Bayerteq Leak Tightness Tester – BT-LTT Series (DN 110 mm to DN 3000 mm)
- Heavy-duty leak tightness testing system for evaluating elastomeric sealing ring joints in underground non-pressure pipes
- Full compliance with ISO 13259 (superseding EN 1277), ISO 13254, ASTM D3212, and ISO 13844:2022
- Universal test benches supporting pipe dimensions from DN 110 mm up to DN 3,000 mm (both smooth and corrugated)
- Integrated hydraulic deflection mechanism: angular deflection up to 2° and vertical diametric deflection with joystick control
- Dual positive hydrostatic pressure (HPM 2B) and negative vacuum pressure (Kaeser/Pfeiffer pumps) operating simultaneously
- Kevlar-reinforced inflatable pipe plugs with built-in internal water bypass for non-destructive filling
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The leak tightness tester (BT-LTT Series) manufactured by Bayerteq is an advanced testing system engineered for rigorous verification of elastomeric sealing ring joints in underground non-pressure thermoplastic piping networks. Built in full conformity with international standards including ISO 13259 (superseding EN 1277), ISO 13254, ASTM D3212, and ISO 13844:2022, this comprehensive test rig verifies the watertightness and airtightness of sewer, drainage, and gravity pipeline assemblies under multi-axial mechanical deformation.
Buried non-pressure pipe systems must endure external earth pressures, trench settlement, soil subsidence, and groundwater infiltration without joint leakage. The Bayerteq leak tightness tester reproduces these real-world underground conditions by simultaneously applying diametric compression and angular pipe misalignment while subjecting the elastomeric seal to positive internal hydrostatic pressure and negative internal vacuum pressure.
Leak Tightness Tester Architecture & Multi-Stress Capabilities
The BT-LTT system integrates heavy-duty structural test benches with intelligent pressure cabinets and non-destructive sealing technology:
- Universal Heavy-Duty Test Benches (DN 110 mm to DN 3,000 mm): Heavy-gauge steel reaction frames accommodate both smooth-wall and structured-wall corrugated pipes without requiring expensive specialized tooling or custom mounting adapters.
- Proportional Joystick Deflection Control: Precise hydraulic actuators generate angular deflections up to 2° (DN 200–1200 mm) or 1° (DN 1200–1800 mm) alongside calibrated vertical diametric loads, continuously tracked via electronic sensors and photocells.
- Dual Positive & Negative Pressure Cabinets: Combines an HPM 2B positive hydrostatic pressure station (15 l/min @ 100 bar) with an HPM 2B-02-100 negative vacuum station powered by German Kaeser / Pfeiffer vacuum pumps. Dual stations operate independently, allowing simultaneous testing on multiple test benches.
- Inflatable Kevlar Sealing Plugs with Internal Bypass: Constructed from multi-layer SBR/NR rubber reinforced with nylon and Kevlar cords. An integrated central bypass conduit delivers water directly into the pipe specimen from the pressure cabinet, completely eliminating the need to drill test holes or damage pipe samples.
Powered by a Siemens PLC controller and in-house Bayerteq BT software running on Windows 11, this leak tightness tester provides digital pressure transmitter accuracy of 0.3%, 0.01 bar readability, and automatic certification test reports.
Bayerteq BT-LTT Series – Technical Specifications
| Parameter | Specification Details |
|---|---|
| Applicable Standards | ISO 13259 (superseding EN 1277), ISO 13254, ASTM D3212, ISO 13844:2022, EN 1401, EN 1852, EN 13476 |
| Nominal Diameter Range | DN 110 mm up to DN 3,000 mm (Modular bench frames configured to client requirements) |
| Pipe Compatibility | Smooth-wall PVC-U, PP, PE pipes and corrugated structured-wall (twin-wall) piping assemblies |
| Angular Deflection Capacity | Up to 2.0° (for DN 200 mm to DN 1,200 mm); up to 1.0° (for DN 1,200 mm to DN 1,800 mm) |
| Vertical Diametric Deflection | Hydraulically applied parallel compression plates operated via proportional joystick control |
| Deflection Measurement | Continuous electronic displacement transducers and precision photocell sensors with automated BT logging |
| Positive Pressure Generation | HPM 2B cabinet with AR high-capacity pump (15 l/min @ 100 bar), AISI 304/316 accumulator, 10 μm filter |
| Negative Pressure Generation | HPM 2B-02-100 cabinet with German Kaeser / Pfeiffer industrial vacuum pump units |
| Simultaneous Operation | Independent pump channels allow small and large test benches to execute concurrent tests simultaneously |
| Pressure Accuracy & Readability | Setpoint accuracy: ±1%; Transmitter accuracy: 0.3%; Digital readability: 0.01 bar |
| Sealing Plug System | Inflatable Kevlar & nylon cord reinforced SBR/NR rubber plugs with built-in through-plug water fill bypass |
| PLC & Automation Hardware | Siemens Industrial PC / Controller with color HMI touchscreen, 1 TB onboard storage, Ethernet LAN |
| Software Platform | Bayerteq BT Materials Testing Software on Windows 11 with automated ISO/ASTM calculation reports |
Key Operational & Engineering Advantages
Universal Non-Tooling Disc Design
Specially engineered clamping discs secure all pipe diameters from DN 110 to DN 3000 mm without needing expensive auxiliary adapters, reducing changeover times to minutes.
Multi-Stress Test Execution
Simultaneously evaluates angular deflection (up to 2°), diametric compression, positive hydrostatic pressure (0.05 to 0.5 bar), and vacuum (-0.3 bar) in accordance with ISO 13259 Condition A, B, C, and D.
Inflatable Plugs with Internal Bypass
Kevlar-reinforced rubber plugs adapt seamlessly to out-of-round pipe profiles. Integrated fluid bypass conduits allow direct water charging without drilling penetration holes.
Dual Positive & Vacuum Cabinets
Features independent positive hydraulic pressure generators and German Kaeser/Pfeiffer vacuum pumps capable of powering multiple test benches simultaneously.
Proportional Joystick Hydraulic Control
Intuitive joystick positioning enables smooth, millimeter-precise angular and vertical deflection adjustments with continuous electronic sensor feedback.
Siemens PLC & Automated Reporting
Industrial Siemens controller and Windows 11 BT software record real-time pressure curves and deflection values, generating accredited PDF/Excel compliance reports.
Modular Configuration & System Options
1. Test Bench Size Packages
Small Benches (DN 110 – DN 630 mm), Medium Benches (DN 400 – DN 1,600 mm), and Large Benches (DN 1,000 – DN 3,000 mm) tailored to client product ranges.
2. Pressure Generation Modules
HPM 2B positive hydrostatic cabinets (up to 100 bar capability) and dedicated Kaeser/Pfeiffer vacuum pump stations with digital proportional regulators.
3. Inflatable Plug Diameter Sets
Complete inventories of Kevlar-reinforced inflatable sealing plugs with central bypass conduits from DN 110 mm up to DN 3,000 mm.
4. Bayerteq BT Software & IT Package
Pre-installed industrial PC, dual monitors, network integration, automated calibration routines, and custom test report templates.
Industry Standards & Practical Applications
The Bayerteq leak tightness tester is essential for pipe extrusion plants, civil infrastructure laboratories, and international certification bodies:
- Underground Gravity Sewer Joint Certification (ISO 13259 / EN 1277): Testing elastomeric sealing ring joints under four standard conditions:
- Condition A: Diametric deflection with positive internal water pressure.
- Condition B: Diametric deflection combined with internal vacuum (negative air pressure).
- Condition C: Angular deflection with positive internal water pressure.
- Condition D: Angular deflection combined with internal vacuum.
- Drain and Sewer Pipe Joint Testing (ASTM D3212): Proving watertight integrity of flexible elastomeric joints under both deflected and shear-loaded conditions.
- Structured-Wall Corrugated Pipes (EN 13476 / ISO 13254): Verification of twin-wall and spirally wound polyethylene and polypropylene pipe sockets.
- Joint Integrity Under High Groundwater Pressure (ISO 13844:2022): Assessing infiltration resistance of buried pipeline systems in marshland or high water-table environments.
- Quality Assurance of Elastomeric Gaskets: Verifying gasket compound resilience, compression set resistance, and sealing lip design.