in steel — from the steel service pipe through the insulation
Fusion welding — Guidance on quality levels for and the casing to a fixed point
imperfections. (ISO 5817:1991)
ISO 1106-3:1984, Recommended practice for 4 Requirements
radiographic examination of fusion welded joints —
4.1 Steel parts
Part 3: Fusion welded circumferential joints in steel
pipes of up to 50 mm wall thickness. 4.1.1 Material
ISO 3419:1981, Non-alloy and alloy steel butt The material shall be in accordance with 4.1.1 of
welding fittings. EN 253:1994.

© BSI 01-2000 3
 EN 448:1994
Licensed Copy: Akin Koksal, Bechtel Ltd, 12 December 2002, Uncontrolled Copy, (c) BSI

Figure 1 — Examples
4.1.2 Wall thickness and diameter There shall be no folding in the bent area. Waves
The minimum nominal wall thickness of pipes and can be accepted, when the maximum height
butt welding fittings shall prior to processing be at between trough and crest of the wave does not
least the same as for the straight pipes. exceed 25 % of the nominal wall thickness of the
bent pipe.
The nominal and the outside diameter shall be the
same as the straight pipes in accordance with 4.1.3.3 Tolerances of bending angles
Table 1 of EN 253:1994. The deviation from the nominal bending angle shall
4.1.3 Bends not exceed the tolerances given in Table 1.
4.1.3.1 Butt welding bends Table 1 — Tolerances
The dimensions shall be in accordance with 6.1.2 of Nominal diameter of
Deviation tolerance
service pipe
ISO 3419:1981 with the exception that the bend
radius can be larger, but not smaller. u DN 200 ± 2,0°
4.1.3.2 Cold formed bends > DN 200 ± 1,0°
After bending, the minimum wall thickness of the 4.1.4 T-pieces
bent pipe shall be not less than 85 % of the nominal
wall thickness of the straight pipe (see Table 1 of 4.1.4.1 Forged T-pieces
EN 253:1994). The wall thicknesses T and T1 — see Figure 4 of
The maximum ovality o in the bent area shall not ISO 3419 — shall be at least the same as those for
exceed 6 %. the straight pipes (see Table 1 of EN 253). The other
dimensions shall be in accordance with 6.1.4 of
The formula for the calculation of the ovality is:
ISO 3419:1981.
2 ( d max – d min ) 4.1.4.2 Welding saddles
o = ---------------------------------------- × 100 %
d max + d min
Welding saddles shall be of the type which shall be
where welded into the wall of the main pipe.
dmax is the maximum diameter; and The wall thicknesses of the welding saddles shall be
dmin is the minimum diameter in the same at least the same as the wall thicknesses of the main
cross section in the bent area. pipes and the branch pipes which shall be welded to
the saddles.

4 © BSI 01-2000
 EN 448:1994

4.1.4.3 Welded T-pieces

Welded T-pieces shall be manufactured either by
using welding saddles or by drawing a collar on
which the branch pipe is welded or by welding the
branch pipe directly to the main pipe. The wall
thickness of the collar shall be at least the same as
that for the branch pipe (see Table 1 of
EN 253:1994).
The collar shall be drawn opposite the welding seam
in the main pipe. Figure 2 — Adaption of inside diameter
4.1.4.4 Tolerances of angles between branch pipes
and main pipes The difference between average diameter of the 2
pipe or fittings ends to be welded together shall not
The branch pipes shall be perpendicular to the main exceed a value of 0,66 times pipe wall thickness; if
pipes within a tolerance of ± 2,0°. the pipes and fittings have different wall
4.1.5 Reducers thicknesses, a value of 0,66 times t in accordance
Reducers shall be in accordance with 6.1.3 of with Figure 2 applies.
ISO 3419:1981, except for the wall thicknesses When manufacturing T-pieces with the branch pipe
T and T1 — see Figure 3 of ISO 3419:1981 — which welded directly to the main pipe, preparations shall
shall be at least the same as for the straight pipes comply with Figure 3.
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(see Table 1 of EN 253:1994) to be welded to the 4.1.7.4 Inspection of welds

fittings.
A. Visual surface examination
4.1.6 Anchors
When visual surface examination is carried out, it
The wall thickness of the pipe shall be at least the shall be in accordance with 5.2.1.
same as for the straight pipe (see Table 1 of The welding shall comply with quality level
EN 253:1994). “intermediate” of EN 25817.
4.1.7 Fusion welding of steel fittings B. Tightness test
4.1.7.1 Material When a tightness test is carried out in accordance
Filler metals shall after welding have mechanical with 5.2.2 or 5.2.3, the welds shall fulfil the
characteristics comparable with the parent metal. conditions stated there.
4.1.7.2 Welding process C. Radiographical examination of butt welds
All types of fusion welding are acceptable but arc When radiographical examination is carried out, it
welding with covered electrodes and gas-shielded shall be in accordance with 5.2.4.
metal-arc welding are preferred. The welding The weld shall be at least a quality “Colour blue”
process shall be specified in accordance with classified in accordance with the IIW rules.
clause 4 of EN 288-1:1992 and approved in 4.1.7.5 Competence of the welder
accordance with 5.1.1 of EN 288-1:1992.
The welder shall have a valid certificate in
The method of approval may be chosen by the accordance with EN 287-1.
manufacturer.
4.1.8 Surface condition
Fittings of diameter W 400 mm shall be welded in
more than one pass. The surface conditions before applying the foam
shall be in accordance with 4.1.4 of EN 253:1994.
4.1.7.3 Preparation for welding
4.2 Casing pipes
Pipe ends shall be prepared in accordance with the
welding procedure used. When using covered The casing pipes shall meet the requirements of 4.2
electrodes or gas-shielded metal-arc welding, pipe of EN 253:1994 with the following exception.
ends and fittings shall be prepared in accordance Prior to foaming, the minimum wall thickness,
with ISO 6761 and Figure 2. emin, of the casing pipe shall be in accordance with
Table 3 of EN 253:1994, with a minimum of 3 mm.
The casing pipes shall be tested in accordance
with 5.3 of this standard.

© BSI 01-2000 5
 EN 448:1994
Licensed Copy: Akin Koksal, Bechtel Ltd, 12 December 2002, Uncontrolled Copy, (c) BSI

Figure 3 — Preparations of set-on branches

4.3 Polyurethane rigid foam insulation (PUR) 4.4 Fitting assemblies
The polyurethane rigid foam insulation for fitting 4.4.1 Fitting ends
assemblies shall meet the requirements of 4.3 4.4.1.1 Service pipe
and 4.4 of EN 253:1994 except 4.3.3.2 and 4.4.3 of
EN 253:1994 and shall be tested in accordance The ends of the service pipe shall be prepared for
with 5.4 of this standard. welding in accordance with ISO 6761 and shall be
free from insulation for a minimum length
Test specimens from fitting assemblies to establish
of 150 mm.
foam properties shall be taken in accordance
with 5.1 of this standard.

6 © BSI 01-2000
 EN 448:1994

4.4.1.2 Centre line deviation 4.4.4 Tightness of the welded casing pipe after
When tested in accordance with 5.5.1 the distance foaming
between centre lines of the service pipe and the After foaming no PUR-foam shall be visible on the
casing pipe at fitting ends shall not exceed the limits outside of the weld(s), when tested in accordance
given in Table 2. with 5.5.3.
Table 2 — Centre line deviation The complete casing shall be replaced should foam
Outside diameter of Centre line deviation
occur outside the weld.
casing pipe 4.4.5 Increase in diameter of the casing pipe
mm mm
After foaming, the mean outside diameter of the
75 – 160 3,0
casing pipe shall not have increased by more
180 – 400 4,5 than 2 % when measured in accordance with 5.5.4.
450 – 630 6,0
4.4.6 Minimum insulation thickness in bends
710 – 800 8,0
The insulation thickness in the bends, measured in
4.4.1.3 Angular deviation between service pipe and accordance with 5.5.5, shall not at any point be less
casing pipe than 50 % of the nominal insulation thickness and
When tested in accordance with 5.5.1, the angular nowhere less than 15 mm.
deviation between centre lines of the uninsulated 4.4.7 Tolerances on the main fitting
end of the service pipe, and the casing pipe at a dimensions
length of 100 mm from the end, shall not exceed 2°.
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The tolerances on the main fitting dimensions

4.4.2 Angle between casing pipe segments of shown in Figure 5 shall be in accordance with
bend and minimum length Table 3.
The maximum angle, µ, between two adjacent
segments of the casing pipe of a bend shall not 5 Test methods
exceed 45°, see Figure 4. Where test requirements specified in this standard
The length l, see Figure 4, of the casing pipe at the differ from those in other standards referred to, the
ends of the fittings shall not be less than 100 mm. requirements of this standard apply.
4.4.3 General requirements of polyethylene 5.1 Test specimens
welding 5.1.1 Test specimens shall only be taken from the
The melt flow rate of the pipes to be welded shall not casing pipe after it has been stored at room
differ more than 0,5 g/10 min when determined in temperature for not less than 16 h, or from the PUR
accordance with 4.2.1.2 of EN 253:1994. foam and fitting assemblies after they have been
At any point on the circumference of the weld, the stored at room temperature for not less than 72 h.
displacement between the joined pieces in the radial Deviations from these periods are allowed, e.g. for
direction shall not exceed 30 % of the wall quality control purposes; however, in event of a
thickness. All welds shall be examined in dispute the required periods shall be observed.
accordance with 5.5.2 of this standard.

Figure 4 — Segmental casing pipe bends

© BSI 01-2000 7
 EN 448:1994

Table 3 — Main dimensions tolerances 5.2.4 Radiographic examination of butt welds

DN
H L The examination shall be carried out on the entire
mm mm length of the weld.
u 300 ± 10 ± 20 Radiographic examination with X-rays or
> 300 ± 25 ± 50 gamma-rays shall be carried out in accordance with
ISO 1106-3.
5.1.2 To establish foam properties, test specimens 5.3 Casing pipes
shall be taken from all ends of the fitting
assemblies, but in such a way as to exclude at Casing pipes shall be tested in accordance with 5.2
least 100 mm from the end of the injected (poured) of EN 253:1994.
foam, and 50 mm from welded areas of the 5.4 Polyurethane rigid foam insulation (PUR)
polyethylene casing. Polyurethane rigid foam insulation shall be tested
Provided that there is no dispute, test specimens in accordance with 5.3, 5.4.4 and 5.4.5 of
may be taken closer to the fitting ends and welded EN 253:1994.
areas of the polyethylene casing, for example for
5.5 Fitting assemblies
quality control purposes.
5.5.1 Centre line deviation and angular
5.1.3 When taking out test specimens from the foam
deviation
to determine the cell structure, core density,
compressive strength, and water absorption the The centre line deviation and angular deviation
foam adjacent to the service pipe surface and casing shall be measured between the centre lines with the
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pipe surface shall be excluded. A clearance of at largest deviation.

least 5 mm and 3 mm respectively shall be allowed. 5.5.2 Visual examination of welds on casing
5.1.4 At the locations where test specimens are pipes
taken to determine cell structure, core density, Visual examination shall be carried out on the
compressive strength and water absorption, at least entire length of the weld. See Annex B for
three test specimens shall be taken, equally guidelines.
distributed around the circumference.
5.5.3 Tightness test
5.1.5 The outside dimensions of the test specimens
shall be measured by means of a gauge having a The tightness of the PE-weld is proved when the
square or circular face area of 100 mm2 and an assembled fitting is foamed.
applied force of 0,75 N to 1,0 N. The overpacking “E” of the reactive mixture shall
5.2 Steel parts be > 1,5.
The overpacking “E” can be calculated from the
5.2.1 Visual surface examination of welds
formula:
The entire length of the weld shall be visually
examined for defects. g ov
E = -------
-
5.2.2 Tightness test with water gf
Clean water shall be used. gov = calculated overall density in the fitting
The test pressure shall be at least 1,3 times the assembly (kg/m3);
design pressure. gf = free rise foam density at room
No water shall be visible at the surface of the weld temperature (minimum 1 kg shot in a
after a test period of 10 min. suitable bag) (kg/m3).
5.2.3 Tightness test with air 5.5.4 Increase in diameter of the casing pipe
The test pressure inside the pipe shall be at The increase in diameter of the casing pipe shall be
least 0,02 MPa over the external pressure determined by measuring the circumference at the
or 0,02 MPa under the external pressure. No air same position before and after foaming.
bubbles shall be visible at the surface of the weld The increase in diameter shall be expressed as a
when immersed in water or when wetted with soap percentage of the diameter before foaming.
water or any other test liquid after a test period
5.5.5 Minimum insulation thickness
of 30 s.
Other test methods using e.g. nitrogen and helium Bends shall be cut longitudinally in the tube axis
are acceptable. and the minimum insulation thickness measured at
the cutting surface.

8 © BSI 01-2000
 EN 448:1994
Licensed Copy: Akin Koksal, Bechtel Ltd, 12 December 2002, Uncontrolled Copy, (c) BSI

Figure 5 — Main fitting dimensions

6 Marking 6.2 Fitting assemblies

The fitting shall be marked by any suitable method The manufacturer of the fitting assemblies shall
which does not affect the functional properties of the mark on the casing pipe:
casing pipe, and which is able to withstand — nominal diameter and nominal wall thickness
conditions of handling, storage and use. of the service pipe(s);
6.1 Casing pipes — bend angle (where applicable);
The manufacturer of the casing pipe shall mark — steel specification and grade of the service
thereon: pipe(s);
— raw material of the PE, by trade name or code; — manufacturer’s identification;
— MFR — table value as declared by the raw — EN 448;
material supplier; — year and week of foaming (possibly by a code).
— nominal diameter and nominal wall thickness
of the casing pipe;
— year and week of manufacture (possibly by
a code);
— manufacturer’s identification.

© BSI 01-2000 9
 EN 448:1994

Annex A (informative)
Guidelines for inspection
Use of EN 29002, Quality systems — Model for quality assurance in production and installation, or
EN 29001, Quality systems — Model for quality assurance in design/development, production, installation
and servicing, will assure proper inspection.
Otherwise the following inspection is recommended to assure the user that the manufactured preinsulated
fittings comply with the requirements specified in this standard.
The inspection may include the following:
A.1 Manufacturer’s type test
A type test is used to obtain an initial validation of materials and production methods. A new test should
be performed where these materials or methods are essentially changed.
A.2 Manufacturer’s quality surveillance
This surveillance is applied to ensure that the intended quality level of the products is maintained. The
manufacturer is responsible for ensuring that the tests specified in this standard are carried out and the
results recorded.
A.3 External inspection
This inspection is primarily intended as an evaluation of the extent and the proper functioning of the
manufacturer’s quality surveillance. This inspection also includes sampling of products to ensure that the
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requirements specified in this standard are fulfilled.

A.4 Extent of inspection
The suggested extent of the inspection is given in the Table A.1 and Table A.2.
External inspection should normally be made at least once a year.
A.5 Manufacturer’s responsibility
Where a manufacturer of preinsulated fittings makes their own raw material or produces parts for which
there is a requirement for “manufacturer’s certificates”, the manufacturer of the preinsulated fittings
should take over the responsibilities of the supplier.

10 © BSI 01-2000
 EN 448:1994

Table A.1 — Steel parts inspection

Test frequency
Clause Item Manufacturer’s Manufacturer’s quality External
type test surveillance inspection
4.1 Steel parts

4.1.1 to 4.1.6 Material, make, None Receiving or production None

delivery, inspection procedure
specification
4.1.7 Steel welding
4.1.7.1 Material, make, None Receiving inspection procedure None
delivery,
specification
4.1.7.4 Inspection of welds A. Check of Visual surface None
A, B and C procedure examination 5 % of welds
Equally distributed over the
yearly production
B. Check of Tightness test 100 % for Inspection of
procedure DN u 350 mm internal records
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C. Check of Radiographical examination of Inspection of

procedure butt welds internal records
5 % for DN u 125 mm
10 % for DN 150 u 350 mm
100 % for DN W 400 mm
Equally distributed over the
yearly production, see note
4.1.8 Surface condition None Receiving inspection procedure None
NOTE The test can also be performed in accordance with ISO 2859-2:1985 Sampling procedures for inspection by attributes.
Part 2: Sampling plans indexed by limiting quality (LQ) for isolated lot inspection.

© BSI 01-2000 11
 EN 448:1994

Table A.2 — Polyethylene casing, polyurethane and fitting assembly inspection

Test frequency
Clause Item Manufacturer’s type test Manufacturer’s quality External inspection
surveillance
4.2 Polyethylene casing See EN 253 Table C.2 See EN 253 Table C.2 See EN 253 Table C.2
4.3 Polyurethane See EN 253 Table C.3 See EN 253 Table C.3 See EN 253 Table C.3
4.4 Fitting assembly
4.4.1 Fitting ends Measured on one Continuous random 5 different fittings per
fitting per dimension inspection equally inspection visit
distributed over the yearly
production
4.4.3 General Check of procedure Receiving and production 5 different fittings per
requirements on PE inspection procedure inspection visit
welding
4.4.4 Tightness of welded Check of procedure 100 % 5 different fittings per
PE-casing inspection visit
4.4.5 Increase in None Continuous random 5 different fittings per
diameter of the inspection equally inspection visit
casing pipe distributed over the yearly
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production
4.4.6 Minimum Once by taking out of Min. twice a year Inspection of internal
insulating thickness fitting for other test records
4.4.7 Tolerances on main Check of procedure Continuous random Once per inspection
fitting dimension inspection equally visit per type of fitting
distributed over the yearly
production

Annex B (informative)
Guidelines for welding polyethylene casing
B.1 General remarks
Butt fusion and extrusion welding are preferred due to the obtainable quality of these types of weld. For
additional information see DVS 2207 T1.
B.2 Butt fusion welding
B.2.1 Preparation of the weld
Pipe ends should be cut by a precision saw or planed to achieve parallel, clean surfaces with the desired
angle.
B.2.2 Melting
Melting and butt fusion should take place in a machine facilitating the lining up of pipe ends and control
of melt and butt fusion pressure.
Melt temperature and pressure are set considering the recommendations for the specific raw material.
The surfaces of the heater element should be plane and parallel, clean and coated with e.g. PTFE so that
the melted PE-HD does not stick to the tools.
The temperature in the heater element should be controllable.
B.2.3 Butt fusion
The time between removal from the welding tool and assembling of the pipes should be minimized in order
to prevent undercooling of the PE-HD melt.
The pipe ends should be pressed together considering weld parameters of the raw material.
B.2.4 Cooling
Cooling should not be forced.
During the cooling periods the weld should be compressed in a fixed position.

12 © BSI 01-2000
 EN 448:1994

The cooling period will be complete when the material temperature is below 70 °C.
No load should be applied to the joint before cooling down to ambient temperature.
B.2.5 Indications of good butt welding
A well formed bead around the pipe.
The bead on the inside and outside of the pipe is approximately equal in size.
The height of the bead is more than 0 mm but does not exceed 2 % of the outer diameter of the pipe.
The surface of the bead is smooth.
For additional information see DVS 2207 T2.
B.3 Extrusion welding
B.3.1 Preparation of the weld
The weld area should be cleaned and scraped thoroughly.
To achieve an optimal joint, a V-groove should be made in the weld area.
The gap between the pieces should be minimized.
B.3.2 Welding
The difference between the melt flow rates of the extruded material and the casing material should be not
more than 0,5 g/10 min when determined in accordance with 4.2.1 of EN 253:1994.
The angle and size of the groove, accurate temperature, welding speed and pressure on the extruded
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material should be related to the raw material specification.

Extrusion welding should only be used for longitudinal and circumferential welds.
B.3.3 Cooling
Cooling should not be forced.
B.3.4 Indications of good extrusion welding
The shape of the weld is uniform and symmetric. The surface of the weld is smooth.
The start and finish of the extruded material is properly overlapped. The shape of the seam is convex.
For additional information see DVS 2209 T1.
B.4 Destructive test of welds
Bend test in accordance with guiding principles in DVS 2203 T5 can be carried out.
Guidelines for the test requirements can be found in DVS 2203 T1.

Annex C (informative)
Bibliography
Deutscher Verband fur Schweisstechnik e.V.
Richtlinie Fehler an Schweissverbindungen aus thermoplastischen Kunststoffen
DVS 2202 Teil 1 Merkmale, Beschreibung, Bewertung
(Dez. 1989)
Richtlinie Prüfen von Schweissverbindungen aus thermoplastischen Kunststoffen
DVS 2203 Teil 1 Prüfverfahren — Anforderungen
(März 1986)
Richtlinie Prüfen von Schweissverbindungen aus thermoplastichen Kunststoffen
DVS 2203 Teil 5 Technologischer Biegeversuch
(Juli 1985)
Entwurf Schweissen von thermoplastischen Kunststoffen
Richtlinie Heizelementschweissen von Rohrleitungsteilen aus PE-HD
DVS 2207 Teil 1 (Polyethylen hoher Dichte)
(Mai 1992)

© BSI 01-2000 13
 EN 448:1994

Entwurf Schweissen von thermoplastischen Kunststoffen

Richtlinie Extrusionsschweissen; Tafeln und Rohre
DVS 2207 Teil 4
(Juli 1991)
Richtlinie Schweissen von thermoplastischen Kunststoffen
DVS 2207 Teil 5 Schweissen von PE-Mantelrohren;
(Febr. 1993) Rohre und Rohrleitungsteile
Richtlinie Schweissen von thermoplastischen Kunststoffen
DVS 2209 Teil 1 Extrusionsschweissen
(Dez. 1981) Verfahren — Merkmale
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14 © BSI 01-2000
 BS EN 448:1995

National annex NA (informative)

Committees responsible
The United Kingdom participation in the preparation of this European Standard was entrusted by the
Refrigeration, Heating and Air Conditioning Standards Policy Committee (RHE/-) to Technical Committee
RHE/9, upon which the following bodies were represented:

Autoclaved Aerated Concrete Products Association

Chartered Institution of Building Services Engineers
Combustion Engineering Association
Concrete Block Association
Cork Industry Federation
Cranfield Institute of Technology
Department of Health
Department of the Environment (Building Research Establishment)
Department of Trade and Industry (National Physical Laboratory)
Electricity Association
Eurisol (UK Mineral Wool Association)
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European Phenolic Foam Association

Gypsum Products Development Association
Power Generation Contractors’ Association PGCA (BEAMA Ltd.)
Royal Institute of British Architects
Thermal Insulation Manufacturers’ and Suppliers’ Association (TIMSA)
Thermal Insulations Contractors’ Association

The following bodies were also represented in the drafting of the standard, through subcommittees and
panels:

British Coal Corporation

British Gas plc
British Steel Industry
Combined Heat and Power Association
Institute of Energy
PRE, Insulated Mains Contractors’ Association (PMCA)
PSA Projects Ltd.
Pipeline Industries Guild

National annex NB (informative)

Cross-references

Publication referred to Corresponding British Standard

EN 253:1994 BS EN 253:1994 Preinsulated bonded pipe systems for underground hot water
networks — Pipe assembly of steel service pipes, polyurethane thermal insulation
and outer casing of polyethylene
EN 287-1:1992 BS EN 287 Approval testing of welders for fusion welding
Part 1:1992 Steels
EN 288-1:1992 BS EN 288 Specification and approval of welding procedures for metallic
materials
Part 1:1992 General rules for fusion welding
EN 25817:1992 BS EN 25817:1992 Arc-welded joints in steel. Guidance on quality levels for
imperfections

© BSI 01-2000
 BS EN
448:1995
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