Advice For Laying Blutop

Advice for Laying
Pipeline for the

distribution of
drinking water
Comprehensive pipe solutions

Guidance on fitting BLUTOP - Edition 2015
CONTENTS
THE BLUTOP RANGE................................. 2
PIPES AND FITTINGS.............................................................. 2
- Range of pipes.................................................................... 2
- Range of fittings.................................................................. 2
JOINTS AND ACCESSORIES................................................... 3
- Range of joints DN/OD 75, 90, 110, 125, 140 and 160....... 3
- Range of accessories........................................................... 3
BLUTOP PIPES..................................................................... 4
- Main characteristics............................................................. 4
FITTINGS AND ACCESSORIES................................................. 5
- BLUTOP fittings................................................................. 5
- Accessories......................................................................... 5
DELIVERY OF PRODUCTS.......................... 6
DELIVERY OF PIPES................................................................ 6
STORAGE OF PIPES................................................................ 7
- Height of bundles................................................................ 7
DELIVERIES OF FITTINGS/JOINTS............................................ 8
- BLUTOP fittings................................................................. 8
- BLUTOP locking rings........................................................ 8
DRILLING TOOLS.................................................................... 9
- Drilling tools........................................................................ 9
- The advantages of BLUTOP drilling tools............................. 9
IMPLEMENTATION..................................... 10
LIFTING THE BUNDLES........................................................... 10
CLADDING THE PIPES............................................................ 11
LUBRICATING PASTE............................................................. 12
RECOMMANDED PIPE CUTTING PRACTICE........................... 13
- Paint for pipe cutting........................................................... 13
- Restoring the coating.......................................................... 13
ADVANTAGES OF LAYING...................................................... 14
- Portability............................................................................ 14
- Use of crowbar for insertion recommended......................... 14
- Hydraulic excavator............................................................. 14
- The advantages of cast iron................................................. 14
- Trench width....................................................................... 15
- Implementing the supplies................................................... 15
- Progress.............................................................................. 16
- Seating............................................................................... 16
- Pipe packing material.......................................................... 17
- Excavated soil reused.......................................................... 17
- Reuse of excavated lime-treated materials........................... 17
- Use of filler material............................................................ 17
ECOPOSE.............................................................................. 18
- The advantage of ECOPOSE with BLUTOP............................ 18
- Savings with ECOPOSE........................................................ 18

BLUTRAK................................................... 19
FITTING TROLLEY................................................................... 19
- The advantages of using the BLUTRAK trolley..................... 19
- Operating principle.............................................................. 19
- Implementation................................................................... 20
- Simultaneous fitting of the gate valve.................................. 21
- Packaging........................................................................... 21
CONNECTIONS........................................... 22
FITTING THE JOINT................................................................ 22
- Very clean ends................................................................... 22
- Assembling the joint ring.................................................... 22
- Preparing the assembly surfaces.......................................... 23
SOCKETING........................................................................... 24
SLEEVE.................................................................................. 25
- Role of the sleeve................................................................ 25
- Installing the sleeve............................................................ 25
COMPATIBILITIES.................................................................. 26
- BLUTOP compatible........................................................... 26
- Assembly............................................................................ 27
- Locking cases...................................................................... 27
CUTTING..................................................... 28
CUTTING A BLUTOP PIPE..................................................... 28
REPAIRING A CUT................................................................. 29
- Making the chamfer............................................................ 29
- Reconstituting the coating.................................................. 30
- Reconstituting interlock limit marks..................................... 30
CONNECTION............................................. 31
TOOLS................................................................................... 31
- Using the right tools and drilling method............................ 31
- Useful advice...................................................................... 31
DRILLING MACHINE UNDER LOAD........................................ 32
- BLUDRIL drilling machine................................................... 32
- Recommendations for use................................................... 32
- Adapter kit for EIE drilling machine..................................... 32
- Adapter kit for other drilling machines................................. 32
EXECUTION........................................................................... 33
- Operating procedure........................................................... 33
PROJECT ACCEPTANCE............................. 34
PRESSURE TEST..................................................................... 34
- Main provisions................................................................... 34
- Checks................................................................................ 34
- Pressurising and inspection................................................. 34
CLEANING AND COMMISSIONING........................................ 35
- Cleaning and disinfecting.................................................... 35
- Commissioning and satisfaction.......................................... 35
Guidance on fitting BLUTOP - Edition 2015 1

PIPES AND FITTINGS
BLUTOP, A COMPREHENSIVE RANGE

DESIGNED FOR SMALL DIAMETERS
Range of pipes:
DN/OD 75, 90, 110, 125, 140 and 160
DN/ OD L Class DE Weight PFA PMA PEA Reference
m bar mm Kg/m bar bar bar
75 6 25 75 5.1 25 30 35 KXL75H60
90 6 25 90 6.1 25 30 35 KXL90H60
110 6 25 110 7.5 25 30 35 KXM11H60
125 6 25 125 8.6 25 30 35 KXM12H60
140* 6 25 140 10.0 25 30 35 KXM14H60
160 6 25 160 12.5 25 30 35 KXM16H60
* DN/OD 140: Please inquire
Range of fittings
Bends, tees, tapers;
Sleeves, plugs;
Socket flange fittings;
Spigot flange fittings,
Blue epoxy coating applied by powder spraying.
2 Guidance on fitting BLUTOP - Edition 2015

The BLUTOP range
JOINTS AND ACCESSORIES
Range of joints
DN/OD 75, 90,110, 125,140 and 160:
Non-locked version PFA 25 bar
Compatible with BLUTOP pipes and fittings, pipes
PVC and PE tubes;
Locked version PFA 16 bar
Compatible only with
BLUTOP pipes and fittings
Range of accessories:
QUICK and QUICK Locked;
Gate valve Euro 20 BLUTOP;
ULTRALINK;
BLUDRIL drilling tools and drill bits for connection;
Special BLUTOP lubricating paste;
BLUTRAK fitting trolley.

BLUTOP PIPES
Main characteristics:
Length: 6 metres;
External coating:
ZINALIUM 400 g/m + acrylic paint 100 m;
Internal coating - DUCTAN 300 m min.;
Joint - BLUTOP and BLUTOP Vi;
DN/ E
DE Lu DI P B Weight Reference
OD nominal
mm mm m mm mm mm mm Kg/m
75 75 6 3.0 77.7 82.0 113.0 5.10 KXL75H60
90 90 6 3.0 92.7 84.0 130.2 6.10 KXL90H60
110 110 6 3.0 112.8 87.0 149.5 7.60 KXM11H60
125 125 6 3.0 128.0 92.0 164.0 8.60 KXM12H60
140* 140 6 3.2 143.1 94.5 185.0 10.00 KXM14H60
160 160 6 3.4 163.3 97.5 202.0 12.50 KXM16H60
* DN/OD 140: Please inquire
Important:
BLUTOP pipes are defined by their outside diameter.
Example: BLUTOP DN/OD 110 - outside diameter 110 mm
DN/OD = Outside diameter
BLUTOP pipes must not be fitted into cast iron pipes of the NATURAL
type ductile or any pipes that comply with EN 545 or ISO 2531 standards.

The BLUTOP range
FITTINGS AND ACCESSORIES
BLUTOP fittings:
Bends 1/4, 1/8, 1/16 and 1/32;
Socket flange (BE), Spigot Flange (BU);
Semi-sliding collar;
Tee 2 socket flanges, tee 3 sockets;
Taper, plug;
Boot.
Accessories:
QUICK and QUICK with anchor ring;
Euro 20 BLUTOP wedge gate valves;
Pipe saddle;
ULTRALINK;
BLUDRIL drilling tools and drill bits for connection;
Special BLUTOP lubricating paste;
BLUTRAK fitting trolley.

DELIVERY OF PIPES
Pipes:
Delivered in bundles:
DN/OD Number of pipes Weight of bundle (kg)

75 30 921
90 30 1095
110 20 904
125 20 1032
140 16 960
160 12 788
Store flat on wooden battens;

Always use hoisting slings to hoist the bundle;
Pipes are delivered on grooved battens.
They do not fall off when the banding is cut;
The BU ends are fitted with protective sleeve.

Delivery of products
STORAGE OF PIPES
Height of bundles:
Stack the bundles square, without exceeding the maximum heights specified
in the table below.
Stacking height
DN Stacking heights
75 6 bundles
90 6 bundles
110 6 bundles
125 5 bundles
140 5 bundles
160 5 bundles
Warning:
Make sure the banding of the bundles is taut. Never hoist bundles with
hooks or a vacuum lifting beam, hoist them with slings looped under the
base. The banding is not designed to bear the load of the bundle.

DELIVERIES OF FITTINGS/JOINTS
BLUTOP fittings:
Palletization;
Foam packing for protection against knocks;
Keep the foam packing until the fitting is fitted.
BLUTOP locking rings:

Packed in tubes
- Tube of 15 locking rings in DN/OD 75 and 90
- Tube of 20 locking rings in DN/OD 100, 125, 140 and 160;
Do not take the locking rings out of the tube before fitting;
Use the locking rings as and when needed;
In case of frost, make sure the locking rings are flexible,
if necessary keep them at a temperature greater than 0C.
Important:
Each tube of joints is delivered with fitting instructions and a ruler for
checking the position of the joint.

Delivery of products
DRILLING TOOLS
Drilling tools:
Packed singly
Reference of
DE tube Pitch centre Reference of
DN Valve chamfering
PVC/PE diameter complete tools
cutter
20 25 19 214191 215444
25 32 24 214193 215445
32 40 30 214195 215446
40 50 28 214196 215447
- The advantages of BLUTOP drilling tools:
These tools deliver excellent drilling quality;

The cut on the inner DUCTAN coating is clean and even;
The cut-out part is recovered by the tool after drilling;
Feedback from PAM shows that roughly 50 drilling operations can
be carried out with a rotation speed of 400 rpm;
Manual tool: use of a manual tool such as a ratchet

wrench is highly inadvisable. Its inadequate rotation speed
would cause premature wear of the chamfering cutter
(5 drilling operations at the most with one tool).
Refer to pages 32, 33 and 34 for guidance on drilling as
recommended by PAM.
NB: Drilling devices not approved by Saint-Gobain PAM should not be used (please inquire)
Important:
An analysis of the risk involved in installing pipes, fittings or accessories
and their control are the responsibility of the company in charge (in
particular the use of personal protective equipment).

LIFTING THE BUNDLES
Lifting bundles of BLUTOP pipes:

The lifting slings must be fitted with snap hooks;
Loop the sling tightly around the bundle (one or two slings);
Repeat the operation;
The bundle can now be lifted in complete safety without damaging
the pipes.
Warning:
Hooks are prohibited when lifting bundles in socket and spigot.

Implementation
CLADDING THE PIPES
Cladding BLUTOP pipes:
Distance between
DN/OD
2 bundles
75 L = 180 m
90 L = 180 m
110 L = 120 m
125 L = 120 m
L 140 L = 96 m
160 L = 72 m

LUBRICATING PASTE
LUBRICATING PASTE:
The BLUTOP lubricating paste made with

silicone allows dynamic fitting of the joint
when pressure first builds up in the pipe. Its
lubricant properties reduce insertion force
by 20 to 30% (depending on diameter)
compared with a conventional lubricating
paste.
850 g box with applicator brush:

Product number 214611
Ambient temperature 5C Ambient temperature 16C

DN/OD One box for DN/OD One box for
75 40 joints 75 60 joints
Using the applicator brush ensures the

product remains clean throughout the site
work.
Warning:
Only BLUTOP lubricating paste should be used to lubricate the BLUTOP

range. No other lubricants should be used, even Lub A (NATURAL).

Implementation
RECOMMENDED PIPE CUTTING PRACTICE

Paint for pipe cutting:
Box of 0.75 kg
Product number 240992
DN/OD One box for

75 100 cuts
90 80 cuts
110 70 cuts
125 60 cuts
140 50 cuts
160 45 cuts
Quantities are given as a rough guide, they depend on working conditions,

the proportioning of the operator and ambient temperature.
Restoring the coating:

After each cut, the continuity of the coating on the bare edge and the
chamfer must be restored.
Important:
Abide by the recommendations for use in the safety data sheets available at
http://www.pamline.fr/images/add/documentattache/(FicheSecurite)_
AQUACOAT.pdf

ADVANTAGES OF LAYING
Portability:
BLUTOP pipes can be transported
and lowered into the trench
without any machinery up to DN
140 (2 operators per pipe);
The fittings are designed with
handles.
DN/OD (mm) 75 90 110 125 140 160

Weight (kg/pipe) 30.6 36.6 45 51.6 60.0 75.0
Use of crowbar for insertion recommended:

The design of the joints and the use of lubricating paste made with silicone
means that the pipes and fittings can be inserted using a crowbar. We
recommend inserting a wooden wedge between the crowbar and the edge
of the pipe being fitted.
Hydraulic excavator:
The two aforesaid advantages free up the mechanical excavator for
trench-digging or backfilling operations. As a result, the pipe laying rate
is significantly faster.
The advantages of cast iron:

Robustness and solidity;
Pipe seating and packing with the natural excavated soil free of rocks
and stones;
Reliability.

Implementation
Trench width:
BLUTOP pipes, which are less sensitive to lateral compacting than flexible
plastic pipes, can be laid in wider trenches, in particular for sections that do
not involve any angular deflection.
DN/OD (mm) 75 90 110 125 140 160

Width (cm) 45 45 45 45 50 50
Assemble the pipes alongside the trench for narrow trenches, using
appropriate fitting techniques (see page 19, 20, 21), either accompanying
the trencher (chain width 28 cm) or a 30 cm dipper bucket (trench width of
32 to 34 cm depending on the nature of the excavated soil).
Implementing the supplies:

Important:
An analysis of the risk involved in installing pipes, fittings or accessories and
their control are the responsibility of the company in charge (in particular
the use of personal protective equipment).

Progress:
On gradients, pipes are generally laid in the uphill direction, with spigots
pointing downhill. We recommend applying insertion force on the facing
of the pipe joins, not on the end of the spigot, to avoid damaging them.
Seating:
The pipe is laid:
Either on a seating of filler material roughly 10 cm thick, according to
any recommendations of the principal contractor;
Or directly on the bottom of the trench if the ground is composed of
granular and homogeneous material (ECOPOSE).
In any event, recesses should be made for the sockets.

Implementation
Pipe packing material:
The high mechanical strength and rigidity of BLUTOP pipes generates
savings on the cost of packing and compaction material;
The fulcrum is a determining factor. It must be chosen with care;
The rest of the packing can be done with excavated material.
Excavated soil reused:

Recommended by booklet 71 - Article 66.1
The excavated soil can be reused after removing any rocks or stones
(Dmax > 40 mm) liable to be in contact with the pipe (seating and
packing);
This solution preserves the natural resources and avoids numerous
truck journeys back and forth while at the same time reducing
greenhouse gas emissions (mainly CO2).
Reuse of excavated lime-treated materials:

One can consider using clayey materials excavated in situ after lime treat-
ment, subject to meeting the following conditions:
The lime treatment of the excavated material comprises no more than
2% of lime and is homogeneous (efficient mixing for enough time);
All the packing material must be lime-treated (the pipe must not be in
contact with any other material);
The level of the water table must be lower than the pipe's lower
generatrix.
Use of filler material:

This solution is implemented if need be pursuant to highway
regulations;
The nature of the filler material is imposed by the project's technical
specifications.

ECOPOSE
The advantage of ECOPOSE with BLUTOP:
Conventional pipe-laying ECOPOSE

with external backfill with backfill in situ
Compaction: 95% (OPN*) Compaction: 85% (OPN*)

* Optimum Proctor Normal
Savings with ECOPOSE:

Packing = less external filler material
Fewer truck journeys back and forth = less CO2 emitted
Ductile cast iron = recyclable ad infinitum
insertion = no concrete end stop = less CO2 emitted
500 metres of piping laid using ECOPOSE equals a saving of one tonne
of CO2 emissions
Unloading
zone
12 m
in -
15
k m
m
Savings on transport:
k
Zone
30
150 of production
-
25 min
of backfill
Savings on backfill:
2,160
Site Total savings:
2,310 per
construction site
and laying rate: +20%
m
30 min - 35 k

BLUTRAK
FITTING TROLLEY
BLUTRAK is a mobile device designed by Saint-Gobain PAM that provides

mechanical assistance in laying ductile cast iron pipes in the BLUTOP
range. Its design allows pre-fitted sections to be laid in the bottom of the
trench after the pipes are interlocked at the edge of the trench.
The advantage of using the BLUTRAK trolley:

The BLUTRAK trolley allows pipes to be laid in narrow trenches, which:
Significantly reduces trench volume;
Accelerates site work;
Reduces greenhouse gas emissions.
Moreover, assembling the pipes outside the trench very significantly
improves operator ergonomics and inspection of the fitted joint (reliability).
Operating principle:
BLUTRAK comprises two trolleys with
width and height-adjustable wheels that
can advance over the trench behind a
trencher or hydraulic excavator with a
narrow bucket (30 cm).
The first trolley, called "parent trolley", is
towed either directly by the trencher or
subsequently by a excavator or backhoe
loader.

FITTING TROLLEY
Operating principle (continued):
Guide wheels lift the first pipe by approximately 20 mm. A reaction
wheel placed horizontally centres the pipe in the trench before the pipe is
lowered towards the second trolley, called "child trolley".
The two trolleys are linked by two 4-metre chains. The "child"
trolley is fitted with 4 wheels and advances behind the "parent"
trolley, lowering the BLUTOP pipes and guiding them on to the seating at
the bottom of the trench. A height adjustment of 30 to 100 mm of the pipe
support wheels enables it to be used for different trench depths.
Implementation:
BLUTOP pipes must be pre-assembled at the edge of the trench but not
obstructing the passage of the trencher or hydraulic excavator.
The link with the excavator or trencher is made with a 24-metre chain
with BLUTRAK. The chain is coupled either with a hook attached to the
hydraulic excavator bucket or with a permanent self-disengaging magnet
attached to the trencher's chassis.
For more details, refer to the BLUTRAK user manual.
Trolley interlinked to the hydraulic excavator Trolley interlinked to the trencher

BLUTRAK
FITTING TROLLEY
Simultaneous fitting of the gate valve:
The design of the BLUTRAK trolley also allows in-line fitting of gate
valves in the Euro 20 BLUTOP range. The "parent" and "child" trolleys
are sized to allow the passage of valve bodies.
Packaging:
The BLUTRAK laying trolley is delivered in a secure metal container with
all the fittings required for using it.
It comes with assembly instructions.
Please contact us when you use it for the first time.

FITTING THE JOINT
Very clean ends:

It is recommended to install the sealing ring inside the pipe fitting
outside the excavation and as far as possible to put the protective
cap back in place, in order to prevent dirt accumulation before
fitting together.
Assembling the joint ring:

See page 23 opposite.
Lubricate the inside of the socket [1];
Present the gasket without any prior deformation, the white
segments facing outward [2];
Gentle pressure is sufficient to insert it right into its seating in the
socket;
Make sure that the joint is correctly in place in its seating, by
pushing it back towards the outside until abutment [3] and by
pressing it at the bottom of the fitting [4];
Lubricate the inside of the sealing ring over its entire
periphery[5];
Lubricate the spigot of the pipe to be fitted [6].
Useful to know:
To be certain to lubricate the entire sealing ring, apply the grease
using the applicator brush by rotating by one and half turn;
Maintain the spigot and the fitting plugged until fitting together;
The BLUTOP sleeve enables the pipes spigot to be placed in the
trench without making it dirty.

Connections
FITTING THE JOINT

Preparing the assembly surfaces:
LUBRICATE 1 INSTALL 2
POSITION 3 PRESS 4
LUBRICATE
5
LUBRICATE 6

SOCKETING
The BLUTOP pipes and connections require moderate force for

fitting, exerted with a crowbar;
Protect the fitting or the spigot with a hard piece of wood;
At the end of fitting, one of the two lines on the spigot must
remain visible including for junctions with anchor (BLUTOP
Vijoints);
Use the handle to lock the joints;
Fit together aligned, then deflect according to the desired angle up
to a maximum of 6, i.e. approximately an offset of 63 centimetres
for a full pipe of 6 metres length;
In case of inconsistent installation overhead or at the bottom of the
excavation, the use of a ratchet strap of 500 daN is recommended.
Useful to know:
Manual fitting with a mechanical excavator enables to continue
digging the trench, if it is not mobilised for this operation.
Controlling the assembly: Metal rule
The rule must go in up to the same

depth all around the periphery. It is
provided with each joint box

Connections
SLEEVE
The BLUTOP pipes are delivered
with a protective sleeve
Role of the sleeve:
Protection of the spigot during trans-
portation and storage; Before fitting
Maintaining the cleanliness of the
spigot until fitting;
Information on the type of junction:
- Without anchor
- With anchor
- DN/OD
- Tool required for drilling
Installing the sleeve:

Position
Just before fitting, retract the sleeve; without anchor
After fitting-together, cover the socket
with the sleeve;
If the junction is without anchor -
top face with marking:
If the junction is with anchor-

top face with marking: Position with anchor
Important:
During automated laying of pipes in
a narrow trench using the BLUTRAK
laying carriage, it is recommended not
to cover the junction area with the
sleeve, in order to be able to observe
the correct position of fitting marks at
the bottom of the excavation (first small
white line must not be visible).

COMPATIBILITIES
BLUTOP compatible:
The spigots of
- EN 1452 compliant PVC tubes
- EN 12201 compliant HDPE tubes
- NFT54948 compliant bi-oriented tubes
may be fitted-together in pipe fittings and BLUTOP unions.
The PFA or PN of the joint is then that of the tube or plastic pipe
(marked on the product).
For an online assembly, only the PVC-U or

PVC-BO pipes may be assembled with a
BLUTOP joint. In case of a connection with
a HDPE tube, it is recommended to use a
secured IZIFIT joint for ND 75, 90, 110 and
125 and a locking companion flange for ND
Cast iron/ PVC PN 16 junction 140 and 160.
Junction with anchor with BLUTOP union (PVC and HDPE)
For assembling a PVC pipe or a

HDPE tube with a union of the
BLUTOP range, it is necessary to
use a secured IZIFIT joint for ND
75, 90, 110 and 125.
For assembling a PVC pipe or a

HDPE tube with a union of the
BLUTOP range, it is necessary to
use a locking companion flange for
ND 140 and 160.
Important:
The joint of the BLUTOP range is specially designed to confer
leaktightness with spigots of BLUTOP pipes.
As a result, the spigots of BLUTOP pipes must not be installed in
sockets designed for other seals (plastic or other cast iron parts).
Prohibited: BLUTOP pipe in PVC or HDPE socket

Connections
COMPATIBILITIES
Assembly:
The rules for assembly are identical to
those for BLUTOP pipes (see page 24) :
- Really clean ends PVC-U
- Well lubricated surfaces
- An appropriate chamfer
- The sleeve placed over the socket
Before fitting-together, transfer on the BU PE
side the equivalent of the marking of two
small white lines. Respecting this rule (only
the second small line must remain visible)
will enable to retain the benefit of angular PVC-BO
deviations offered by the BLUTOP range.
Locking cases:
Important:
The BLUTOP Vi locking ring can be used only on BLUTOP pipes and
unions.
For locking PVC pipes (U or BO) or HDPE, exclusively use a secured

IZIFIT joint for ND 75, 90, 110 and 125.
Securing Securing Use the secured IZIFIT joint on
BLUTOP Vi IZIFIT
the PVC pipes (U or BO) or HDPE
tubes.
- Fit together a sleeve or a
BLUTOP bend;
- Lock on the BLUTOP side with
the BLUTOP Vi sealing ring;
HDPE or PVC tube
- Lock on the plastic side with the
BLUTOP pipe ND 75, 90, 110 and 125 secured IZIFIT joint.
For locking PVC (U or BO) or HDPE pipes, ND 140 and ND 160 use
exclusively a locking companion flange.
Securing Use the locking companion flange
BLUTOP Vi Locking companion flange
on the PVC pipes (U or BO) or
HDPE tubes.
- Fit together a sleeve or a
BLUTOP bend;
- Lock on the BLUTOP side with
the BLUTOP Vi sealing ring;
HDPE or PVC tube - Lock on the plastic side with the
BLUTOP pipe ND 140 and 160 locking device.

CUTTING A BLUTOP PIPE
Important:
The analysis of risks of conditions of cutting a pipe and their control are the
responsibility of the company that is managing them (particularly the use
of personal protective equipment).
Cutting:
In case of cutting in a section located at less than 2.00 m from
the fitting side end, check beforehand with a circometer that the
outside diameter measured is less than the maxOD.
DN/OD Max OD (mm)

2.00 m Inspection area of the OD with a circometer
75 75.5
90 90.6
110 110.7
125 125.8
140 140.9
160 161.0
Preferably cut within 4 metres from the pipe spigot;

Draw the cutting plane perpendicular to the pipe axis;
Cut with:
- A rotary saw
- A pipe cutter (after having cut the metal, complete the
cutting of the DUCTAN coating with a knife)
- A chain saw for cast iron pipes.
- The EXACT cutting machine

Section
REPARING A CUT
Making the chamfer:
After cutting the pipe,
deburr the DUCTAN
internal coating with
a cutting blade (knife,
trimmer, etc.) or a half-
round file.
Recreate the end chamfer to facilitate insertion and avoid damaging

the joint. Respect the dimensional characteristics of the chamfer
profile.
The end of the pipe must not be sharp, the residual thickness at the
end of the chamfer must be between 0.5 and 1.00 mm max. The sharp
edge resulting from the deburring must be polished with a grinder or
file.

REPARING A CUT
Reconstituting the coating:
It is mandatory after all cutting operations (BU or BU-BU tip), to
reconstitute the protection of the exposed metal.
Recreate the protection on the exposed
trench and on the chamfer;
Using cut repair paint;
Apply with a brush or filling knife;
Apply the product with criss-cross
strokes;
Leave to dry.
It is recommended to lightly preheat the

metal using a heater, before applying the
repair coating, this prior operation enables to
reduce the drying time.
Reconstituting interlock limit marks:

In order to preserve the angular deviation priorities of BLUTOP pipes (6
per junction), it is necessary to make marks of the indentation limit on
each cutting.
Practically, it is possible to use as model, a clipping of the spigot of a
BLUTOP tube of the same nominal diameter, with the marking of two
small white lines at the factory.

Connection
TOOLS
Using the right tools and drilling method:

The specific drilling tools used with the BLUTOP pipes enable to
carry out connections with:
- A regular cut out of the metal and the internal DUCTAN coating;
- Systematic recovery of the cast iron blank cut out, either with load
or in absence of pressure;
- Wet connection in lateral position or on top.
Useful advice:
Use only BLUTOP drilling tools proposed by Saint-Gobain PAM:
- HS bimetal multi-tooth chamfering cutter;
- With a central guide drill;
- Equipped with an elastic ring for retaining the disc cut-out;
Respect the operating procedure of the drilling:

- Preferably use a portable drill (with load, equip it with BLUDRIL);
- The rotation speed must not be less than 200 rpm;
- Do not use a hand ratchet that will destroy the teeth of chamfering
cutters.
Important:
Standard drills used for cast iron pipes are internally coated with cement
mortar and must not be used to drill BLUTOP pipes.
Drill bits designed exclusively for drilling pipes

of the BLUTOP range

DRILLING MACHINE UNDER LOAD
The drilling operation to create a connection may be carried out either
with the BLUDRIL drilling machine developed specifically by Saint-Gobain
PAM for the BLUTOP range, or with one of the other drilling machines
available on the market.
BLUDRIL drilling machine:
The BLUDRIL drilling machine is delivered
with its accessories in a carrying case, which
includes a kit of adaptors, a set of rods and
the series of 4 drill bits-bells for cocks of ND
20, 25, 32 and 40.
Reference: 228099
For more details, refer to the operating instructions
Recommendations for use:

Check beforehand that the length of the shaft used is sufficient
before undertaking the drilling operation.
Do not stop the rotation of the tool during drilling in order to avoid
damaging the teeth of the drilling bell.
Spray soapy water or silicon on the tool-holder shaft in order to
reduce friction with the bronze ring of the drilling machine.
Adapter kit for EIE drilling machine:

BLUTOP drilling adapters for EIE machine
Description Reference
ND 20 220947
ND 25 220948
ND 32 220949
ND 40 220950
Adapter kit for other drilling machines:

Description Reference
Adapter kit HUOT/ND 20, 25, 32 and 40 220932
Saint-Germain and Staub + PAM/DN 20, 25, 32 adapter kit 220933
Pamco/ND 20,25, 40 adapter kit 220934
Iseo/Bayard/ND 20, 25, 32, 40 adapter kit 220935
AVK/ND 20, 25, 32 and 40 adapter kit 220946
HAWLE M/M adapter kit 225113
Adapter kit for VHL machine (2F) 228109

Connection
EXECUTION
Operating procedure:
Installing the pipe ring and the cock
- Either PAM connecting pipe ring;
-O r BLUTOP compatible pipe ring proposed by another
manufacturer (contact us);
- Installing the curb cock on the pipe ring;
- Check that the cock is indeed in the open position.
Drilling
Use a boring and screwing machine equipped with a 13 mm
mandrel
- Recommended rotation speed of 300 to 400 rpm;
- Screw on the "bell-shaped cutter" tool holder on the machine
shaft;
- Screw on the machine plate on the threaded part of the cock;
- During drilling, apply a moderate and continuous feed;
- With load, use a battery-operated boring and screwing machine
(to ensure a more regular rotation of the borer at slower speed)
equipped with BLUDRIL;
- The cutting tip retained by the snap ring will be retrieved by
removing the central bit.

PRESSURE TEST
Main provisions:
The length of the section to be tested depends on the configuration of
the line and the data in the Special Technical Specifications;
It is recommended not to exceed 2000 metres (Fascicle 71);
Plug the ends of the concerned section with blanking disks fitted with
valves, for air filling and extraction;
Evaluate the hydraulic forces developed on the ends of the pipeline
and set up a suitable system of stops or locking mechanisms;
Avoid bearing down on the ends of the pipe which is already laid and
has undergone hydraulic testing.
Checks:
Check the efficiency of suction devices;
Progressively fill the pipe from the low point;
Bleed the air at the various high points of the section;
Use the outlet gate valves to check the progressive influx of the water.
Pressurising and inspection:

Once the pipe is completely filled, gradually
increase pressure up to the prescribed test
pressure;
Keep a constant check on the stops;
Apply the defined test criteria. The test
pressure must not reduce by more than
0.2 bar while it is maintained (30min
according to Manual 71 or 1h according
to the EN 805 standard);
Empty the pipe, remove the test equipment
and connect the section.
Important:
The BLUTOP joints without anchor can be tested up to 35 bar (PEA) if the
forces are taken up by suitable stops.
The BLUTOP joints with anchor can be tested up to 24 bar. In the event of
a test lasting more than 1 hour, the effect of temperature variations must
to be taken into account.

Project acceptance
CLEANING AND COMMISSIONING

Cleaning and disinfection:
Wash the inside of the new pipes by means of flushing with water
or other suitable processes.
Repeat this washing if necessary, so that the water turbidity is lower
than the maximum permitted by the standards and regulations in
force.
Disinfect and rinse out the pipes.
Take a sample of the water for internal testing in compliance with
the instructions in force.
Rinse out the pipework properly again.
Ensure that random samples are immediately taken by the
accredited laboratory responsible for monitoring the water.
Repeat the operation under the same conditions if the results are
unfavourable.
Operations to clean and disinfect the pipes are carried out by the
contractor.
Commissioning and satisfaction:

Respecting all implementation recommendations proposed by this
installation board will ensure the reliability and safety of the distribution
network laid.
Like every constituent of the water network, it deserved the full attention
of its designer, this document is created to be fully consistent with this
approach.

NOTES
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NOTES
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SAINT-GOBAIN PAM worldwide
ALGERIA FRANCE & DOM-TOM NETHERLANDS
SAINT-GOBAIN PAM ALGERIE SAINT-GOBAIN PAM (HEAD OFFICE) SAINT-GOBAIN PIPE SYSTEMS
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Advice For Laying Blutop

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Advice for Laying

Pipeline for the

Comprehensive pipe solutions

Guidance on fitting BLUTOP - Edition 2015

Guidance on fitting BLUTOP - Edition 2015 1

BLUTOP, A COMPREHENSIVE RANGE

DN/OD 75, 90, 110, 125, 140 and 160

DN/ OD L Class DE Weight PFA PMA PEA Reference

m bar mm Kg/m bar bar bar

110 6 25 110 7.5 25 30 35 KXM11H60

125 6 25 125 8.6 25 30 35 KXM12H60

140* 6 25 140 10.0 25 30 35 KXM14H60

160 6 25 160 12.5 25 30 35 KXM16H60

* DN/OD 140: Please inquire

2 Guidance on fitting BLUTOP - Edition 2015

JOINTS AND ACCESSORIES

Guidance on fitting BLUTOP - Edition 2015 3

75 75 6 3.0 77.7 82.0 113.0 5.10 KXL75H60

90 90 6 3.0 92.7 84.0 130.2 6.10 KXL90H60

110 110 6 3.0 112.8 87.0 149.5 7.60 KXM11H60

125 125 6 3.0 128.0 92.0 164.0 8.60 KXM12H60

140* 140 6 3.2 143.1 94.5 185.0 10.00 KXM14H60

160 160 6 3.4 163.3 97.5 202.0 12.50 KXM16H60

* DN/OD 140: Please inquire

DN/OD = Outside diameter

4 Guidance on fitting BLUTOP - Edition 2015

FITTINGS AND ACCESSORIES

Guidance on fitting BLUTOP - Edition 2015 5

DN/OD Number of pipes Weight of bundle (kg)

Store flat on wooden battens;

6 Guidance on fitting BLUTOP - Edition 2015

Guidance on fitting BLUTOP - Edition 2015 7

BLUTOP locking rings:

8 Guidance on fitting BLUTOP - Edition 2015

- The advantages of BLUTOP drilling tools:

These tools deliver excellent drilling quality;

Manual tool: use of a manual tool such as a ratchet

Guidance on fitting BLUTOP - Edition 2015 9

Lifting bundles of BLUTOP pipes:

10 Guidance on fitting BLUTOP - Edition 2015

CLADDING THE PIPES

Cladding BLUTOP pipes:

Guidance on fitting BLUTOP - Edition 2015 11

The BLUTOP lubricating paste made with

850 g box with applicator brush:

Ambient temperature 5C Ambient temperature 16C

Using the applicator brush ensures the

Only BLUTOP lubricating paste should be used to lubricate the BLUTOP

12 Guidance on fitting BLUTOP - Edition 2015

RECOMMENDED PIPE CUTTING PRACTICE

DN/OD One box for

Quantities are given as a rough guide, they depend on working conditions,

Restoring the coating:

Guidance on fitting BLUTOP - Edition 2015 13

DN/OD (mm) 75 90 110 125 140 160

Use of crowbar for insertion recommended:

The advantages of cast iron:

14 Guidance on fitting BLUTOP - Edition 2015

DN/OD (mm) 75 90 110 125 140 160

Implementing the supplies:

Guidance on fitting BLUTOP - Edition 2015 15

In any event, recesses should be made for the sockets.

16 Guidance on fitting BLUTOP - Edition 2015

Compaction: 95% (OPN) Compaction: 85% (OPN)