Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)

BRITISH STANDARD BS 4825-5:

1991 +A1:2009

Stainless steel tubes

and fittings for the food
industry and other
hygienic applications —
Part 5: Specification for recessed ring
joint type couplings

ICS 67.260; 77.140.75

BSI
Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
BS 4825-5:1991 +A1:2009

Committees responsible for this

British Standard

The preparation of this British Standard was entrusted by the Piping Systems
Components Standards Policy Committee (PSE/-) to Technical Committee
PSE/8, upon which the following bodies were represented:

Adhesive Tape Manufacturers’ Association

British Compressed Air Society
British Gas plc
British Malleable Tube Fittings Association
British Steel Industry
British Valve and Actuator Manufacturers’ Association
British Welded Steel Tube Association
Engineering Equipment and Materials Users’ Association
Food and Drink Federation
Institution of Civil Engineers
Institution of Gas Engineers
Institution of Water and Environmental Management
Large Diameter Steel Tube Association
Mechanical Handling Engineers’ Association
Stainless Steel Fabricators’ Association of Great Britain
Steel Tube Fittings Manufacturers’ Technical Association
Water Companies Association
BSI

Water Research Centre

Water Services Association of England and Wales
Coopted member

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

Brewers Society
Dairy Trade Federation
Institution of Production Engineers
Milking Machine Manufacturers’ Association

This British Standard, having

been prepared under the
direction of the Piping Systems
Components Standards Policy
Committee, was published under
the authority of the Standards
Board and comes into effect on
31 January 1992

© BSI 2009 Amendment

31 August 2009 See foreword
No. 1
The following BSI references
relate to the work on this
standard:
Committee reference PSE/8
Drafts for comment 88/72923 DC ,
09/30194311 DC

ISBN 978 0 580 65643 9

Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
BS 4825-5:1991+A1:2009

Contents

Page
Committees responsible Inside front cover
Foreword iii
1 Scope 1
2 Information to be supplied by the purchaser 1
3 Definitions 1
4 Symbols 1
5 Design 2
6 Materials 7
7 Dimensions and tolerances 7
8 Surface finish 7
9 Assembly 7
10 Hygiene 7
11 Manufacturer’s certificate 7
Appendix A Essential information to be supplied by the purchaser in
the enquiry and/or order 8
Appendix B Purchaser options 8
Appendix C Cross section of coupling assemblies 8
Appendix D Screw threads for male parts and nuts 9
Appendix E Grooves for expanded type male parts and liners 10
Appendix F Lock rings for expanded type male parts and liners 11
Appendix G Guide for expanding with straight tube 12
Appendix H Effect of non-metallic products on water quality 15
BSI

Appendix J Marking 15
Figure 1 — Expanded type male part 2
Figure 2 — Expanded type liner 3
Figure 3 — Welded type male part 4
Figure 4 — Welded type liner 5
Figure 5 — Hexagon nut 6
Figure 6 — Seal 7
Figure 7 — Cross section of expanded type coupling 8
Figure 8 — Cross section of welded type coupling 8
Figure 9 — Male part thread form 9
Figure 10 — Nut thread form 9
Figure 11 — Dimensions of grooves 10
Figure 12 — Lock ring 11
Figure 13 — Positioning of tube and partial expansion of male part 12
Figure 14 — Final expansion of tube on to male part 13
Figure 15 — Positioning of tube and partial expansion of liner 14
Figure 16 — Final expansion of tube onto liner 14
Figure 17 — Cutting chamfer on expanded tube for liner 14
Table 1 — Expanded type male part 2
Table 2 — Expanded type liner 3
Table 3 — Welded type male part 4
Table 4 — Welded type liner 5
Table 5 — Hexagon nut 6
Table 6 — Seal 7
Table 7 — Male part 9

© BSI 2009 i
Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
BS 4825-5:1991+A1:2009

Page
Table 8 — Nut 9
Table 9 — Dimensions of grooves 10
Table 10 — Dimensions of lock ring 11
Table 11 — Steel hardness 11
Publication(s) referred to 17
BSI

ii © BSI 2009
Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
BS 4825-5:1991+A1:2009

Foreword

This Part of BS 4825 has been prepared under the direction of the Piping Systems
Components Standards Policy Committee.
BS 4825-5:1991+A1:2009 supersedes BS 4825-5:1991, which is withdrawn.
BS 4825 is published in five Parts:
— Part 1: Specification for tubes;
— Part 2: Specification for bends and tees;
— Part 3: Specification for clamp type couplings;
— Part 4: Specification for threaded (IDF type) type couplings;
— Part 5: Specification for recessed ring joint type couplings.
This Part of BS 4825 specifies the dimensional details of all components for ring
joint type fittings and covers surface finish, manufacturer’s certificate and
marking.
Couplings specified in BS 4825 are intended for the following uses:
— Part 3: where either in-place cleaning or frequent dismantling is necessary;
— Part 4: where cleaning in-place techniques are normally practised;
— Part 5: where piping systems are frequently dismantled.
The essential differences between this Part of BS 4825 and BS 1864:1966 are as
follows.
a) Specifications for tube sizes and materials are now given in BS 4825-1.
b) Dimensions for bends and tees are given in BS 4825-2.
c) Dimensions for straight through and three way cocks have been withdrawn.
BSI

d) The range of sizes has been extended to include 4 in couplings.

The start and finish of text introduced or altered by Amendment No. 1 is

indicated in the text by tags !". Minor editorial changes are not tagged.

Compliance with a British Standard cannot confer immunity

from legal obligations.

Summary of pages
This document comprises a front cover, an inside front cover, pages i to iv,
pages 1 to 17 and a back cover.
This standard has been updated (see copyright date) and may have had
amendments incorporated. This will be indicated in the amendment table on the
inside front cover.

© BSI 2009 iii

Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
BSI

iv
blank
Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
BS 4825-5:1991+A1:2009

1 Scope 3.5
seal
This Part of BS 4825 specifies the dimensions,
tolerances, surface finish, materials, assembly and an elastomer which provides a liquid tight joint
hygienic requirements for welded and expanded when compressed by the liner sealing face
type male parts, liners, nuts and seals for recessed 3.6
ring joint type fittings for the food industry and hexagon nut
other hygienic applications.
an internally threaded component providing the
NOTE 1 The male parts and liners specified are intended to be clamping of the coupling and compressing the seal
used with stainless steel tubes specified in BS 4825-1.
NOTE 2 The titles of the publications referred to in this between the liner and male part
standard are listed on !page 17" .
4 Symbols
2 Information to be supplied by the For the purposes of this Part of BS 4825, the
purchaser following symbols apply:
2.1 The purchaser is to provide to the supplier the C1 outside diameter of neck of expanded type
information given in Appendix A to enable products male part and liner
to be supplied in accordance with this standard. C2 spigot diameter of welded type male part
2.2 A number of options are permitted by this
C3 inside diameter of nut
standard as given in Appendix B.
Both the definitive requirements specified C5 inside diameter of expanded type male part
throughout this standard and the options selected and liner
by the purchaser shall be satisfied by the C6 inside diameter of welded type male part and
manufacturer before a claim of compliance with this liner
standard can be made and verified. In the event that C7 outside diameter of expanded and welded type
the purchaser does not indicate his requirements at liner
BSI

the time of enquiry and order the manufacturer C10 outside diameter of neck of welded type male
shall select the options where appropriate. part and liner
C11 centring diameter of the ring groove
3 Definitions
C12 diameter of spigot recess of expanded and
For the purposes of this Part of BS 4825 the
welded type liner
following definitions apply.
C13 inside diameter of spigot recess of welded type
3.1 liner
expanded male part
C14 diameter of flange neck of welded type liner
externally threaded part of the coupling providing a
C15 diameter of thread undercut of nut
sealing groove. To be attached to a tube end by
expansion d major diameter of male part thread
3.2 d1 minor diameter of male part thread
expanded liner d2 pitch diameter of male part thread
coupling part having a shoulder and providing a D major diameter of nut thread
sealing face. To be attached to a tube end by D1 minor diameter of nut thread
expansion
D2 pitch diameter of nut thread
3.3
welded male part F1 total length of expanded type male part
externally threaded part of the coupling providing a F2 effective length of welded type male part
sealing groove. To be attached to a tube end by a F3 total length of expanded type liner
butt weld
F6 total length of welded type liner
3.4
welded liner G1 length of external thread of expanded and
welded type male part
coupling part having a shoulder and providing a
G2 length of internal thread of nut
sealing face. To be attached to a tube end by butt
weld K1 ring groove depth
K2 length of spigot of welded type male part

© BSI 2009 1
Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
BS 4825-5:1991+A1:2009

K3 ring groove section diameter 5.3 The design of the coupling shall be such to
ensure satisfactory operation in a properly
L1 flange thickness of expanded type liner
assembled pipeline system operating at a maximum
L2 inside flange thickness of nut working pressure of 1 MPa.
L3 flange thickness of welded type liner Table 1 — Expanded type male part
L4 depth of recess of expanded type male part (see Figure 1)
Tube outside diameter C1 C5 C11 F1
L5 depth of recess of expanded type liner
L6 depth of recess of welded liner mm mm mm mm mm

N2 width across flats of nut 25.4 32.5 25.4 33.3 20

38.1 45.2 38.1 46.0 24
R3 radius of groove of expanded and welded male 50.8 57.9 50.8 58.7 28
parts 63.5 70.6 63.5 71.4 32
U diameter of gasket section. 76.2 83.3 76.2 84.1 32
Tolerances (see !BS EN 20286-1 and BS EN 20286-2")
5 Design C1 : + 0, – 0.08 mm
NOTE The purchaser should specify whether expanded or C5 : A10
welded type couplings are required in his enquiry and/or order C11 : ± 0.13 mm
(see Appendix A). F1 : ± 0.25 mm
G1 : ± 0.20 mm
5.1 The dimensions of the couplings shall be as K1 : ± 0.13 mm
given in Table 1 to Table 6 and Figure 1 to Figure 6. R3 : ± 0.13 mm

5.2 The screwed components of the couplings shall

be of the basic Whitworth parallel form as specified
in BS 84. The cross section of screwed coupling
assemblies shall be as shown in Appendix C.
BSI

Figure 1 — Expanded type male part (see Table 1)

2 © BSI 2009
Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
BS 4825-5:1991+A1:2009

Table 2 — Expanded type liner (see Figure 2)

Tube outside
C1 C5 C7 C12 F3
diameter

mm mm mm mm mm mm

25.4 32.5 25.4 41.3 27.8 20

38.1 45.2 38.1 54.0 40.5 24
50.8 57.9 50.8 66.7 53.2 28
63.5 70.6 63.5 79.4 65.9 32
76.2 83.3 76.2 92.1 78.6 32
Tolerances (see !BS EN 20286-1 and BS EN 20286-2")

C1 : + 0, – 0.08 mm F3 : ± 0.25 mm
C5 : A10 L1 : ± 0.20 mm
C7 : ± ,th > 0.25 mm L5 : ± 0.20 mm
C12 : ± 0.25 mm
BSI

Figure 2 — Expanded type liner (see Table 2)

© BSI 2009 3
Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
BS 4825-5:1991+A1:2009

Table 3 — Welded type male part (see Figure 3)

Tube outside C11
C2 C6 C10
diameter
mm mm mm mm mm
25.4 25.4 22.2 25.65 33.3
38.1 38.1 34.9 38.35 46.0
50.8 50.8 47.6 51.05 58.7
63.5 63.5 60.3 63.75 71.4
76.2 76.2 73.0 76.45 84.1
101.6 101.6 97.6 101.85 109.5
Tolerances (see !BS EN 20286-1 and BS EN 20286-2")
C2 : ± 0.20 mm G1 : ± 0.20 mm
C6 : N11 K1 : ± 0.13 mm
C10 : h11 K2 : ± 0.20 mm
C11 : ± 0.13 mm K3 : ± 0.10 mm
F2 : ± 0.25 mm R3 : ± 0.13 mm
BSI

Figure 3 — Welded type male part (see Table 3)

4 © BSI 2009
Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
BS 4825-5:1991+A1:2009

Table 4 — Welded type liner (see Figure 4)

Tube outside diameter C6 C7 C10 C12 C13 C14 F6

mm mm mm mm mm mm mm mm

25.4 22.2 41.3 25.65 27.8 26.2 32.5 10 or 12.7

38.1 34.9 54.0 38.35 40.5 38.9 45.2 10 or 12.7
50.8 47.6 66.7 51.05 53.2 51.6 57.9 10 or 12.7
63.5 60.3 79.4 63.75 65.9 64.3 70.6 10 or 12.7
76.2 73.0 92.1 76.45 78.6 77.0 83.3 10 or 12.7
101.6 97.6 117.5 101.85 104 102.4 108.5 12.7 or 25.4
Tolerances (see !BS EN 20286-1 and BS EN 20286-2")

C6 : N11 C12 : ± 0.25 mm

C10 : h11 C7 : ± 0.25 mm
C14 : ± 0.25 mm L6 : ± 0.25 mm
C13 : ± 0.25 mm F6 : ± 0.25 mm
BSI

Figure 4 — Welded type liner (see Table 4)

© BSI 2009 5
Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
BS 4825-5:1991+A1:2009

Table 5 — Hexagon nut (see Figure 5)

Tube outside diameter C3 C15 N2

mm mm mm mm

25.4 33.3 46.6 50.8

38.1 46.0 59.3 65.0
50.8 58.7 73.6 79.4
63.5 71.4 86.3 92.1
76.2 84.1 99.0 104.8
101.6 109.5 124.4 130.2
Tolerances (see !BS EN 20286-1 and BS EN 20286-2")

N2 : h15
C3 : ± 0.20 mm
C15 : ± 0.20, 0 mm
G2 : ± 0.25 mm
L2 : ± 0.20 mm
F4 : ± 0.25 mm
Dimension C15 (undercut) is optional
BSI

Figure 5 — Hexagon nut (see Table 5)

6 © BSI 2009
Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
BS 4825-5:1991+A1:2009

Table 6 — Seal (see Figure 6) 7.2 Expanded type male parts and liners shall be
Tube outside diameter C11
provided with grooves on the internal surface to give
adequate strength to the expanded joint between
mm mm the male part or liner and the tube.
25.4 33.3 NOTE Appendix E gives details of grooves suitable for sizes
38.1 46.0 from 25.4 mm up to and including 76.2 mm.
50.8 58.7
63.5 71.4 8 Surface finish
76.2 84.1 The surface finish of contact and sealing surfaces
101.6 109.5 shall have a surface roughness value, Ra, of not
Tolerances (see !BS EN 20286-1 and BS EN 20286-2") more than 1.0 4m as defined in BS 1134-1.
U : ± 0.10 mm
C11 : ± 0.13 mm 9 Assembly
9.1 Expansion
Expanded type male parts and liners shall be
attached to the tube ends by expansion of the tube.
NOTE A method for carrying out the expansion is described in
Appendix G. The method is suitable for sizes up to and
including 76.2 mm.
9.2 Welding
Welded type male parts and liners shall be attached
to the tube ends by a butt weld.

10 Hygiene
BSI

10.1 All surfaces of the coupling !likely to

Figure 6 — Seal (see Table 6)
6 Materials
6.1 Male parts, liners and nuts
Male parts, liners and nuts shall be made from
austenitic stainless steel equivalent to those listed
in Table 1 of !BS 4825-1:1991+A2:2009".
NOTE !European steel numbers " , comparable in
chemical composition to those listed in Table 1 of
!BS 4825-1:1991+A2:2009" are recommended.
6.2 Seals
The seal material shall be compatible with the
processing conditions.
NOTE The purchaser should specify the processing conditions
(temperature/pressure/chemical) in his enquiry and/or order
(see Appendix A).
If synthetic rubber seals are specified the material
shall have a hardness range 75 IRHD to 85 IRHD in
accordance with !BS ISO 48". (See 10.3.)
7 Dimensions and tolerances
7.1 The dimensions and tolerances of expanded and
welded type male parts, liners, nuts and seals shall
be as given in Table 1 to Table 6, as appropriate.
NOTE The purchaser should specify the dimensions of the
couplings in his enquiry and/or order (see Appendix A).
come into contact with the food" product shall
be accessible for cleaning by manual methods
when disassembled. Removable parts shall be
readily demountable.
NOTE Care should be taken to ensure that no deposit of any
material which might prove harmful during subsequent use
and/or fabrication is permitted to remain on the couplings.
10.2 The seal shall be of a material compatible
under processing conditions with the foodstuffs
and/or cleaning fluids. In addition, the seal material
shall not constitute a toxic hazard, shall not support
microbial growth and shall not give rise to
unpleasant taste or odour.
10.3 If the seal material comes, or is likely to come,
into contact with potable water then it shall comply
with the requirements in Appendix G.
11 Manufacturer’s certificate
The manufacturer shall supply, when requested by
the purchaser in the enquiry and/or order, a
certificate !in accordance with
BS EN 10204," stating that the couplings
!conform to" the requirements of this
standard for the appropriate type of coupling
(see Appendix B).

© BSI 2009 7
Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
BS 4825-5:1991+A1:2009

Appendix A Essential information to Appendix B Purchaser options

be supplied by the purchaser in the
enquiry and/or order
The purchaser should provide the following
information in the enquiry and/or order:
a) the number and date of this British Standard,
i.e. !BS 4825-5:1991+A1:2009"
(see also Appendix J);
b) the normal working pressure, temperature,
and chemical conditions of the pipe system
(see clause 6);
c) type of coupling (see clause 5);
d) size of coupling (see clause 7).
BSI
This standard lists certain options. The purchaser
should state in the enquiry and/or order whether a
manufacturer’s certificate is required
(see clause 11). If no such statement is made, supply
is at the option of the manfacturer.
Appendix C Cross sections of coupling
assemblies
Illustrations of expanded and welded type coupling
cross sections are shown in Figure 7 and Figure 8.

Figure 7 — Cross section of expanded type coupling

Figure 8 — Cross section of welded type coupling

8 © BSI 2009
Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
BS 4825-5:1991+A1:2009

Appendix D Screw threads for male

parts and nuts
The thread form is to the basic Whitworth form as
specified in BS 84. Screw threads shall comply with
the thread dimensions shown in Figure 9 and
Table 7 or Figure 10 and Table 8 as appropriate.
Table 7 — Male part (see Figure 9)
Tube outside d d2 d1 Threads per
diameter maximum minimum maximum minimum maximum minimum inch

mm mm mm mm mm mm mm

25.4 45.720 45.415 43.688 43.383 41.656 41.351 8

38.1 58.420 58.115 56.388 56.083 54.356 54.051 8
50.8 72.720 72.415 70.002 69.697 67.310 67.005 6
63.5 85.420 85.115 82.702 82.397 80.010 79.705 6
76.2 98.120 97.815 95.402 95.097 92.710 92.405 6
101.6 123.520 123.215 120.802 120.497 118.110 117.805 6
BSI

Figure 9 — Male part thread form (see Table 7)

Table 8 — Nut (see Figure 10)
Tube outside D D2 D1 Threads per
diameter maximum minimum maximum minimum maximum minimum inch

mm mm mm mm mm mm mm

25.4 46.635 46.330 44.603 44.298 43.079 42.266 8

38.1 59.335 59.030 57.303 56.998 55.779 54.966 8
50.8 73.635 73.330 70.917 70.612 68.733 67.920 6
63.5 86.335 86.030 83.617 83.312 81.433 80.620 6
76.2 99.035 98.730 96.317 96.012 94.133 93.320 6
101.6 124.435 124.130 121.717 121.412 119.533 118.720 6

Figure 10 — Nut thread form (see Table 8)

© BSI 2009 9
Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
BS 4825-5:1991+A1:2009

Appendix E Grooves for expanded Table 9 — Dimensions of grooves (see Figure 11)
type male parts and liners Tube outside diameter Lock ring groove diameter
X1
E.1 General
Expanded type male parts and liners shall be mm mm
provided internally with some form of groove to give 25.4 27.65
adequate strength to the joint between male part or 38.1 40.35
liner and tube end. Figure 11 and Table 9 show the 50.8 53.05
dimensions of the grooves. 63.5 65.65
NOTE This appendix is applicable to sizes 25.4 mm up to and 76.2 78.35
including 76.2 mm. The use of the lock ring is optional for
expanded type male parts and liners. E.3 Tolerances (see !BS EN 20286-1 and
E.2 Dimensions BS EN 20286-2")
Table 9 gives the lock ring groove dimensions. The tolerance on the lock ring groove diameter X1
is N12.
BSI

Figure 11 — Dimensions of grooves (see Table 9)

10 © BSI 2009
Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
BS 4825-5:1991+A1:2009

Appendix F Lock rings for expanded F.3 Materials

type male parts and liners A steel with the hardness shown in Table 11 should
be used.
F.1 Conditions of use
The use of a lock ring is recommended in special Table 11 — Steel hardness
cases (for instance under conditions of high Hardness
BS reference
pressure, high temperatures or large thermal Scale No.
expansion with long lengths of tubing).
Vickers 450 to 480 !BS EN ISO 6507-1
F.2 Dimensions
The dimensions of lock rings are shown in Figure 12 Brinell 425 to 445 BS EN ISO 6506-1
and Table 10. Rockwell C 44.5 to 47 BS EN ISO 6508-1"
Table 10 — Dimensions of lock ring
(see Figure 12)
Tube outside diameter Lock ring outside
diameter
X2

mm mm

25.4 27.65
38.1 40.35
50.8 53.05
63.5 65.65
76.2 78.35
BSI

Figure 12 — Lock ring (see Table 10)

© BSI 2009 11
Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
BS 4825-5:1991+A1:2009
Appendix G Guide for expanding with
straight tube
G.1 General
This appendix describes a method of expansion for
assembling expanded type male parts and liners
with nominal sizes 25.4 mm up to and
including 76.2 mm or straight tubes of the
dimensions given in BS 4825-1.
G.2 Tools
The tools shown in Figure 13 to Figure 17 are
suitable for male parts and liners with or without
lock ring. The set of tools consists of the following:
a) base plate (see Figure 13);
b) clamp block (see Figure 13);
c) split cutting ring (see Figure 13);
d) adaptor plate (see Figure 14);
e) expander (see Figure 13);
f) torque wrench and sockets (not illustrated);
g) cutting tool holder (see Figure 17);
h) chamfering cutter (see Figure 17);
i) centring pilot (see Figure 17);
j) distance tubes (see Figure 15);
BSI
k) distance sleeve (for 25.4 mm only) (not
illustrated).
The following tools are also required: hacksaw,
spanners for clamp block nuts, file and mallet.
Figure 13 — Positioning of tube and partial expansion of male part
12
G.3 Procedure
G.3.1 Preparation
Fasten the base plate (a) to the bench. Put a clamp
block (b) of the required size on to the base plate
with the plain bore facing the front (see Figure 13).
If long lengths of tubes are to be used, an additional
support is required to keep the tube level.
G.3.2 Cutting the tube
G.3.2.1 Mark the tube to the length required. Push
the tube through the centre hole of the clamp block.
Fit the split cutting ring (c) in the clamp block. Place
the cutting mark on the tube in line with the face of
the cutting ring. Tighten the clamp block
(see Figure 13).
NOTE The end of the polished tube tends to be tapered. Cut off
the tapered portion before marking off the length of the tube.
G.3.2.2 Cut the tube with a hacksaw. File the tube
end square against the split cutting ring.
G.3.3 Expansion
NOTE The procedures for fitting male parts and for fitting
liners are basically similar but the tube projection lengths differ
and the clamp block has to be reversed on the baseplate between
fitting a male part and fitting a liner.
G.3.3.1 Male part expansion
G.3.3.1.1 Release the clamp block, push the tube
forward and reclamp. Place male part on the end of
the tube against the face of the split cutting ring
with the gasket groove facing outwards. Adjust the
position of the tube so that there is 4 mm of tube
projecting beyond the face of the male part.
© BSI 2009
Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
G.3.3.1.2 Place adapter plate (d) against the face of
the male part so that it locates into the seal groove.
Ensure that the tube end butts against the adapter
plate (see Figure 13). Adjust tube if necessary.
G.3.3.1.3 Insert the expander (e) through the
adapter plate into the tube (see Figure 13).
NOTE The expander rollers are to be lightly oiled.
G.3.3.1.4 Set the torque wrench (f) in accordance
with the manufacturer’s instructions. Apply wrench
and rotate expander in a clockwise direction just
sufficiently to allow the tube to grip the male part so
that it will not move.
G.3.3.1.5 With the expander still in position release
the clamp block and take out the tube and split
cutting ring.
G.3.3.1.6 Release the base plate, reverse the clamp
block so that the threaded bore is facing forward and
then reclamp (see Figure 14).
G.3.3.1.7 Continue rotating the expander in a
clockwise direction until the wrench releases.
G.3.3.1.8 Release the expander by an anti-clockwise
rotation and remove with the adapter plate.
G.3.3.1.9 Release the clamp block and remove tube
and male part assembly.
BSI
G.3.3.2 Liner expansion
G.3.3.2.1 Release the clamp block, push the tube
forward and reclamp. Place liner on end of the tube
against the face of the split cutting ring with the
liner flange facing outwards. In this position the
tube should not project into the taper bore of the
liner. Adjust tube if necessary (see Figure 15).
G.3.3.2.2 Place the distance tube (j) into the tapered
bore of the liner and against the end of the tube
(see Figure 15).
Figure 14 — Final expansion of tube on to male part
© BSI 2009
BS 4825-5:1991+A1:2009
G.3.3.2.3 Insert the expander (e) through the
distance tube and into the tube (see Figure 15).
NOTE The expander rollers should to be lightly oiled and never
used dry.
G.3.3.2.4 Set the torque wrench (f) in accordance
with the manufacturer’s instructions. Apply wrench
and rotate expander in a clockwise direction just
sufficiently to allow the tube to grip the liner so that
it will not move.
G.3.3.2.5 With the expander still in position release
the clamp block and take out the tube and split
cutting ring.
G.3.3.2.6 Re-insert the tube into the clamp block so
that the liner fits into the liner location in the clamp
block and reclamp (see Figure 16).
G.3.3.2.7 Continue rotating the expander in a
clockwise direction until the wrench releases.
G.3.3.2.8 Release the expander by an anti-clockwise
rotation and remove with the distance tube.
G.3.3.3 Facing off tube (liner only)
G.3.3.3.1 To remove surplus tubing extruded as a
result of expanding, fit the correct size chamfering
cutter (h) and centring pilot (i) to the cutting tool
holder (g), then insert the tool assembly into the
tube with the centring pilot approximately 13 mm
from the face of the liner (see Figure 17).
NOTE For 25.4 mm tube only, fit also the distance sleeve (e) on
to the tool spindle between the centring pilot and the chamfering
cutter. Lock the pilot tight into the bore of the tube, bring up the
cutter and adjust the spring pressure to keep the cutter against
the edge of the tube. Rotate the cutter and remove surplus metal.
G.3.3.3.2 Release the centring pilot and withdraw
the cutting tool holder assembly as one unit.
G.3.3.3.3 Release clamp block and remove tube liner
assembly.
13
Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
BS 4825-5:1991+A1:2009

Figure 15 — Positioning of tube and partial expansion of liner

BSI

Figure 16 — Final expansion of tube onto liner

Figure 17 — Cutting chamfer on expanded tube for liner

14 © BSI 2009
Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
BS 4825-5:1991+A1:2009

Appendix H Effect of non-metallic Appendix J Marking

products on water quality It is recommended that each coupling is legibly and
When used under the conditions for which they are indelibly marked with the following:
designated, non-metallic products in contact with or a) the manufacturer’s name or identification
likely to come into contact with potable water shall mark;
!conform to" BS 6920-1. b) the number of this British Standard,
!NOTE In July 1999 the Water supply (Water fittings) i.e. BS 4825-51);
regulations 1999 replaced local water byelaws in England c) the !European steel number" used.
and Wales. In Scotland, reference should be made to the
Scottish Water byelaws 2004. Guidance can be obtained
from The Water Regulations Advisory Scheme, Fern Close,
Pen-Y-Fan Industrial Estate, Oakdale, Gwent NP11 3EH.
A list of WRAS approved water fittings is available on-line
at http://www.wras.co.uk/directory/fittings_search.asp."
BSI

1) Marking BS 4825-5 on or in relation to a product is a claim by the manufacturer that the product has been manufactured to
the requirements of this standard. The accuracy of such a claim is therefore solely the manufacturer’s responsibility. Enquiries
as to the availability of third party certification should be addressed to the appropriate certification body.

© BSI 2009 15
Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
BSI

16
blank
Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
BS 4825-5:1991+A1:2009

Publication(s) referred to

BS 84, Specification for parallel screw threads of Whitworth form (obsolescent)

!BS 1134-1, Assessment of surface texture — Part 1: Methods and instrumentation
BS 4825-1, Stainless steel tubes and fittings for the food industry and other hygienic
applications — Part 1: Specification for tubes
BS EN 10204, Metallic materials — Types of inspection documents
BS EN 20286-1, ISO system of limits and fits — Part 1: Bases of tolerances, deviations and fits
BS EN 20286-2, ISO system of limits and fits — Part 2: Tables of standard tolerance grades
and limit deviations for holes and shafts
BS EN ISO 6506-1, Metallic materials — Brinell hardness test — Part 1: Test method
BS EN ISO 6507-1, Metallic materials — Vickers hardness test — Part 1: Test method
BS EN ISO 6508-1, Metallic materials – Rockwell hardness test — Part 1: Test method (scales
A, B, C, D, E, F, G, H, K, N, T)
BS ISO 48, Rubber, vulcanized or thermoplastic — Determination of hardness (hardness
between 10 IRHD and 100 IRHD)"
BSI

© BSI 2009 17
Licensed Copy: The Open University Library, The Open University Library, 11/10/2010 11:41, Uncontrolled Copy, (c)
BS 4825-5:1991
+A1:2009
BSI — British Standards Institution
BSI is the independent national body responsible for preparing
British Standards. It presents the UK view on standards in Europe and at the
international level. It is incorporated by Royal Charter.

Revisions

British Standards are updated by amendment or revision. Users of

British Standards should make sure that they possess the latest amendments or
editions.

It is the constant aim of BSI to improve the quality of our products and services.
We would be grateful if anyone finding an inaccuracy or ambiguity while using
this British Standard would inform the Secretary of the technical committee
responsible, the identity of which can be found on the inside front cover.
Tel: 020 8996 9000. Fax: 020 8996 7400.

BSI offers members an individual updating service called PLUS which ensures
that subscribers automatically receive the latest editions of standards.

Buying standards

Orders for all BSI, international and foreign standards publications should be
addressed to Customer Services. Tel: 020 8996 9001. Fax: 020 8996 7001.

In response to orders for international standards, it is BSI policy to supply the

BSI implementation of those that have been published as British Standards,
unless otherwise requested.

Information on standards
BSI

BSI provides a wide range of information on national, European and

international standards through its Library and its Technical Help to Exporters
Service. Various BSI electronic information services are also available which give
details on all its products and services. Contact the Information Centre.
Tel: 020 8996 7111. Fax: 020 8996 7048.

Subscribing members of BSI are kept up to date with standards developments

and receive substantial discounts on the purchase price of standards. For details
of these and other benefits contact Membership Administration.
Tel: 020 8996 7002. Fax: 020 8996 7001.

Copyright

Copyright subsists in all BSI publications. BSI also holds the copyright, in the
UK, of the publications of the internationalstandardization bodies. Except as
permitted under the Copyright, Designs and Patents Act 1988 no extract may be
reproduced, stored in a retrieval system or transmitted in any form or by any
means – electronic, photocopying, recording or otherwise – without prior written
permission from BSI.

This does not preclude the free use, in the course of implementing the standard,
of necessary details such as symbols, and size, type or grade designations. If these
details are to be used for any other purpose than implementation then the prior
written permission of BSI must be obtained.

If permission is granted, the terms may include royalty payments or a licensing

agreement. Details and advice can be obtained from the Copyright Manager.
BSI Tel: 020 8996 7070.
389 Chiswick High Road
London
W4 4AL