General Information
Threadless Connection Technology
Product Categories
1.1 BAIO® System 1-4
1.2 ZAK® System 1-12
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1.1 BAIO® System
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General Information Threadless Connection Technology
1.1 BAIO® System
For decades, the connection of pipes and pipe fittings in buried pipeline construction has been mainly effected via
flangeless connections as this connection technology has both technical and economical advantages over conventional
flanged and welded connections. In the past, threaded connections were used in the construction of service lines. The
bare transition areas typical of in this way of connection were susceptible to contact corrosion causing incrustation which
often permanently damaged the connection and the sealing.
Therefore, in the early 1980s, Hawle Armaturen GmbH developed the Hawle BAIO® system with a view to affording
customers a simple and stress-relieved installation of pipeline elements and valves, while simultaneously ensuring a long
service life of the system due to integral corrosion protection. This idea was also the basis of the Hawle ZAK® system for
the service line sector to provide for a long service life of the service system in this field, too. Meanwhile, both connection
technologies have become widely accepted as the state of the art.
These generally acknowledged advantages can be fully applied to the connection between pipelines and valves, as well
as between valves. Beside the technical advantages of the threadless connection technology, the economic benefits of
this push-fit socket technology must be emphasized. In case of the Hawle BAIO® system, the savings are due to the
compact design facilitating storage and transport, as well as the considerably shorter installation times compared with
conventional flanged and welded connections (see graphics on page 1-6).
This innovative idea resulted in a consistent threadless system from DN 25 to DN 300! For more than 30 years, this range
of threadless products has been advanced and extended. You can find the threadless system in the following categories:
Section 1: Threadless Connection Technology
Section 3: Air Valves
Section 4: Hydrants
Section 6: Control valves
Section 4.1 Section 3.2
Section 3.3
Section 1.1.3
Section 1.1.1
Section 1.1.2
Section 1.1.2
Section 1.2.2
Section 1.2.3
Section 1.2.1
Section 1.1.2
Section 1.2.1
Design of a threadless connection system with a main line and two service lines.
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General Information Threadless Connection Technology
1.1 BAIO® System
Threadless connection - BAIO® system
Locking and sealing
Establishing a form-locked connection of valves and pipe
fittings in the BAIO® system is effected via a bayonet con-
nection and requires only little force. Therefore, it is possible
to use the system for CI pipes with BAIO® lip seal (BLD®),
on the one hand, and with CI-plastic gasket (GKS) for PVC
and PE pipes, on the other hand. Moreover, for PE and steel
pipes there are components with a fusion tail for welding
with the respective pipe ends. The longitudinally force-
locked connection between the BAIO® components is posi-
tively established via the bayonet lock well known from a lot
of technical fields.
Technical features BAIO® system
• Medium: potable water, sewage water, gas • Push-fit socket connection can be bended to all
(On ordering, please specify the medium and the type of sides (up to 3° per spigot/socket connection)
pipe to ensure that the correct gasket is supplied. • Stress-relieved when installed
Standard gasket: BAIO® lip seal for water) • Low storage costs
• Nominal widths 80 - DN 300 • Restraint joint with Hawle Stop without the need for
• Max. operating pressure 16 bar earthing
• Easy and time-saving installation • Integral high-quality corrosion protection due to Hawle
• Low number of components and connections epoxy powder coating
• Universal use with CI, steel*, PE, PVC and AC** pipes
(* with steel welding tail 452-01,
** with cut-in socket fitting with Multi/Joint® socket
530-01)
Note regarding BAIO® system for gas
As special gaskets are required when used for gas applications, please make sure to specify “Use for gas” on your order!
These gaskets are factory-mounted. Gas gaskets must be identified as such. Non-identified gaskets must not be used
for gas applications.
The BAIO® system compared with flanged valves
Flanged system: 307 components BAIO® system: 7 components
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General Information Threadless Connection Technology
1.1 BAIO® System
ONE push-fit socket – FOUR types of pipe: CI, PVC, PE, and steel pipe (use of steel welding tail 452-01). To establish a
tight and longitudinally force-locked connection of pipes in BAIO® sockets, different gaskets and restraint joints have to
be used, depending on the type of pipe. Please observe the following overview.
Gasket Grip ring Locking ring Type of pipe
®
BLD Segmented Hawle Stop CI pipe
grip ring DN 80 - DN 200
® ®
BLD Express ring BAIO -Sit CI pipe
DN 250 - DN 300
GKS Corundum Hawle-Stop PVC pipe
grip ring DN 80 - DN 200
®
GKS Brass grip ring BAIO -Sit PVC pipe
DN 250 - DN 300
Sliding ring
®
BAIO -Muffe GKS Interlocked Hawle-Stop Support liner PE/PEX pipe
grip ring DN 80 - DN 200
®
GKS Interlocked BAIO -Sit Support liner PE/PEX pipe
grip ring DN 250 - DN 300
®
GKS Welding ring BAIO -E-Stop Support liner PE pipe
BBD Blutop- Hawle-Stop Blutop pipe
grip ring
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General Information Threadless Connection Technology
1.1 BAIO® System
Installation of valves in the BAIO® system in connection with different types of pipes
Pipe Gasket Longitudinally force-locked connection
(restraint joint)
CI pipe (GGG) acc. to DIN Potable water / sewage: CI pipe grip ring Express ring
EN 545 BAIO® lip seal
Steel pipes with CI pipe
outside diameter
Gas:
CI pipe gasket, gas-proof
528-00, Hawle-Stop 527-00, BAIO®-Sit
(CI) DN 80 - DN 200 (CI) DN 250 - 300
PVC pipes acc. to DIN Potable water/ sewage:
8061/8062 GKS gasket Brass grip ring
Gas:
GKS gasket, gas
Sliding ring
528-00, Hawle-Stop 527-00, BAIO®-Sit
(PVC) DN 80 - DN 200 (PVC) DN 250 - 300
PE pipe: PE 80, PE 100 Trinkwasser/Abwasser: Interlocked Interlocked
acc. to DIN 8074/75 SDR GKS gasket grip ring grip ring
11 / 17 / 17.6
PE-X pipes acc. to DIN
16892/93 SDR 11 /17 /
17.6 528-00, Hawle-Stop (PE), 527-00, BAIO®-Sit (PE)
use of support liner Use of support liner
In case of pipes with very smooth surfaces (e.g. PE-X pipes) we (to be ordered separately)! (to be ordered separately)!
recommend roughening the pipe end in the area of the grip ring! DN 80 - DN 200 DN 250 - 300
PE pipe: PE 80, PE 100 Potable water/ sewage:
acc. to DIN 8074/75 SDR BAIO® lip seal acc. to DVGW W 270
11 / 17 / 17.6
Gas:
PE-X pipes acc. to DIN CI pipe gasket, gas-proof
16892/93 SDR 11 / 17 / 452-00, PE fusion tail with integral support
17.6 liner and lock ring
Steel pipe acc. to EN 10224 / Gas:
DIN 2460 DN 80, DN 100, DN 150 and DN
200: CI pipe gasket, gas-proof
DN 125: GKS gasket, gas-proof
452-01, steel pipe welding tail with
integral lock ring
PE pipe: PE 80, PE 100 Potable water/ sewage: Locking ring
acc. to DIN 8074/75 SDR GKS gasket
11 / 17 / 17.6
528-01, restraint joint BAIO® E-stop for PE pipes
Note: When connecting PE pipes, a support liner (Ord. No. 590) must be used.
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General Information Threadless Connection Technology
1.1 BAIO® System
Schematic of a BAIO® spigot/socket connection
1
1. Bayonet lugs (for locking ring)
2
2. Locking lugs
3 3. BAIO® lip seal (standard gasket)
Schematic of a restraint connection in the BAIO® system by means of Hawle Stop
1 3
1. Bayonet lugs (for locking ring)
2
2. Support liner
3. Interlocked grip ring (for PE pipes)
4. Locking ring
5. Dirt gasket for socket
4
6. GKS gasket
5
6
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General Information Threadless Connection Technology
1.1 BAIO® System
Installation of PE pipes DN 125 / d 125, DN 200 / d 200 and DN 250 / d 250 in BAIO® sockets
For the following nominal widths a supporting ring must be inserted into the BAIO® socket in addition to the GKS gasket
to avoid the excessive bending of the pipe!
BAIO® socket Pipe outside Position of supporting
DN ø (d) mm ring in BAIO® socket
BAIO® socket
125 125 At the back of the BAIO® socket
Supporting ring GKS gasket
200 200 At the back of the BAIO socket
®
BAIO® socket
At the front and back of the
250 250
BAIO® socket
Supporting and GKS gasket Supporting ring
stop ring
Installation of PE pipes DN 100 / d 125, DN 150 / d 180 in BAIO® sockets
The connection of PE pipes d 125 in BAIO® sockets DN 100 and/or PE pipes d 180 in BAIO® sockets DN 150 is possible
only in combination with special SM fittings (Ord. No. 532-00). In these SM fittings, the GKS gasket is already facto-
ry-mounted.
Moreover, for the pipe outside diameter d 180 the spigot socket valve DN 150 / d 180 (4511501801) can be used.
The spigot end of this gate valve fits into the all socket tees specifically developed for this purpose (5421501800,
5421801500, 5421801800).
Accessories in the Hawle BAIO® system
In the following, you will find useful products supplementing the Hawle BAIO® system.
Dirt gasket for sockets (529-04)
When connecting plastic pipes in BAIO® sockets and in case
of very clayey or sandy soils we recommend the use of the dirt 2
1
gasket for sockets to avoid any impairment of the sealing ef- 3
fect because of dirt washed in or pressed in during installation.
4
The dirt gasket for sockets is to be inserted into the ring gap in
front of the GKS gasket before installing the pipe.
Explanation of the image (right):
1: Hawle-Stop, 2: Grip ring, 3: GKS gasket, 5
4: BAIO® socket, 5: Dirt gasket, 6: Plastic pipe, chamfered
(PE or PVC) 6
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General Information Threadless Connection Technology
1.1 BAIO® System
Dirt cover and locking ring (490-05)
All vertical BAIO® connections such as hydrants, air valve assemblies,
and pipe fittings (e.g. vertically installed SM fitting) with BAIO® spigot
ends have to be secured against unintentional unlocking by means of
a dirt cover and locking ring.
Twist-lock device for BAIO® spigot/socket connection (529-05)
The twist-lock device prevents the unintentional unlocking of BAIO®
spigot/socket connections, e.g. in case of extensive preliminary instal-
lation work outside the trench.
Transition fittings to nominal widths smaller than DN 80
In case of form-locked transitions to nominal widths smaller than DN
80, for example, the transition adaptor with BAIO® spigot end DN 80
and ZAK® socket ZAK 46 and/or ZAK 69 shall be used. In the ZAK®
system, valves, pipe fittings and fittings are locked by means of a bay-
onet connection similar to the one used in the BAIO® system. Detailed
information about the ZAK® system is given on the following pages.
Figure: Transition fitting BAIO® spigot
For more information on our fittings please refer to Section 5.
end DN 80 to ZAK® socket (ZAK 46)
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1.2 ZAK® System
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General Information Threadless Connection Technology
1.1 ZAK® System
Threadless connection - ZAK® system
Locking and sealing
For installation, it is sufficient to push the ZAK® spigot end into
the ZAK® socket, to lock it by turning it 90°clockwise, and to pull
it back as far as it will go. To engage the ZAK® spigot end into the
ZAK® socket, the connection has to be secured against uninten-
tional unlocking by means of a locking ring.
The connection is reliably sealed via the bayonet connection con-
sisting of a corrosion protected socket with inside bayonet locking
and a spigot end with locking keys, also corrosion protected, plus
a double O-ring gasket.
Technical features
• Medium: potable water, sewage water, gas • Easy and quick installation
• Nominal widths: • Threadless connection technology
ZAK 34 – corresponding to dimension 1” • Stress relief due to movability of the connection
ZAK 46 - corresponding to dimension 1 ½“ • Reliable double O-ring sealing of the connection
ZAK 69 - corresponding to dimension 2” • Long service life due to integral corrosion protection
• Max. operating pressure: potable water 16 bar, • No tools required for installation
sewage water 16 bar (gas on request)
Drilling in the ZAK® system
Via a Hawle pipe drilling saddle, in-service drilling of the line is possible up to a maximum operating pressure of 16 bar.
By means of the Hawle drilling device “Hawlomat” (see Section 7) you can drill CI, steel, PVC, PE, and AC pipes via a pipe
drilling saddle, e.g. in the ZAK® system. Both potable water and sewage water lines can be drilled. For the field of sewage
water, the ZAK 69 system has been developed specifically. The drilling of a Hawle free-flow underground hydrant installed
later is also possible. To this end, an extra-long drill spindle with claw adapter has to be used. (For more information on
the Hawle pipe drilling saddles please refer to Section 2.)
Details see page 2-19
Application in the field of potable water Application in the field of sewage water
Drilling of an existing PE supply line by means of Drilling of a waste pipe through a sewage water
HAKU Hawlinger ZAK 46 service valve ZAK 69 with HAKU pipe saddle
For more information on our drilling device Hawlomat and/or our loan units please refer to Section 7.
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