composite pipe solution

8/3/2019 Composite Pipe Solution

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COMPOSITE PIPE SOLUTION

STEEL REINFORCED

PE SPIRAL- CORRUGATE PIPE

KONTI KAN - SRP- HIGH RING STIFNESS PIPE

SN 10- SN 16

New solution

ISO 9001:2008

ISO 14001:2004

No. 01442/0

No. 00211/0


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There are big demands of large diameter drain pipes at the global market, especially for infrastructure

projects. Nowdays in contemporary projects concrete pipes are used as the only solution with all its

minuses, only because so far the plastic corrugated pipes as well as the pipes with spiral wall havent met

the requirements for high stiffness yet.

The outcome of this common problem was our work on developing the new product KONTI KAN-SRP

composite and steel reinforced PE spiral and corrugated pipe, which can reach high ring stiffness from

SN10 up to Sn16.

DESCRIPTION OF THE PRODUCT

Steel reinforced PE spiral and corrugated pipe SRP- KONTI KAN COMPOSITE PIPE has three layered

reinforced structure. The pipe is composed by HDPE layers (inner and outer) and U shaped steel band,

The inside HDPE tube is formed by wrapping of the PE sheet, and the steel band is pre-coated with

adhesive resin.The steel and the HDPE are wrapped around the mandrel and bond together so that theycan form one integrated spiral-corrugated pipe. The steel provides outstanding stiffness and the outer PE

layer protects the steel out of corrosion. The advantages as high rigidity and strength of the steel as well

as the uniqueness of this pipe come from the combination of different organic materials.

REINFORCED STRUCTURE

The elastic modulus of carbon steel is 200 times higher than polyethylene, by combining the advantages

of both steel and plastic we developed a composite pipe suitable for application in buried sewage pipe

systems, with outstanding anti-corrosive properties and easy installation process.


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STEEL AND POLYETHYLENE BONDING

The mechanical bond between the steel U-shaped plate and the polyethylene is stronger then the tensile

strength of the polyethylene resin, and this is the major reason why this pipe came out to be so

successful option. The bonding between the steel and the polyethylene layer is extremely strong and

there is absolutely no chance of separation of any two layers in any way. The process of the bonding is

developing in that way so the steel band is pre-coated with a special bond resin in order to create a

medium layer between the steel and the plastic, meanwhile the processing temperature, pressure an

press-cooling time are strictly controlled, to ensure that the fusion and the bonding are developing

under the best proper conditions.

The other process point is to protect the metal layer out of corrosion.In SRP pipes, the steel i completely

covered with polyethylene so the liquids, air and soil can not contact with the steel reinforcement which

guarantees the anti-corrosive performance of the SRP pipe.With the new wall structure, the pipe system

can easily reach high ring stiffness up to SN 16 (based on testing by ISO 9969), in other hand when it

comes to the weight of the pipe its obiously lighter than other competitive pipes.

3

Stell ReinforceVee Shape Plate

Polyetylene

Polyetylene



FLEXIBLE VERSUS RIGID PIPE

Pipes on the market are generally fall into two categories : flexible pipe and rigid pipe.

There is a classification of type of pipe according to performance during interaction with soil ( before

permanent damage to the structure , as follow:

Flexible pipe are manufactured from plastic, metal or their combination. These materials have different

mechanical characteristics. Metal present with elastic properties whereas plastic present with viscoelastic

properties, where the influence of time is noticeable. In case of combination of metal with plastic, our SRP

pipe, make collection of their properties which gave one stable flexible pipe with balance of elastic and

viscoelastic properties of both material.

Flexible pipe benefit from their capacity to move or modify under loads without structural damage. The

principal materials of flexible pipe are HDPE, Steel, SRP and aluminum.. Flexible pipes are generaly

defined as those pipes that accept a certain deflection without structural damage. This deflection or

distortion enables the pipe to adapt to the shape of the outside casing, the vertical loa is thus transferred

for the most part to the outside casing, which is the backfield and the soil.

Rigid pipe materials such as glazed clay, GRP, reinforced or non reinforced concrete have a minimum

deflection tolerance before reaching the acceptable limit of cracking. To illustrate, figure below show the

difference of ultimate performance of flexible and rigid pipe under load.

Pipe classification

rigid

Semi-rigid

flexible

% of deflextion before damage

0.1%

3.0%

Cracking

under application of

ultimate load with time

Flexible igid R



Both , flexible and rigid pipes required and appropriate backfield , even though the interaction of the pipe

with the backfield is different. That is, the flexible pipe works with the backfield , and the load is

transferred by the wall to the foundation. For both types of material ,the choice of good backfield, and the

load is transferred and carried bt the backfield . In the case of the rigid pipe, the load is transferred by the

wall to the foundation. For both types of material, the choice of good backfield and compaction material

is very important to enable this transfer of load. Figure below( strana 5) show the interaction between

backfield and pipe as well as the transfer of load.

Flexible pipe offers significant structural offers significant structural advantages to the project designer.

In many situation, a flexible pipe correctly installed can be buried much deeper than a rigid pipe installed

in a similar manner, because of the interaction pipe/backfield. A rigid pipe is often stronger that the

surrounding backfield material, leading to the necessity to support soil loads much greater then the prism

load over the pipe. On the other hand, flexible pipe is not as strong as the surrounding backfield, thereby

forcing a mobilization of the surrounding backfield casing in order to sustain the dead weight and the live

weight.

The interaction between flexible pipe and the backfield is extremely efficient in maximizing the structural

characteristics of pipe, permitting the installation of pipe in very deep installation, many times superior to

the covering admissible for rigid pipe in an identical installation.

When flexible pipes is submitted to vertical pressure, the soil surrounding the pipe is compressed and the

circular shape of the pipe becomes and ellipsis with a horizontal increasing of the diameter of Dx and a

decrease of the diameter of Dy. These distorsion are desirable up to certain point beyond whichthe

pipe /soil system can no longer accomplish the task for which it was designed. The vertical deflection is

generally limited to 7% for a flexible pipe.

STRUCTURAL ACTION

RigidFlexible



The distorsion of the pipe is linked in part to its rigidity and to its casing. The first factor is determined byits own structure without support and the second factor is linked to the relationship/soil.

Flexibility is a desirable attribute of buried pipe. As previous indicated , the flexible pipe connects with the

surrounding soil to establish a structure/pipe unit, which is the principal key to as successful design.

A buried pipe and the adjacent casing of soil will support the dead load and the live load according to the

fundamental principle of structural analysys: the stiffest element attract a larger proportion of shared

load than those that are more flexible.This principal is illustrated in figure below (slika strana 9) whichshow the effect of load bearing of the soil surrounding a flexible pipe,properly embanked and compacted.

For the flexible , the soil is more rigid , which creates a lateral support , reducing the possibility of

deflection and thereby enabling the development of soil stopper, a necessary condition for the formation

os a structural arch on the pipe.

A second condition required for the formation of the arch is achieved when the resistance to inter-

granular cutting of soil correctly compacted for a certain distance over top of the pipe is mobilized to

maintain its geometry . The direct load on the crown of the pipe is mobilized to maintain its geometry. The

direct load on the crown of the pipe is the part between the crown an dthe soil arch.See the dotted line.

The rectangular prism of the soil stretches from over the surface of the pipe to over the top of the

backfield , with a base exactly equal to the width of the external dimensions of the pipe.In contrast, a rigid

pipe by its structure incorporates a column of load into the prism load,mwhich gives a triangular prism

and leads to a greater load.

PIPE IN BACKFIELD

/2 (mm)

Y/2 (mm)

/2 (mm)

F (kN/m)

dint

dext



ADVANTAGES

MATERIAL

SRP pipe technology provides clients and contractors with the following key benefits:

Strenght - :Long-term high ring stiffness

Stronger than usually expected ring stiffnes SN10, SN16and Sn20

Durability:Unique combination of HDPE and steel

Flexibility: Structurally flexible, yet with outstanding long-term stiffness

High deformation resistance and mechanical strength

High impact resistance

Installation: Easy and fast installation Environment: Significant reduction in material consumption and transport

Cost benefit: Reduced installation and whole life spand costs

Anticorrosive and wear proof properties of plastics

Large diameter available up to ID 2200mm

Long life spand

The newly developed process of plastic-steel bonding, and formig technology makes the pipe reliable

composite and with high performance. The specially designed steel bending device can form the

reinforced layer easily. When it comes to the production line itself it is flexible and adjustable whichmeans the dimensions can easily be changed to different size. This is the most economical solution for

large size sewage pipeline systems. The innovative pipe provides high stiffness, less weight and low cost.

The material used for production of SRP-KONTI KAN COMPOSITE PIPE contains the following:

Inner Layer: 100% Polyethylene pipe grade, without the presence of any form of recycled material.

Outer Layer: 100% Polyethylene pipe grade, without the presence of any form of recycled material.

Middle Layer: Steel according EN 10130-1991, steel grade FE PO1, coated with polyethylene based

adhesive.

7



DIMENSION RANGE

APPLICATION RANGE

-Civic buried drainpipe, sewage pipeline

-Industrial waste

-Seawater, rainwater pipeline

-Water collection system

-Water treatment works

e

e1

e2

P

de

di

Specification OD

de

1300

1400

1500

1600

1800

2000

2200

14147

15257

16407

17407

19647

21857

23887

13056

14136

15106

16106

18146

20156

22186

4.50.5

4.50.5

4.50.5

4.50.5

50.5

50.5

50.5

4.00.3

4.00.3

4.20.3

4.30.3

5.30.3

5.30.3

5.30.3

ID

SN 10di

Inner wall thick

e1

Out wall thick

e2



HYDRAULIC PROPERTIES OF SRP - KONTI KAN COMPOSITE PIPE

ROUGHNESS (KS)

The hydraulic characteristics are extremely good providing maximum efficiency and durability.

The roughness coefficient of HDPE for calculation using Colebrook White formula is 0.03ks. However

Sewer and Adoption and certain other standards or codes of practice state that a general roughness

figure of 0.6ks should be applied, irrespective of pipe material. Where this figure is applied, SRP will in all

cases function much more efficiently than the calculated design flows. If the Manning equation is used, aroughness coefficient of 0.01ks should be applied.

ABRASION RESISTANCE

Polyethylene is extremely resistant to abrasion if compared with alternative pipe products, offering muchgreater resistance to abrasion caused by larger solid particles and fines that are present in all sewerage

systems. For this reason, polyethylene pipes are routinely used in mining and quarrying applications, and

for conveyance of slurry.

Testing abrasion resistance generally aims to compare relative performance of ppe materials under

specific conditions which are usually more severe than those encountered in normal stormwater

applications.

The empirical testing used to produce the graph below consisted of charging a 0.5m long section of pipe

with a quartz sand/ gravel mixture and rocking it backwards and towards. After 600.000 cycles theabrasion of the polyethylene pipe was 0.3mm compared to a value of 1.2mm of concrete.


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FLOW RATE TABLE PIPE FILLING 90%

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Q (l/s)

V (m/s)

Q (l/s)

V (m/s)

Q (l/s)

V (m/s)Q (l/s)

V (m/s)

Q (l/s)

V (m/s)

Q (l/s)

V (m/s)

Q (l/s)

V (m/s)

Q (l/s)

V (m/s)

Q (l/s)

V (m/s)

Q (l/s)

V (m/s)

Q (l/s)

V (m/s)

Q (l/s)

V (m/s)

Q (l/s)

V (m/s)

Q (l/s)V (m/s)

Q (l/s)

V (m/s)

1848,60

1,39

2614,32

1,97

3201,88

2,413697,21

2,79

4133,60

3,12

4528,14

3,41

4890,95

3,69

5228,64

3,94

5545,81

4,18

5845,80

4,41

7159,61

5,40

8267,21

6,23

10125,22

7,63

11691,608,81

13071,60

9,85

2252,52

1,46

3185,55

2,07

3901,49

2,544505,05

2,93

5036,80

3,27

5517,53

3,59

5959,62

3,87

6371,10

4,14

6757,57

4,39

7123,11

4,63

8723,99

5,67

10073,59

6,55

12337,58

8,02

14246,219,26

15927,75

10,35

2707,52

1,53

3829,01

2,17

4689,56

2,665415,03

3,07

6054,19

3,43

6632,03

3,75

7163,42

4,06

7658,01

4,34

8122,55

4,60

8561,92

4,85

10486,17

5,94

12108,38

6,86

14829,68

8,40

17123,849,70

19145,04

10,84

3215,99

1.60

4548,09

2,26

5570,25

2,776431,97

3,20

7191,16

3,58

7877,53

3,92

8508,70

4,23

9096,18

4,53

9647,96

4,80

10169,84

5,06

12455,46

6,20

14382,33

7,16

17614,68

8,77

20339,6910,12

22740,46

11,32

4402,72

1,73

6226,38

2,45

7625,73

3,008805,43

3,46

9844,77

3,87

10784,41

4,24

11648,49

4,58

12452,76

4,90

13208,15

5,19

13922,61

5,47

17051,64

6,70

19689,54

7,74

24114,67

9,48

27845,2210,95

31131,90

12,24

5830,96

1,86

8246,23

2,63

10099,52

3,2211661,93

3,71

13038,43

4,15

14282,88

4,55

15427,28

4,91

16492,45

5,25

17492,89

5,57

18439,12

5,89

22583,22

7,19

26076,86

8,30

31937,50

10,17

36878,2511,74

41231,14

13,13

7518,32

1,98

10632,50

2,80

13022,10

3,4315036,63

3,96

16811,46

4,42

18416,04

4,85

19891,59

5,24

21265,01

5,60

22554,95

5,94

23775,00

6,26

29118,31

7,66

33622,93

8,85

41179,51

10,84

47550,0012,52

53162,52

13,99

1/1000

0,001

2/1000

0,002

3/1000

0,0034/1000

0,004

5/1000

0,005

6/1000

0,006

7/1000

0,007

8/1000

0,008

9/1000

0,009

10/1000

0,01

15/1000

0,015

20/1000

0,02

30/1000

0,003

40/10000,04

50/1000

0,05

SLOPE

m/m

DN

ID

1300

1300

1400

1400

1500

1500

1600

1600

1800

1800

2200

2200

2000

2000

Velocity calculation

Velocity:

where:

R - hydraulic radius (m)

R-hydraulic radius for full pipe =ID/4

I - slope of trench (m/m)

Manning number n=0.010

V =C*R1/2*I1/2(m/s)

C =1/n*R2/3*I1/2

V = 1/n*R2/3*I1/2

Flow calculation

Flow:

Chezy coefficient:

where:

A-circular section of the pipe (m2)

R - hydraulic radius (m)

I -slope of trench (m/m)

Q=A*C*R1/2*I1/2 (l/sek)

C =1/n*R2/3*I1/2

Q=A*1/n*R2/3*I1/2



CHEMICAL RESISTANCE

The HDPE bore of SRP-KONTI KAN COMPOSITE PIPE offers

excellent resistance to all substances that would routinely be

discharged into sewerage systems, including water with high

saline contents,fuels,acids and most chemicals.Additionlly,

unlike concrete based products, polyethylene is completely

resistant to sulphates and can therefore provide significantly

better long term performance.

Further information related to chemicals resistance and

performance against a comprehensive list of specificchemicals is available on our web site.

PVC

Asbestos cement

concrete

Fibr eglass

Vitrihed Clay

HDPE

200,000 400,000 600,000

Number of Lload Cycl es

DELIVERY, HANDLING AND TRANSPORTATION ON SITE

Pipes, pipeline component and joint accessories shall be inspected immediately after delivery to ensure

that they are appropriately marked and comply with the desired requirements.Product shall be examined

both on delivery and immediately prior installation to ensure that they are free from damages.

SRP PIPE is robust, reltive light and easy to handle, however care must be taken to prevent damage duringhandling and unloading. Pipes should not be dropped, thrown or dragged.

Pipes that require mechanical lifting should be supported in two evenly spaced positions, adequate

protection should be placed between chains and the pipe. In that case the external corrugation will

prevent pipes from slipping. See picture.

STORAGE

Pipes should be placed or stacked on flat surface free ofprotrusions and large debris, oe in built boxes.Important: Pipes shall be secured to prevent rolling.

Excessive stacking height should be avoided so that pipesin the lower part of the stacks are not overloaded. Seepicture.



INSTALATION

Lightweight Pipes and tanks manufactured using SRP technology are significantly lighter then

conventional plastic, concrete or clay products.

Robust- The combination of polyethylene and steel provides extremely robust products that can easily

withstand routine site handling.

For construction, installation and testing after drain and sewer pipelines has been installed normally

buried in the ground and normally operating under gravity is applicable standard En1610.

INSTALATION GUIDE BEDDING

Bedding material should be laidEvenly along the trench bottom.

DN (mm)

200-350

400-500

600-900

1000-1600

1800-2600

L (mm)

150

200

300

450

600

WORK AREA

b =

b :

DN:

h1 :

(DN/10)+10

Height of bedding (cm)

Nominal diameter (cm) h1= DN/2

Height of embedment (cm) (Max. 30 cm)

h1

b

LDN

Standard trench

Granular

material



PIPE LAYING

Pipes should be laid to the correct line and level on

the bedding material, taking care to ensure that

there are no voids underneath any part of the pipe.

The backfill materials must be coated in layers, in

filling both sides of the pipe in trench.

Compacting the native soil for the backfill is not

required except for the road crossings

(30cm from the crown)

Damaged (crushed, punctured, scratched, etc.) pipes should not be used. The water in the soil should be drained during installation.

If there is any risk of flotation or movement of the pipes occurring prior to backfilling the trench, the

pipes should be fixed in place with pegs or other suitable holding devices.

The backfill height should be min h=100cm considering the regional frost affects.

The granular materials with high ability of compaction should be preferred in the bedding zones and for

the material surrounding the pipe.

If the excavated material is suitable for use as backfill material, the pipe can be directly laid on the

cleared trench bed.

If the soil contains mud and clay, it should be compacted with fine, coarse grained materials. In

extremely loose grounds, the trench wall should be either sloped or sheeting shoulf be applied to thetrench walls for workmanship safety.

MRP pipes(Metal reinforced polyethylene pipes) are manufactured in SN 10kN/m2-SN 20kN/m2 stiffness

classes. The metal reinforcement elements in polyethylene parts of MRPpipes provides extra ring stiffness

to the pipe. MRP pipes are economic solutions compared to other arge diameter or HDPE, PP stiffness to

the pipe. MRP pipes are economic solutions compared to other large diameter or HDPE, PP

(polypropylene) corrugated pipes and RC (reinforced concrete) pipes. Dependable of the national

regulative it is possible not to backfill material properties and compacting capabilities to be required.



CONNECTION

The connection of the pipe could use various joint like plastic welding, electrofusion and welding,

different solution of socket and gasket connection, stainless steel couple or heat shrinkable couple

dependable on the installation conditions but as most reliable and most efficient solution with strong

watertightness is our solution:

INCORPORATED SOCKET AND GASKET CONNECTION

Multiple connecting methods, strong connecting:

Electro thermal welding, thermal shrinkage, internal and external extruding,welding or differentconnecting methods can be used at the same time, the strong connection ensures no leakage of the

pipes.

1 2 3

1. First ensure that the spigot ends of both pipes, that are about to be jointed are clean of any kind of dirt

or remains of debris.

2. Place the flexible coupling over the end of the receiving pipe making sure that the fixings (screws of

bolts) are positioned about 30 around from thw top of the pipe.The coupling should be placed such that

the end of the pipe spigot meets the centere point of the width of the coupling. The easiest way to do this

is to mark an appropriate line on the spigot prior of placing the coupling. Gently tightnen the fixings on

that half of the coupling so that the coupling will retain its position.

3. Carefully lift the adjoining pipe slightly and locate the spigot inside the coupling until the two spigot

ends are approximately 10mm apart (to allow for a small amaunt of movement)ll retain its position.


15/16

JOINT & MANHOLE

There are available range of bends that can be used with MRP pipe. They ae manufactured with cutting

and welding pieces of SRP. Solution for connection with ipe can be done on no one of the above

mentioned jonting solution.

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underground drainage and sewerage.

Structured wall piping system.

DIN 16961 Plastic pipes and fittings with profiled outer and

smooth inner surface.

EN 9969 Determination of ring stiffness

EN 744 Resistance of External blows by the round clock method.

EN 1446- Determination of Ring Flexibility.

EN13476 Thermoplastic piping systems for non-pressure

STANDARDS

Specific standards for SRP pipe have been developed ASTM F 2435-05 and it is intended that a similar

standard will be eveloped for the European market.

In the absence of a specific, appropriate standard for SRP pipe in Europe, to provide complete confidence

in relation to comparative performance against exsisting, recognized standards for structural wall plastic

pipes, SRP KONTI KAN CMPOSITE PIPE has been independally tested in accordance with the following

standards:


16/16

esing

2011

PRINTCHA

OS

Tel:

00 389 34 212 064

00 389 34 211 757

00 389 34 215 225

00 389 34 215 226

Fax:

00 389 34 211 964

e-mail: [email protected]


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MACEDONIA

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00 359 287 081 48

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00 381 21 444 66200 389 71 315 210

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00 389 02 246 846

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00 355 67 2022 043

00 389 75 221 043

00 355 42 419 304


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00 38971315210

Croatia

00 385 91 3234 335

Representatives

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