T E C H N O L O G Y W I T H A F U T U R E

hightech piping systemfor a secure supply of water and gas

Systems for security and quality

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For the operation of piping systemsin the water and gas supply area,reliable systems solutions with along service life are required. Only such solutions offer both ope-rators and users the highest level ofsupply reliability and functionaland investment security.

Today, the security of our water andgas supply goes without saying.Water can be consumed everywhereand at any time of the day. Gas isincreasingly becoming acceptedas an environment-friendly energycarrier.

Functional security and corro-sion-protection are the main criteria when judging piping sys-tems. They have to function reliablyand continuously, independent ofwhere they are used or the nature ofthe ground they are buried in.

The economics of piping systemsare not influenced by the pipe priceitself but rather by taking the costsincurred during the system’s opera-tional life as a whole into considera-tion. From this point of view, secu-rity of investment is much higherfor mature systems.

As the only Swiss manufacturer ofcomplete piping systems in duc-tile castiron, vonRollhydro develops,manufactures and sells the modular,perfectly matched vonRollecosysfull-protection piping system thatmeets all demands of water and gassupply in the communal area.

Our basic duty is to establish theidea that the availability of water is aprimary human right.

Leading compoundmaterialstechnology

Fast and economicpipe-laying

Swiss connectiontechnologywith system

Secureinvestments

Swiss manufacturingcompetence

High availabilityfor Swiss qualityproducts

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Comprehensivecustomerservice

Completerange offittings

leading hydrantstechnology

Valves forlong-termsecurity

The vonRollecosys full-protectionpiping system today alreadymeets all tomorrow’s require-ments.

The vonRollecopur pipe, made ofunbreakable ductile cast-iron, formsthe basis of the system. It is coatedinside and outside with corrosion-resistant, smooth polyurethane(PUR). The pipes, which are manu-factured using a centrifugal castingprocess, are highly stable mechani-cally but are still elastic. vonRoll-hydro has a unique, well-tried PUR-coating process at its disposal that

guarantees top bonding characteri-stics on ductile castings and pore-free coating surfaces.

The complete vonRollecosys sys-tem includes vonRollecopur pipesand vonRollecofit fittings. The pro-duct range is enhanced with multi-functional hydrants – these can befitted with electronic leak detectionand permanent piping-networkmonitoring. All these componentsare perfectly fitted together usingour own connection technology.

System components and connec-tion technology have been specifi-cally developed to meet the highuser quality requirements and thussimplify installation in the very hete-rogeneous topography.

The main components are manu-factured using modern equipmentat our facilities in Choindez andOensingen.

Long-term corrosion prevention and drinking water protection

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Long-term corrosion prevention

The smooth external PUR coatingpermanently protects the pipes frommechanical and chemical damage.The integral PUR coating providesfull protection against electro-corrosion that can arise from neigh-bouring reinforced-concrete founda-tions or inhomogeneous bedding.As a result of using rubber gasket,each section of piping is itself gal-vanically isolated and is thus notelectrically conductive. The PUR coating provides passivecorrosion prevention that is maintai-ned throughout the life of the pipe.

Embedment in all sorts of soil

The PUR coating is immune toaggressive soils and is suitable forboth neutral, acidic or heteroge-neous substrates. Just one type ofpipe for all sorts of soil also reducesstorage costs.

Protection of drinking water

The hydraulically smooth PUR inter-nal lining is hygienic and preventsincrustations forming on its surface.The amount of desinfectants nee-ded can be reduced dramatically.

Suitable for all qualities of water and gas

The PUR lining is perfectly suitable forsoft, neutral and hard water as wellas for gas. It is resistant to solventsand scale formation. Also, the inter-nal lining is not susceptible to abra-sion. In this way, this full-protectionpiping system can be used for allwater qualities and gas, even savingmaintenance costs at the sametime.

Maximum net work performance

The absolutely smooth surface withminimum flow resistance ensuresbest flow performance along withlow pumping effort and energy con-sumption, thus keeping operatingcosts low.In comparison with other materials,smaller pipe diameters can be chosen or increased capacity reser-ves can be enjoyed.

Advantages of PUR

• Long service life• Complete corrosion prevention • 100% application area• Reduced storage costs• Hygienic• Saves maintenance costs• Lower operating costs

PUR coating outside:• corrosion-resistant • high adhesion• impact-resistance

PUR lining inside:• corrosion-resistant • high adhesion• hygienic• abrasion-resistant

Tough all-rounders

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Leading-edge compound-materials technology

The combination of ductile cast-ironand PUR boasts excellent mechani-cal characteristics. The very bestcharacteristics of PUR and ductileiron are permanently united. In urban areas with increasingdemands, this compound materialturns out to be ideal. The service lifeof the piping system is thus leng-thened considerably.

Unbreakable ductile iron

In ductile iron, the embedded gra-phite has a spherical shape. Thisspecial structure gives ductile ironthe elasticity and durability that ena-ble them to take up the loads oftraffic, ground subsidence, lateralpressure and shocks. Ductile ironare also fire resistant, so that in thecase of tunnel fires, the availability ofwater for fighting fires is guaranteed.

Robust polyurethane (PUR)

The mechanical and chemical stabi-lity of PUR is particularly high as themacro-molecules of this plastic areinterconnected in three dimensions.PUR is shockresistant and exhibitsno cold fluency. The adhesion bet-ween the PUR lining and the ductileiron is checked every day in ourlaboratory and certified twice a yearby the external body MPA NRW.

Advantages:

• Long operational life• Compensation of ground

movements• High mechanical stability• Suitable for high operating

pressures• Excellent flow properties• Problem-free cutting and drilling

Special applications

Rescure tunnels place the highestrequirements on the mechanicalstability of suspended pipework, onsafety aspects in the case of fire andon flow performance – criteria thatare met by vonRollecopur pipes inthe best possible way.

vonRollrock pressure pipes withrock-protection jacket are out-standingly suitable for use in rockyground; the jacket protects the pipefrom being damaged by rocks whenfilling in.

Connection with system

Internal restrained joint Fig. 2807with double chambers• Secure and cheap• Simple and fast mounting

DN 80 to 700, up to PFA 100

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Advantages

• Well-tried and secure connection technology

• Fast and flexible installation • Easy dismounting of the restraint

clamps Fig. 2806• High savings as concrete

anchors are no longer needed• Narrower trenches can be dug

Shorter installation time andhigh degree of flexibility

The pipes and fittings are quicklyconnected together using vonRoll’sUniversal laying tool. With the sub-sequent backwards movement, theteeth of the internal restrained jointbite into the pipe. The tooth seg-ments of the external restraint clampare activated by tightening screws.A suitable accu screwdriver speedsup the tightening operation andmakes installation easy. The con-nection can easily be released byunscrewing the screws again, whichleads to increased flexibility whenlaying pipes.

Fast site work

As far as making connections withrubber gasket is concerned, securefastening is important on the onehand and economics on the other.vonRollhydrotight connection sys-tem – proven in thousands of instal-lations – with its internal and exter-nal restrained joint enables fastprogress to be made and reliablyconnects water and gas pipeworkto form a complete tailor-madesystem.

Security is important

Restrained joint takes up longitu-dinal forces. A decisive factor forthe security of the connections isthe clear separation of tighness andrestraining functions.

No more concrete anchor blocks

Longitudinal forces and those asso-ciated with changes of direction inmains piping are taken up byvonRoll restrained joint at highpressures. The costly provision ofconcrete anchor blocks is no longernecessary. Narrower trenches canbe dug.

External restrained joint Fig. 2806with single and doublechambers • Secure and easy

to use • Simple and

flexible mounting

DN 80 to 700, up to PFA 100

Uncomplicated, fast, low-cost pipe-laying

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The requirements placed onpiping systems are constantly getting more and more stringent.

In towns and cities, space is gettingrare and time is running low. Inurban areas, water supply andwastewater systems lie close toeach other in the ground.Traffic must be interrupted or distur-bed as little as possible. Out oftown, long distances have to bebridged. Here, handling, transportcosts and compensation for landdamage are important factors.

Installation without digging trenches

Installing pipelines without diggingtrenches is often the optimal solu-tion when having to tunnel, buildsiphons or for installations in urbanlocations. On account of their highloading capacity, vonRollecopurductile cast-iron pipes are especiallywell suited to trench-free pipelineconstruction. The exterior coating inPUR is extremely robust from themechanical point of view and itsbonding to the cast-iron surface isexcellent.

The vonRollecopur pipe offersdecisive advantages for bothapplication areas.

Independent of the weather

Independent of energy sources,weather conditions and tempera-ture, the pipes and fittings can befitted together using the laying tool.The compact vonRollecopur pipecan be laid in narrower trenches.

No-problem bedding-in

The sturdy vonRollecopur pipe re-quires no special bedding. Thepipes can be bedded-in withoutproblems using appropriate excava-tion material. Expensive gravel bedsare not needed. This also savestransport and building costs. Thesturdy and impact-resistant PURcoating stands up to even the har-dest pipe-laying conditions.

Flexible thanks to deflection tolerance

Our connection technology allowspipe deflections of up to 5 degreeswithout restrained joint and 3 de-grees with.

Pipe-laying made easy

When piping is laid in urban environ-ments, space in trenches gets tight.Often, pipes have to be cut to sizeor fitted with house mains connec-tions. Shortening vonRollecopurpipes to the required length pre-sents no problems and can be donewithout peeling and without dama-ging the PUR coating. Tapping for ahouse connection is just as easy.

Advantages

• Faster and cheaper pipe-laying• Installation independent

of weather conditions • Excavated material can be

re-used• Flexible pipeline deviation• No peeling of the outside

coating• Problem-free shortening • Simple house connections

The cheapest way in the short and long term

High degree

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Ductile cast-iron pipewith simple

corrosion protection,embedded inlean concrete

vonRollecopurfull-protectionpipe, embedded in excavatedmaterial

Civil engineering Fr. 560.– Fr 510.– 80% 75%

Pipes and Fr. 87.– Fr 110.–adapters 11% 16%

Engineering Fr. 63.– Fr 63.– 9% 9%

Your short-term advantage

–3,8%

Your long-term advantage

min. 20 years100

90

80

70

60

50

40

30

20

10

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Investment per metre* Service life of ductile cast-iron pipelines (in years)

*Average for aDN200 pipeline, 650 m long, urban environ-ment. No houseconnections or hydrants.Sources ofinformationand data: SGK, WVZ, GWB, KTI

Servicelife50–80years

Servicelife100–150years

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Protected investments

The overall consideration ofcosts incurred during the sys-tem’s service life is importantwhen examining the economicsof a piping system.

The vonRollecosys full-protectionpiping system costs a little morewhen you buy it, but is the cheapestsolution in the short term because oflower pipe-laying costs and, in thelong term, because of its longer ser-vice life. In the long term, this haspositive effects on your investmentbudget.

Competence in manufacturing

In Choindez, the largest manufactu-ring facility for transforming scrapinto high-quality ductile cast-iron inSwitzerland can be found. Ductilecastings are made to more than90% from recycled material.

Fully automated centrifugal castingequipment produces up to 25’000tons of ductile cast-iron pipes ayear in diameters of DN 80 to DN 700 with a length of 6 meters.Afterwards, the pipes are coatedwith PUR inside and outside.

In Oensingen, up to 31’000 valvesand 6’000 hydrants are producedevery year. The fittings are coatedwith an thick film of epoxy resin toGSK (Gemeinschaft für SchwerenKorrosionsschutz) standards in apowder-coating plant.

of availability of Swiss quality productsfor demanding customers

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High manufacturing qualityand availability from our own works

As the only supplier in Switzerland,vonRollhydro 320 employees deve-lop and produce the main compo-nents of our systems such as ductilecast-iron piping, valves and hyd-rants in our own manufacturingfacilities. In this way, we can guaran-tee our customers not only systemsecurity and high quality but alsofast and reliable delivery.

Environment-friendly materials and workmanship

For the production of ductile cast-iron we use more than 90% recycledscrap. At the end of their service life,the pipes themselves can be 100%recycled. The use of gas and electri-city helps reduce CO2 emissions.The solvent-free PUR coating pro-cess also helps us take care of theenvironment.

Continuous quality

During the manufacturing pro-cess, product quality is monitoredcon-tinuously. Periodically externalaudits are carried out by the labora-torie for material testing MPA NRW.

Approvals and certificates

• Certificates worldwide for drinking water

• Conformity to EN 545 and EN 969

• DVGW / W 270 certificate • MPA tests on PUR adherence • ISO 9001 QS certificate • ISO 14001 environmental

management certificate

Ortomat®

The world’s leading leakagedetection system

Complete Piping systems from one supplier

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leading hydrant technology

High-performance, easy-to-use,maintenance-free and easy toinstall, as well as being pleasing tothe eye, are the main criteria to beconsidered when developing newhydrants. When fitted with sensors,hydrants can become part of anintelligent network that offers additional functionality such as theearly detection of leaks in waterpiping.

Since 1896, vonRollhydro has deve-loped and produced hydrants, inparticular for the Swiss market.

Today’s leading vonRollhytec andvonRollhyclassic hydrants combinelatest technological advances withmany years of practical experience.It is this combination that has madevonRollhydro the leading hydrantmanufacturer in Switzerland.

Fittings that fit needs of practice

Just connecting pipes together doesn’t make a mains network.Every piping system needs a selec-tion of just a few types of fittings thatoffer the user flexibility in planningand pipelaying.

The fittings have to fit the type ofpipe chosen and be of the samequality.

Under the vonRollecofit label,vonRollhydro can supply a compre-hensive range of fittings in ductilecast-iron with integral expoxy coa-ting that offer the same performanceas the vonRollecopur pipes.

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The vonRollecosys full-protectionpiping system meets all the require-ments of a sustainable and securewater and gas supply.

Common qualitycharacteristics of system components

• Long service life• Integrated protection against

electrical corrosion• Immunity to aggressive soils• Excellent hygienic properties • Prevent incrustation

and abrasion• Universal use for soft,

neutral and hard water as wellas for gas

• Minimal flow resistance and optimal flow rate

• Resistance to shock, pressure and vibration

• Standardised sealing andrestraint-clamping systems

• Cheap and user-friendlypipe-laying and operation

Valves for long-term security

Valves must meet especially strictrequirements as far as safety andcorrosion prevention are concernedand exhibit the same quality characteristics as piping systems.Today, flexible solutions from asingle supplier are asked for.

Apart from well-known products likepipes and fittings, vonRollhydro canalso supply a wide range of valvesfor the water and gas supply indus-try that leave nothing to be desired.The valves are permanently protec-ted both inside and outside with anintegral thick epoxy resin coating.

vonRoll hydro (suisse) agvon roll-strasse 24ch-4702 oensingentel. +41 62 388 11 11fax +41 62 388 11 78www.vonroll-hydro.chinfo@vonroll-hydro.ch

The right solution for every job

Ask for system competence

Today, customers are looking for acompetent system supplier, whoprovides solutions and offers sup-port for all types of tasks. vonRollhydro unusually high level ofcompetence is the result of manyyears of experience in the develop-ment, manufacture and applicationof piping systems. It’s worth askingus for advice and making use of ourexperience. Ask for solutions thatare tailored to your own needs –from a single supplier.

Ask also for informations about ourvonRollducpur pipes and vonRoll-geopur severage pipes.

Ask for advice

We regularly organise informationevents and training on pipingsystems, materials and pipe-layingin our factories or even at our custo-mers’ own facilities.Our customer services can carry outsoil analyses for you, calculate pres-sure drops in piping networks orprovide professional advice on theuse of particular products. Furtherservices offered include inspectionand maintenance, leak detectionand refurbishment of hydrants.Our sales representatives give ad-vice during the purchasing processand provide support during theinstallation and commissioning ofpiping systems.

Demand security of supply

All types of pipes, valves, fittingsand hydrants in all common sizesare available ex-stock in vonRoll-hydro delivery store and in the salesstores of most plumbing and steeltraders. This guarantees a high levelof product availability for water andgas supply industry – both in thelong term as well as in the case ofemergencies.