COMPOSITE PIPE SOLUTION FINAL SEPTEMVRI

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 No. 01442/0
ISO 14001:2004 No. 00211/0
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 haven’t 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 they
can 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.
Polyetylene
Stell Reinforce
Vee Shape Plate
Polyetylene
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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:
% of deflextion before damage
0.1%
<0.3%
>3.0%
Pipe classification
rigid
Semi-rigid
flexible
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.
Cracking
under application of
ultimate load with time
Flexible igid
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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.
Rigid
Flexible
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.
STRUCTURAL ACTION
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.
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F (kN/m)
∆Y/2 (mm)
∆Χ/2 (mm)
∆Χ/2 (mm)
dint
dext
The distorsion of the pipe is linked in part to its rigidity and to its casing. The first factor is determined by
its own structure without support and the second factor is linked to the relationship/soil.
PIPE IN BACKFIELD
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) which
show 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 intergranular 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.
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ADVANTAGES
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 which
means 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.
MATERIAL
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.
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DIMENSION RANGE
e
de
di
e2
e1
P
Specification
OD
ID
Inner wall thick
Out wall thick
de
di
e1
e2
4.5±0.5
4.5±0.5
4.5±0.5
4.5±0.5
5±0.5
5±0.5
5±0.5
4.0±0.3
4.0±0.3
4.2±0.3
4.3±0.3
5.3±0.3
5.3±0.3
5.3±0.3
SN 10
1300
1400
1500
1600
1800
2000
2200
1414±7
1525±7
1640±7
1740±7
1964±7
2185±7
2388±7
1305±6
1413±6
1510±6
1610±6
1814±6
2015±6
2218±6
APPLICATION RANGE
- Civic buried drainpipe, sewage pipeline
- Industrial waste
- Seawater, rainwater pipeline
- Water collection system
- Water treatment works
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HYDRAULIC PROPERTIES OF SRP - KONTI KAN COMPOSITE PIPE
The hydraulic characteristics are extremely good providing maximum efficiency and durability.
ROUGHNESS (KS)
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, a
roughness coefficient of 0.01ks should be applied.
ABRASION RESISTANCE
Polyethylene is extremely resistant to abrasion if compared with alternative pipe products, offering much
greater 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 the
abrasion 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%
Flow calculation
Velocity calculation
Flow: Q=A*C*R1/2*I1/2 (l/sek)
Chezy coefficient:
C =1/n*R2/3*I1/2
Q=A*1/n*R2/3*I1/2
where:
A- circular section of the pipe (m2)
R - hydraulic radius (m)
I -slope of trench (m/m)
Velocity:V =C*R1/2*I1/2(m/s)
C =1/n*R2/3*I1/2
V = 1/n*R2/3*I1/2
where:
R - hydraulic radius (m)
R- hydraulic radius for full pipe =ID/4
I - slope of trench (m/m)
Manning number n=0.010
SLOPE
DN
1300
1400
1500
1600
1800
2000
2200
m/m
ID
1300
1400
1500
1600
1800
2000
2200
1/1000
0,001
2/1000
0,002
3/1000
0,003
4/1000
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
40/1000
0,04
50/1000
0,05
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
2,41
3697,21
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
11691,60
8,81
13071,60
9,85
2252,52
1,46
3185,55
2,07
3901,49
2,54
4505,05
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
14246,21
9,26
15927,75
10,35
2707,52
1,53
3829,01
2,17
4689,56
2,66
5415,03
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
17123,84
9,70
19145,04
10,84
3215,99
1.60
4548,09
2,26
5570,25
2,77
6431,97
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
20339,69
10,12
22740,46
11,32
4402,72
1,73
6226,38
2,45
7625,73
3,00
8805,43
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
27845,22
10,95
31131,90
12,24
5830,96
1,86
8246,23
2,63
10099,52
3,22
11661,93
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
36878,25
11,74
41231,14
13,13
7518,32
1,98
10632,50
2,80
13022,10
3,43
15036,63
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
47550,00
12,52
53162,52
13,99
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CHEMICAL RESISTANCE
Asbestos cement
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 specific
chemicals is available on our web site.
Fibr eglass
concrete
Vitrihed Clay
PVC
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 during
handling 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 of
protrusions and large debris, oe in built boxes.
Important: Pipes shall be secured to prevent rolling.
Excessive stacking height should be avoided so that pipes
in the lower part of the stacks are not overloaded. See
picture.
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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
Standard trench
Bedding material should be laid
Evenly along the trench bottom.
DN
L
Granular
material
h1
b
b = (DN/10)+10
b : Height of bedding (cm)
DN: Nominal diameter (cm) h1= DN/2
h1 : Height of embedment (cm) (Max. 30 cm)
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WORK AREA
DN (mm)
L (mm)
200-350
150
400-500
200
600-900
300
1000-1600
450
1800-2600
600
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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 the
trench 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.
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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 different
connecting 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.
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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.
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:
• EN13476 – Thermoplastic piping systems for non-pressure
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.
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