Unrivalled

FlexLock

Couplings & Flange Adaptors

For Ductile Iron or Steel Pipes

PIPE CONNECTIONS, REPAIR & FLOW CONTROL PRODUCTS FOR THE UTILITIES INDUSTRY

FlexLock
Overview

Unique, Patented & Self Anchoring Joints for Ductile Iron or Steel Pipes
The FlexLock system provides a self-anchoring method of joining ductile iron or steel pipes and offers a cost effective, quick and simple alternative to traditional anchoring systems such as site welding, harnessing or thrust blocks.

End Load Restraint

Available as ange adaptors and couplings, FlexLock works on the same compression joint principle as standard Viking Johnson products but as the compression bolts are tightened, the stainless steel teeth grip around the outside diameter of the pipe, providing a fully end load restraint joint. Internal pressure in the pipe causes the assembly to lock rmly providing a leak proof joint. The FlexLock range consists of couplings and ange adaptors with nominal sizes from DN50 (2) up to DN300 (12) and are suitable for use on cold potable water pipelines with a maximum operating temperature of 40C.

Above Ground or Buried Application

FlexLock is a unique pipe jointing system that is fully end load bearing. Gaskets have embedded stainless steel teeth that grip the outer surface of the pipe, yet still allow for angular deection of pipes in service. This prevents pipes from separating under pressure loads, making FlexLock ideal for above ground and buried applications, soft ground conditions or temporary pipe work.

FlexLock Flange Adaptors

Pipe Materials FlexLock Coupling

Viking Johnson FlexLock

Telephone: +44 (0)1462 443322

FlexLock Couplings & Flange Adaptors

Product Design Benefits
Excellent Corrosion Protection Suitable for Water & Gas
A FlexLock is supplied as standard with EPDM gaskets for water applications to EN 681. However it is also available with Nitrile gaskets to EN 682 suitable for natural gas, petroleum products, low aromatic fuels, sewage and drainage. Metal components are coated with Rilsan Nylon 11 which is WRAS approved for use with potable water. The nuts and bolts are Sheraplex coated to WIS 4-52-03, offering long term protection against corrosion, impact and abrasion to ensure continued reliable performance.

Mechanical Couplings & Flange Adaptors Dedicated

Unique Load Bearing Teeth

As the compression bolts are tightened, unique load bearing stainless steel teeth, that are moulded into the gasket grip around the outside diameter of the pipe, providing a fully end load restraint joint.

Customer Benets
FlexLock permits angular deection between pipes, allowing for normal pipeline movement such as ground settlement. Long radius curves can also be accommodated, reducing the need for special ttings. FlexLock couplings allow for a total angular deection of 6 (3 for ange adaptors). Cost effective FlexLock can provide signicant cost savings compared to non-locking couplings with a harnessing system. Restrains pressure thrusts without thrust blocks at bends. Convert cut lengths of pipe into anged pipes - allows use of pipe offcuts. Working Pressure of 16bar on water up to and including DN200 and 10bar for DN250 & DN300. The ability to provide angular deection in ANY plane is a particular advantage - a harness assembly can provide angular deection only in ONE plane.

www.vikingjohnson.com

Viking Johnson FlexLock

FlexLock Unique Sealing System

How FlexLock Works
FlexLock ange adaptors and couplings work on the same compression joint principle as standard Viking Johnson products. As the compression bolts are tightened, unique load bearing stainless steel teeth (moulded into the gasket) grip around the outside diameter of the pipe, providing a fully end load resistant joint. Internal pressure in the pipe causes the assembly to lock even more rmly.

Step 1

Step 2

Step 3

Tightening the bolts compresses the gaskets between the end rings and the centre sleeve, pressing the gasket on to the pipe and driving the edges of the steel teeth to grip on the pipe surface.

Progressive tightening of the bolts drive the teeth into their correct locked position.

When the bolts are tightened to their correct torque, the FlexLock coupling or flange adaptor is securely locked in position providing a leak proof joint whilst at the same time allowing the joint to compensate for angular movement within the pipeline.

Viking Johnson FlexLock

Telephone: +44 (0)1462 443322

United Kingdom - Chesterfield

Yorkshire Water
FlexLock Flange Adaptors - DN250
Mechanical Couplings & Flange Adaptors Dedicated

Project
FlexLock installed on ductile iron pipe.

Client
Yorkshire Water

Contractor
Black & Veatch

www.vikingjohnson.com

Viking Johnson FlexLock

FlexLock Coupling
Specifications
L S 1) Sleeve 2) End Ring 3) Gasket 4) Gripper Teeth 5) Bolt
2

A
3 1 5 4

FlexLock Couplings
Pipe Nom DN50/2" DN65/2.5" DN80/3" DN80/3" DN100/4" DN100/4" DN150/6" DN150/6" DN150/6" DN200/8" DN200/8" DN250/10" DN250/10" DN300/12" DN300/12" Pipe OD (mm) 60.3 76.1/77 88.9 98.0 114.3 118 165.1 168.3 170 219.1 222 273.0 274 323.9 326 Pipe Material steel steel steel ductile iron steel ductile iron steel steel ductile iron steel ductile iron steel ductile iron steel ductile iron Bolt Size No.-Dia x Length 2-M12 x 145 2-M12 x 160 4-M12 x 160 4-M12 x 195 4-M12 x 170 4-M12 x 195 6-M12 x 170 6-M12 x 170 6-M12 x 170 8-M12 x 170 6-M16 x 195 12-M16 x 275 12-M16 x 275 12-M16 x 275 12-M16 x 275

Setting Gap Maximum Gap

Overall Length (L) 157 170 170 203 188 203 188 188 178 188 206 286 286 286 286 End Ring OD (A) 135 152 163 181 195 200 254 256 256 310 316 376 376 436 436 Sleeve Length x Thickness (mm) (S) 80 x 5.5 100 x 6.0 100 x 6.0 115 x 6.4 100 x 6.0 115 x 6.4 100 x 7.2 100 x 7.2 100 x 7.2 100 x 7.2 115 x 6.4 178 x 8.5 178 x 8.5 178 x 6.0 178 x 6.0 Setting Gap Min 15 20 20 20 20 20 20 20 20 20 20 20 20 20 20 Max 30 40 40 40 40 40 40 40 40 40 40 40 40 40 40 Working Pressure (bar) 16 16 16 16 16 16 16 16 16 16 16 10 10 10 10 Gasket Mould 1375 1394 1382 1630 1367 1618 1369 1369 1369 1370 1631 1737 1737 7667/8 7667/8 Coupling Weight (kg) 2.7 3.2 4.2 5.2 6.1 5.6 9.2 9.3 9.2 11.9 12.0 32.2 32.2 33.7 33.7

FlexLock bolt torques: M12 = 55-65Nm M16 = 95-120Nm

Materials & Relevant Standards

Centre Sleeve/End Rings
SG. Iron to BS 1563:1997:Symbol EN-GJS-450-10 or Rolled Steel to: BS EN 10025:2004:Grade S275.

Gaskets
EPDM compound Grade E to BS EN 681-1 WRAS listed. Suitable for: water, sewage, many strong and oxidising chemicals and food applications. Nitrile compound Grade G to BS EN 682-1. Suitable for: natural gas, petroleum products, low aromatic fuels, compressed air, sewage and drainage. Stainless Steel teeth in gaskets BS 3146:1975:Part 2 Grade ANC2.

Coupling Body
Ductile Iron to BS EN 1563 EN-GJS-450-10. or Mild Steel to: BS EN 10025:2004:Grade S275.

Bolts/Nuts/Washers
Bolts - Cold Forged Steel Fasteners to: BS EN ISO898-1: 2001 Property Class 8.8 Nuts - Steel BS EN 20898-2:1994 Property Class 8 Washers - BS 4320 Form B Stainless Steel BS 1449:PT2:1983 Grade 304 S15

Approvals/Standards
Designed and manufactured under quality management systems to BS EN ISO 9001. They have been tested in accordance with the requirements of WRc Water Bye-laws Scheme and conform to the American Water Works Associations standard AWWA/ANSI C.219 for bolted couplings.

Coatings
Body, Centre Sleeve, End Rings are coated in Rilsan Nylon 11 to WIS 4-52-01 Part 1. Bolts, studs and nuts are Sheraplex coated to WIS 4-52-03.
Note: For coated steel pipe the maximum permitted coating thickness is 500 DFT. This is to ensure the stainless steel teeth properly grip onto the pipe surface to mobilize the end load capability of the products. Due to the surface characteristics of stainless steel pipe, FlexLock grippers are unable to achieve a guaranteed grip on the pipe surface. FlexLock is suitable for use on cold potable water pipelines and has a maximum operating temperature of 40C. Every effort has been made to ensure that the information contained in this publication is accurate at the time of publishing. Crane Ltd assumes no responsibility or liability for typographical errors or omissions or for any misinterpretation of the information within the publication and reserves the right to change without notice.

Viking Johnson FlexLock

Telephone: +44 (0)1462 443322

FlexLock Flange Adaptor

Specifications
Setting Gap Maximum Gap

1) Flange Adaptor 2) End Ring 3) Gasket 4) Gripper Teeth 5) Stud L S

2 3 5 1

Mechanical Couplings & Flange Adaptors

FlexLock Flange Adaptors

Pipe Nom DN50/2" DN65/2.5" DN80/3" DN80/3" DN100/4" DN100/4" DN150/6" DN150/6" DN150/6" DN200/8" DN200/8" DN200/8" DN200/8" DN250/10" DN250/10" DN300/12" DN300/12" Pipe OD (mm) 60.3 76.1 88.9 98 114.3 118 165.1 168.3 170 219.1 219.1 222 222 273.0 274 323.9 326 Pipe Material steel steel steel ductile iron steel ductile iron steel steel ductile iron steel steel ductile iron ductile iron steel ductile iron steel ductile iron Bolt Size No.-Dia x Length 2-M12 x 115 2-M12 x 115 4-M12 x 115 4-M12 x 115 4-M12 x 115 4-M12 x 115 8-M12 x 115 8-M12 x 115 8-M12 x 115 8-M12 x 115 8-M12 x 115 6-M16 x 125 8-M16 x 125 12-M16 x 125 12-M16 x 125 12-M16 x 125 12-M16 x 125 Flange OD (A) 160 180 195 195 215 215 285 286 286 341 340 341 340 405 405 467 467 Overall Length (L) 123 123 123 123 123 123 127 123 123 123 127 137 137 137 137 137 137 Flange Thickness (mm) (F) 16 16 16 16 16 16 25 19 19 19 25 19 25 19 19 19 19 Sleeve Length (mm) (S) 75 75 75 75 75 75 75 75 75 75 73 75 75 90 90 90 90 Flange Nominal Drilling BS EN 1092-1 50 PN10/16 60/65 PN10/16 80 PN10/16 90 PN6 80 PN10/16 90 PN6 100 PN10/16 110 PN6 100 PN10/16

A
Working Pressure (bar) 16 16 16 16 16 16 16 16 16 10 16 16 10 10 10 10 10 Setting Gap Min 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 FA Gasket Weight Mould Max (kg) 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 30 1375 1394 1382 1630 1367 1618 1369 1369 1369 1370 1370 1631 1631 1737 1737 7667/8 7667/8 2.3 2.6 3.4 4.0 4.5 4.4 9.3 8.0 8.0 9.7 15.2 10.6 13.9 16.4 16.4 22.7 22.7

150 PN10/16 6E 6ANSI 150 150 PN10/16 150 PN10/16 200 PN10 200 PN16 200 PN16 200 PN10 8E 250 PN10/16* 250 PN10/16* 300 PN10/16* 300 PN10/16*

Dedicated

FlexLock bolt torques: M12 = 55-65Nm M16 = 95-120Nm

Materials & Relevant Standards

Centre Sleeve/End Rings
SG. Iron to BS 1563:1997:Symbol EN-GJS-450-10 or Rolled Steel to: BS EN 10025:2004:Grade S275.

* Working pressure rating is less than flange rating.

Gaskets
EPDM compound Grade E to BS EN 681-1 WRAS listed. Suitable for: water, sewage, many strong and oxidising chemicals and food applications. Nitrile compound Grade G to BS EN 682-1. Suitable for: natural gas, petroleum products, low aromatic fuels, compressed air, sewage and drainage. Stainless Steel teeth in gaskets BS 3146:1975:Part 2 Grade ANC2.

Flange Adaptor Body

Ductile Iron to BS EN 1563 EN-GJS-450-10. or Mild Steel to: BS EN 10025:2004:Grade S275.

Studs - Bolts/Nuts/Washers
Studs/Bolts - Cold Forged Steel Fasteners to: BS EN ISO898-1: 2001 Property Class 8.8 Nuts - Steel BS EN 20898-2:1994 Property Class 8 Washers - BS 4320 Form B Stainless Steel BS 1449:PT2:1983 Grade 304 S15

Approvals/Standards
Designed and manufactured under quality management systems to BS EN ISO 9001. They have been tested in accordance with the requirements of WRc Water Bye-laws Scheme and conform to the American Water Works Associations standard AWWA/ANSI C.219 for bolted couplings.

Coating
Body, Centre Sleeve, End Rings are coated in Rilsan Nylon 11 to WIS 4-52-01 Part 1. Bolts, studs and nuts are Sheraplex coated to WIS 4-52-03.

Note: For coated steel pipe the maximum permitted coating thickness is 500 DFT. This is to ensure the stainless steel teeth properly grip onto the pipe surface to mobilize the end load capability of the products. Due to the surface characteristics of stainless steel pipe, FlexLock grippers are unable to achieve a guaranteed grip on the pipe surface. FlexLock is suitable for use on cold potable water pipelines and has a maximum operating temperature of 40C. Every effort has been made to ensure that the information contained in this publication is accurate at the time of publishing. Crane Ltd assumes no responsibility or liability for typographical errors or omissions or for any misinterpretation of the information within the publication and reserves the right to change without notice.

www.vikingjohnson.com

Viking Johnson FlexLock

United Kingdom - Liverpool

West East Link Main

FlexLock - DN150 & Large Diameter - DN800

Project
West East link transmission main. The 53km pipeline runs from Prescot near Liverpool to Bury, near Manchester.

Client
United Utilities

Contractor
Murphys

Viking Johnson FlexLock

Telephone: +44 (0)1462 443322

www.flowoffluids.com
ISO 14001 EMS 51874 ISO 9001 FM 00311

Visit www.owofuids.com to order your copy of the New Technical Paper 410.

46-48 WILBURY WAY HITCHIN, HERTFORDSHIRE SG4 0UD. UNITED KINGDOM TELEPHONE: +44 (0)1462 443322 FAX: +44 (0)1462 443311 EMAIL: [email protected] www.vikingjohnson.com

Designed and manufactured under quality management systems in accordance with BS EN ISO 9001. Environmental Management System accredited to ISO 14001. For full terms and conditions, please visit our website. We hope our communications have an impact on you - but not the environment - we have taken steps to ensure this brochure is printed on Forestry Stewardship Council material and the paper is made by totally chlorine free process.

Every effort has been made to ensure that the information contained in this publication is accurate at the time of publishing. Crane Ltd assumes no responsibility or liability for typographical errors or omissions or for any misinterpretation of the information within the publication and reserves the right to change without notice.

www.cranebsu.com

DR5700_04_2011