AVK SERVICE CONNECTION SYSTEMS

SYSTEM
EXPECT A
COMPLETE
A COMPLETE SYSTEM FOR
SERVICE CONNECTION

In 1969 AVK introduced the very first gate valve for water. Five years later we launched
our first service connection valves in cast iron and later on we expanded our range by
launching our brass and POM service connection valves.

For a complete service connection system we offer a comprehensive range of extension

spindles, surface boxes and tapping saddles. Furthermore, the Supa Lock™ range also
comprises a wide range of fittings.

AVK’s service connection system is a well-proven solution that secures easy and
maintenance-free installation and long life. Each product in the range has outstanding
design features, and when combined, the products form a system with the best possible
durability and reliability.

2 | SERVICE CONNECTION SYSTEM

 SURFACE BOXES FIXED OR TELESCOPIC
EXTENSION SPINDLES
SYNTHETIC DUCTILE

COMPOSITE

TAPPING SADDLES

AC PIPES

SERVICE CONNECTION VALVES

CAST IRON PIPES

DUCTILE IRON PIPES

DUCTILE
TAPPING SADDLES

PVC PIPES BRASS POM

PE PIPES SUPA LOCK™

TAPPING SADDLES

SUPA LOCK™ FITTINGS PE/PVC PIPES

IRON/STEEL PIPES

SUPA LOCK™ CONNECTORS SUPA LOCK™ SUPA LOCK™

FOR DRILLING MACHINES BALL VALVES SERVICE VALVES

SERVICE CONNECTION SYSTEM | 3

HIGH STRENGTH STEMS
AND SUPERIOR WEDGE
DESIGN

AVK service connection valves are long lasting and

maintenance-free due to high strength stems and superior
wedge design securing low operating torques as well as a
smooth operation of the valve.

Stainless steel stems with rolled threads

The stem threads are rolled in a cold pressing
process which maintains the steel structure and
therefore increases the strength of the stem.
This method results in smooth thread surfaces
and brings about low operating torques and
prolonged durability.

4 | SERVICE CONNECTION SYSTEM

Superior wedge design
AVK’s wedges are superior to the traditional
wedge design. The wedge is made of
dezincification resistant brass vulcanized with
drinking water approved EPDM rubber. The
wedge core is immersed in two different baths
providing a unique bonding between the rubber
and brass core. As a result, we can offer the
best rubber adhesion and corrosion protection
at the market.

Unique features and benefits Impurities are absorbed in the rubber when the
• Double bonding vulcanization process ensures wedge is in closed position.
maximum adhesion of the rubber.
• Shaped with a wedge guide and a special
rubber profile ensuring low closing torques.
• Rubber vulcanized to the core with min.
1.5 mm on all pressure bearing surfaces and
4 mm on all sealing surfaces giving optimum
corrosion protection.
• AVK’s rubber compound features an
outstanding compression set value and
resistance to water treatment chemicals
as well as it ensures minimised biofilm
formation.
• All dimensions have full and straight bore
which prevents head loss and deposits in the When the impurities have been flushed away,
the rubber will regain its shape.
valve bottom.

AVK rubber compounds adhesion and the tensile strength meet the Impurities will not affect the rubber surface
AVK GUMMI A/S develops and manufactures predefined requirements. or the tightness of the valve, as they will be
the rubber compound for wedges and gaskets absorbed in the rubber when the valve is in
using highly advanced technologies. AVK GUMMI A/S has a profound know-how closed position. When the valve is reopened,
within the science of a rubber’s compression the impurities will be flushed away, and thus
Data is collected throughout the entire set. Even after many years of service where the the rubber will regain its shape.
manufacturing process securing traceability wedge rubber has been compressed numerous
of every individual ingredient, each compound times, the rubber will regain its original shape
and the finalized components. Tests are made and ensure a tight sealing.
to ensure that the compression set values, the

SERVICE CONNECTION SYSTEM | 5

DUCTILE IRON SERVICE
CONNECTION VALVES
AVK offers a
comprehensive range of
service connection valves
of ductile iron. With internal
threads, push-in socket
ends, screw couplings and
PRK couplings as well as
combinations with external
thread.

Unique stem sealing Two strong coatings In addition to our own tests, the adhesion
Our ductile iron valves are designed with a Our ductile iron valves are as standard with and cathodic disbonding of the epoxy coating
triple safety stem sealing system, where a internal and external epoxy coating according are examined several times per year by the
manchette (1) is the main seal to the flow. Also to DIN 30677-2. The epoxy is applied manually independent GSK authorities.
four NBR O-rings in a polyamide bearing (2) or using a fluidized bed epoxy coating system.
provide tightness around the stem and an NBR Optionally, we offer inside enamelling suitable Enamelled products are tested for a minimum
wiper ring (3) protects against impurities from for installation in special corrosive media layer thickness of 200 μ and a pinhole-free
the outside. A full circle thrust collar (4) of where the complete smooth surface ensures surface.
dezincification resistant brass provides a low that no impurities will stick to the surface.
free running torque and fixation of the stem. Enamelling gives a durability and resistance to Tight assembly of valve body and bonnet
be compared with glass and prevents creeping A bonnet gasket fits into a recess between the
corrosion. valve body and the bonnet, which prevents it
from being blown out at pressure surges. The
Thorough control of the coating stainless steel bonnet bolts are encircled by the
We thoroughly check each batch of coated bonnet gasket, countersunk in the bonnet and
components. The epoxy coated components finally sealed to prevent corrosion.
are checked to ensure a layer thickness of
3 minimum 250 μ and a pore-free surface. The
coating must be completely free of penetrating
2
pores to avoid subsequent corrosion of the
casting underneath. The impact resistance and
4
the curing of the coating is tested right after
the coating process, see technical appendix for
1
further information.

6 | SERVICE CONNECTION SYSTEM

Series 03/00 - Internal thread. Optionally series Series 03/30 - push-in socket ends for PE pipes Series 03/40 - side tapping with external thread /
03/10 with enamel internally internal thread and tensile resistant socket joint

Series 03/65 - Tensile resistant screw couplings Series 03/85 - Tensile resistant screw coupling Series 03/90 - PRK couplings for PE pipes
for PE pipes for PE pipes/external thread

Series 03/93 - PRK coupling for PE pipes / Series 11/00 - angle valve with external thread Series 11/30 - angle valve with external thread
external thread, enamelled internally on inlet and internal thread on outlet on inlet and tensile resistant socket joint for PE
pipes on outlet

Series 36/80 - PE pipe ends PE 100, PN 16

SERVICE CONNECTION SYSTEM | 7

BRASS SERVICE
CONNECTION VALVES

Series 16/00 - Tensile resistant screw couplings

for PE pipes and AVK-top for AVK extension
spindles.

Series 16/29 - Tensile resistant screw couplings

for PE pipes and T-top for Norwegian extension
Brass valves in four variants • An NBR O-ring ensures tightness in the spindles.
Our service connection valves of hot stamped boltless connection between valve body
dezincification resistant brass are available with and bonnet. The O-ring is countersunk
tensile resistant brass screw couplings or PRK and compressed when the valve bonnet is
couplings and with AVK or T-type top - all in screwed on to the body thus ensuring a tight
DN 25-50 for 32-63 mm PE pipes. valve.
• An NBR wiper ring encircles the acid-
resistant stainless steel stem as protection
against impurities from outside (1). Two NBR
O-rings complete the stem sealing (2). The
full circle thrust collar (3) of dezincification Series 16/20 - PRK couplings for PE pipes and
resistant brass provides a low free running T-top for Norwegian extension spindles.

1 torque.
2 • Designed to fulfil the requirements of PN 16.

3 All couplings are fitted with a standard pipe

thread.

Series 16/25 - PRK couplings for PE pipes and

AVK-top for AVK extension spindles.

8 | SERVICE CONNECTION SYSTEM

POM SERVICE
CONNECTION VALVES

Series 16/01 - With PRK coupling for PE pipes /

external conical pipe thread.

Series 16/29 - Tensile resistant socket joint for

PE pipes / external conical pipe thread.

POM valves in eight variants • Bonnet, body and joints of POM are friction
Our service connection valves in POM welded ensuring optimum strength.
are available with PRK couplings, tensile • A built-in friction collar prevents overtorque of
resistant socket joints and PE ends as well as the valve (3).
combinations with external thread. In addition • An NBR wiper ring encircles the stem Series 16/50 - With tensile resistant socket joints
for PE pipes. Optionally series 16/53 with T-top.
there are options of a special T-top. of stainless steel as protection against
penetration of impurities (1). Two EPDM
O-rings seal against the internal pressure (2).

3 Series 16/80 - with PE ends for fusion welded

installations. Optionally series 16/83 with T-top.

Series 16/90 - with PRK couplings for PE pipes.

Optionally series 16/93 with T-top.

SERVICE CONNECTION SYSTEM | 9

AVK SUPA LOCK™
THREADLESS CONNECTION
SYSTEM
The Supa Lock™
system guarantees a
2 100% corrosion free
joint combined with fast
and easy assembly with
maximum flexibility.
1
The wide Supa Lock™
range consists of valves,
tapping saddles and fittings
in ductile iron as well as
ball valves and fittings in
dezincification resistant
brass.

Easy two-step assembly

After having greased the O-rings, the Supa Lock™ spigot end is pushed into the Supa
Lock™ socket end, and the safety retainer is clicked on - and the assembly is done!

Heavy duty O-rings provide extra safety Self-locking safety retainer

All Supa Lock™ joints are fitted with heavy Supa Lock™ is designed as a tensile joint 2
duty Ø7 mm O-rings. They provide extra safety and withstands pressures up to PN 16 x 1.5.
when taking into account that a moderate The safety retainer is designed with an edge
permanent deformation of the O-rings is to (1), which makes it self-locking whenever
be expected over the lifetime of the product. there is pressure in the pipeline. Therefore,
Also, when the joint is exposed to bending as a no accidental dissambly can take place. The 1
result of ground movements, the large O-rings safety retainer has two finger knobs (2) for
provide maximum safety. easy assembly and disassembly.

No rotation of valves and connectors

Free rotation is restricted for the valves and the
threaded connectors used for drilling machines
to enable effective drilling. Small cast notches main pipe, thus avoiding collision with other
placed on the outer rim of the socket end and pipes or obstacles in the trench.
on the inner rim of the spigot end interlock and
prevent rotation. Corrosion-free access point
For flanged connections in DN 80-400, the
360° rotation of fittings wafer type spacer with Supa Lock™ socket
The design allows for a 360° rotation of the connections offers a corrosion protected access
fittings, which is a unique feature only offered point to the pipe. It can replace a tapping and
by the Supa Lock™ system. The free rotation in that way avoid weakening of the pipe.
of the joint allows the installer to direct the
service pipe outlet in any direction from the

10 | SERVICE CONNECTION SYSTEM

Series 103/00 - Service connection valves with Series 343/81 - Brass ball valve with BSP Series 343/84 - Brass ball valve with PRK
one Supa Lock™ spigot end and one Supa thread. coupling.
Lock™ socket end with a full bore of Ø 32 mm,
ductile iron.

Series 343/85 - Brass ball valve with screw Series 100/00 - Tapping saddle for PE/PVC Series 100/14 - Tapping saddle for iron/steel
coupling. pipes, Ø 63-225mm, ductile iron. pipes, Ø 60-223 mm, ductile iron.

Series 107/31 - 90° push-in fitting for PE pipes, Series 107/21 - Straight push-in fitting for PE Series 107/36 - Fitting with PE pipe end, for
Ø 32-63 mm, ductile iron. pipes, Ø 32-63 mm, ductile iron. 32-40 mm PE pipes, ductile iron.

Series 106/01 - Ductile fitting with PRK coupling, Series 106/02 - Brass fitting with screw Series 106/02 - Brass fitting with PRK coupling,
for 32-40 mm PE pipes. coupling, for 32-40 mm PE pipes. for 32-40 mm PE pipes.

Series 106/01 - Threaded connector for drilling Series 106/02 - Threaded connector for drilling Series 109/10 - spacer for flanged connections,
machines, ductile iron. machines, brass. DN 80-400, ductile iron.

Series 106/00 - Blind plug for temporary

plugging, DN 80-400, ductile iron.

SERVICE CONNECTION SYSTEM | 11

USER FRIENDLY
EXTENSION SPINDLES

Extension spindles are

used for easy access
to operation of valves
installed below ground.
AVK extension spindles
are produced on fully
automated state-of-the-art
production equipment to
ensure a uniform quality.

The extension spindles are made of corrosion

resistant materials and random samples are
torque tested with up to 450 Nm to ensure
long service life. The conical key adaptor fits
most standard T-keys. The inner tube is press
fit to the top spanner and bottom adaptor to
safeguard the galvanization of the tube and the
bottom cover protects the valve spindle from
impurities and enables it to rotate freely.

"click"
Safe click
system

12 | SERVICE CONNECTION SYSTEM

Telescopic and fixed length Telescopic design facilitates on-site
• Fixed length version offers the market’s adjustments
easiest shortening of length Telescopic extension spindles are used when
• Telescopic version enables height adjustment the distance between the valve and the ground
after installation surface is unknown and when an adjustment
• Patented AVK “Safe Click” provides a fast and of the extension spindle is required after the
safe mounting on the service connection valve. installation. The top adaptor is designed with a
defrosting hole and with ears that can be fixed
Fixed length design features easy into AVK surface boxes and support tiles. A
shortening lock spring prevents the telescopic part from Expanding bolt design facilitates easy height
Fixed length extension spindles are used when collapsing during installation, as it creates adjustment on fixed length extension spindles.
the distance between the valve and the ground friction inside the inner tube. The blue center
surface is known so that adjustment of the sleeve protects against penetration of impurities
length after installation is required to a limited between the two outer PE pipes.
extent or not at all.

The patented AVK design facilitates fast and

easy shortening of the extension spindle. The
complete adjustment of the length can be done
by mere use of a hacksaw.
The extension spindles are available with a pipe
cover of 800-1000-1500-2000-3000 mm.
The top spanner and the inner tube are press fit on
telescopic extension spindles.

SERVICE CONNECTION SYSTEM | 13

COMPREHENSIVE RANGE
OF SURFACE BOXES
AVK offers a very comprehensive range of surface boxes
in various material combinations: synthetic body with
synthetic lids, synthetic body with cast iron lids, synthetic
body with ductile iron surface plate/lid as well as cast iron
body and lid.

Cast iron surface boxes Floating surface boxes with great

The ductile iron surface boxes are available in flexibility
a floating design and a fixed/floating reversible The internal fixation of telescopic extension
design. The reversible surface box allows for spindles enables height adjustment after
deflection and internal fixation of telescopic installation. The deflection ability secures
extension spindles from both ends. optimal fit on sloped surfaces.
The large chamber provides easy access for
The fixed surface boxes of grey cast iron are mounting and demounting of the extension
height adjustable using ductile iron distance spindle, and the closed design protects the
rings of a height of 10-50 mm. extension spindle against impurities.

Series 04/11: Series 04/10: Cast Series 04/12: Series 04/43: Series 04/007: Series 04/007: Series 04/008:
Ductile iron surface iron surface box, Ductile iron surface Composite surface Composite surface Composite surface Ductile iron surface
box, floating fixed box, reversible box, floating box, floating box, floating box, floating
- Grey cast iron lid - Grey cast iron lid - Ductile iron lid - Ductile iron lid - Ductile iron lid - Ductile iron lid - Ductile iron lid
- Ductile iron body - Grey cast iron body - Ductile iron body - Synthetic body - Synthetic body - Synthetic body - Ductile iron body

14 | SERVICE CONNECTION SYSTEM

 Fixed height surface boxes Recognisable synthetic lids
Classic range fixed height surface boxes are Lids made of synthetic materials are corrosion
DVGW DIN approved and can withstand high free, unattractive to thieves, more aesthetic
traffic loads and are therefore often used in (making them highly suitable for shopping areas
medium- and heavy duty application areas. and city centres) and lightweight, complying
The Futura range offers a lightweight and with Health and Safety Regulations.
economical version of the Classic range surface
box and is often used in light- to medium duty To prevent the lid from being lifted by the
application areas. suction of a passing vehicle, the reduced
weight is compensated with a locking clip
Height adjustable surface boxes around the bolt. In cases where surface box
AVK offers a wide range of DVGW DIN approved lids get covered with snow, leafs or soil, AVK
height adjustable surface boxes, which are offers a solution making the surface box
specifically designed for tarmac installation. easily detectable by means of a ferromagnetic
Using height adjustable surface boxes enables detector.
easy and precise installation thanks to flexible
positioning of the top part. Height adjustable Support tiles for Classic and Futura
surface boxes prevent costly corrections after surface boxes
installation and save time and money when A support tile increases the support surface
roads are renovated. AVK also offers height in weak soils, secures center location of the
adjustable surface boxes with reinforced rim, extension spindle and prevents telescopic
ensuring better support of the top part and extension spindles from being pushed back.
making this product even more robust, stable
and suitable for heavy duty application areas.

Series 80/32: Series 80/32: Series 80/32: Series 80/32: Series 80/32: Series 80/44: Series 80/46:
Synthetic surface Synthetic surface Synthetic surface Synthetic surface box, Synthetic surface box, Synthetic surface Support tile
box, fixed height, box, fixed height, box, fixed height, adjustable height, adjustable height, box, fixed height, - Synthetic
"Futura" "Futura" "Classic" "Classic" reinforced rim, - Cast iron lid
- Synthetic/cast iron lid - Synthetic lid - Synthetic/cast iron lid - Cast iron lid "Classic" - Synthetic body
- Synthetic body - Synthetic body - Synthetic body - Synthetic body - Cast iron lid
- Synthetic body

SERVICE CONNECTION SYSTEM | 15

WIDE RANGE
OF TAPPING SADDLES
AVK offers a wide range of
tapping saddles. A range
that comprises tapping
saddles for PE/PVC, ductile
iron, cast iron, asbestos
cement and steel pipes.
Furthermore, AVK tapping
saddles offer easy and
fast installation and reliable
function and they are
maintenance-free and
designed to last.

Series 10/00: Series 10/14: Series 727/10: Series 740:

Tapping saddle for PVC and PE pipes. Tapping saddle for ductile iron and Universal tapping saddle for PVC and Universal tapping saddle for
DN 50-300, steel pipes, DN 50-300, BSP 1-2" PE pipes, DN 80-200, BSP ½-2" underpressure drilling and tapping
BSP ¾-2" for shut-off, for ductile iron, steel and
other metal pipes, DN 50-300, BSP
½-2"

16 | SERVICE CONNECTION SYSTEM

Series 10/00 and 10/14 Series 10/9-20
• Stainless steel bolts and nuts and a fusion • Valve gasket in PUR (polyurethane) for
bonded epoxy coating secure long life maximum resistance.
without the risk of corrosion. • Fitted with a swivelling shut off that moves to
• Nut of acid-resistant stainless steel with the side during drilling and returns to closed
anti-friction coating to prevent it from galling position when the tapping device is removed.
against the stainless steel bolt. The nut is • Upper part of the valve and lower sleeve
located in a recess in the lower part making enclose the plastic pipe completely to provide
the installation fast and easy. an optimum load distribution on the plastic
• A large profiled rubber gasket of drinking pipe.
water approved EPDM rubber ensures a
drop tight seal against a rough pipe surface. Series 727/08 and 727/09
Only a quick cleaning and lubrication of the • Integrated cutter enables under pressure
surface is necessary. tapping where the cut off piece stays in the
• The female pipe connection is a standard cutter.
BSP pipe thread. The thread depth is kept to • After drilling the tapping saddle can be used
a minimum to ensure that no raw threads are as a valve.
exposed to the water once the male thread • No electrical machines needed when drilling.
fitting is mounted. Drilling done within a few minutes.
• Bolts, washers and nuts of stainless steel
Series 727/10 and 740 and a fusion bonded epoxy coating secure
Ductile iron saddle head with an open slot on long life without the risk of corrosion.
one side and a closed slot on the other side for • An NBR wiper ring encircles the stainless
easy mounting of the stirrup. steel stem and protects against impurities
• Bolts of stainless steel with anti-friction from outside.
coating supported by a POM washer to give • Only one type of saddle head needed for all
optimum flexibility and minimum friction upon dimensions.
installation.
• M16 bush cylinder, drilled and tapped, with
the stirrup plate rolled around ensuring long
life and passive safety without welding.
• A large profiled rubber gasket of drinking
water approved EPDM rubber ensures a drop
tight seal against a rough pipe surface.
• Safety without welding.

Series 10/9-20: Series 727/X9: Series 727/08:

Tapping saddle type SVK Tapping saddle type Tapping saddle type SWIC
for PVC pipes, SWIC for PE and PVC for metal pipes e.g. ductile
DN 100-250, BSP 1½-2" pipes with integrated iron, cast iron, asbestos
cutter, DN 50-225, cement and steel pipes,
BSP ½-2" DN 80-300, BSP/NPT ½-2"

SERVICE CONNECTION SYSTEM | 17

TECHNICAL APPENDIX - QUALITY
ASSURANCE AND OPERATION

Pressure tests: the procedures and specifications laid down in Operation:

Hydraulic test according to EN 1074-1 and 2 / the »AVK quality manual«. To avoid a seizure of the internal parts, it is
EN 12266 recommended to operate water valves every
AVK is certified according to: year, which at the same time ensures a long
Shell test with water: ISO 9001 / EN 29001 (quality) durability.
Valves PN 10 tested at 15 Bar ISO 14001 (environment)
Valves PN 16 tested at 24 Bar OHSAS 18001 (working environment and After operation the valve must be fully open
safety) and the stem released from stress or closed
Seat test with water: Valve PN x 1.1 with the closing torque stated in the table
Seat tests are done from both sides and with Field of application: below.
one end open. The field of application is stated in the data
sheet of each valve series. If the medium Temperature: Max. 70°C. For valves with
Certifications: contains special substances, information of the PE ends max. 40°C. The valve must not be
The production of all products in the AVK chemical designation, concentration, and the exposed to low temperature, causing the
programme are controlled in accordance with temperature of the medium must be given on medium to freeze.
inquiry of the valves.

Stem dimensions:

F1
DN H H1 F F1 F F1
F
mm mm mm mm mm mm mm
AVK-top AVK-top T-top T-top

H1 25 180 35 12.3 15.4 12.1 14.0

32 190 35 12.3 15.4 12.1 14.0
40 203 35 12.3 15.4 12.1 14.0
50 213 35 12.3 15.4 12.1 14.0

Torques and number of turns to open:

A
VK series 03 (ductile iron) and 16 (brass) AVK series 16 (POM)

Valve Closing Rupture Turns to Closing Rupture Rupture Turns

dimension torque torque open torque torque, torque, to open
Dd
DN Nm Nm Nm Nm opening closing Nm
direction direction
25 35 200 7 20 100 200 7
32 L 35 200 9 20 100 200 9
40 35 200 11 40 100 200 11
50 35 200 14 40 100 200 14

Advanced technology in products and processes

AVK products are manufactured in modern factories characterized by streamlined flows and a high
degree of automation. We are entirely committed to ensuring that quality remains an integrated part
of our production flow.

AVK’s quality assurance system is certified according to ISO 9001. Moreover, we are certified to
ISO 14001, the international standard for environmental management, and OHSAS 18001, the
international Occupational Health and Safety Standard.

18 | SERVICE CONNECTION SYSTEM

EXPECT SUSTAINABILITY

AVK products form part of the infrastructure around the world and as such they are important in environmental considerations.
As a large-scale valve manufacturer we are aware of the harmful effects industrial processes can have.
Therefore, we are constantly looking for ways to minimising our environmental impact, seeking to identify areas of improvement in our manufacturing
processes and in the environmental precautions of our sub-suppliers.

We systematically work on:

• Complying with existing environmental legislation and applicable work environmental legislation.
• Reducing the amount of waste within the company. Whenever possible we recycle waste materials. Alternatively we use the most environmentally friendly
waste disposal methods.
• Minimising our consumption of energy and raw materials.
• Minimising our use of materials and processes that can put the environment at risk.
• Educating our employees and thus enabling them to act in accordance with our environmental objectives.
• Taking environmental factors into consideration when we assess and build our supplier network.

SERVICE CONNECTION SYSTEM | 19

AVK International A/S
Bizonvej 1 Tel.: +45 8754 2100
Skovby Fax.: +45 8754 2120
8464 Galten [email protected]
Denmark www.avkvalves.eu
2017-10-17
Copyright©AVK Group A/S 2016

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