Global Pipe Australia Pty Ltd - Water Services Association of Australia

Transcription

WSAA Product Appraisal 1014 Part 3
1
Global Pipe Australia Pty Ltd
PRODUCT APPRAISAL REPORT NO 1014 PART 3
HOBAS Centrifugal Cast (CC) Glass Fiber Reinforced Plastic (GRP) Jacking
Pipes for Pressure and Non Pressure Applications. DN 250 – DN 3600
ISO 25780 – Plastic piping systems for pressure and nonpressure water supply, irrigation, drainage or sewer - Glassreinforced thermosetting plastics (GRP) systems based on
unsaturated polyester (UP) resin – Pipe with flexible joints
intended to be installed using jacking techniques
Publication Date: 9 December 2014
COPYRIGHT
2
Document History
The following information indicates the changes made to this document.
Date
Version
12/10/2014
Peer Review
9/12/2014
Publication version
File Location
U:\PP1IND~1\PP1-01~3\CIVILA~1\2012\PA1014~2\PA
1014 Part 3 Global Pipe Australia Pty Ltd HOBAS CC-GRP
Jacking Pipe Peer Review Draft.docx
U:\PP1IND~1\PP1-01~3\CIVILA~1\2012\PA1014~2\PA
1014 Part 3 Global Pipe Australia Pty Ltd HOBAS CC-GRP
Jacking Pipe Final 9122014.docx
Peer Reviewers
Name/Title
Organisation
IPAM Members
Date
14 November 2014
Mohamed Yoosuf, Senior Engineer, Standards
City West Water
14 November 2014
Adam Glasson , Technical Officer
Goulburn Valley Water
14 November 2014
Colin Paxman - Standards and Design
South East Water
14 November 2014
Carl Radford, Program Manager Asset Creation
WSAA
12 October 2014
Name/Title
Signature
Date
Carl Radford, Program Manager Asset Creation
Carl Radford
9/12/2014
Approvals
COPYRIGHT
3
Overview of WSAA
The Water Services Association of Australia (WSAA) is the peak industry body that
supports the Australian Urban Water Industry. Its members and associate members
provide water and sewerage services to approximately 20 million Australians and many of
Australia’s largest industrial and commercial enterprises.
The Association facilitates collaboration, knowledge sharing, networking and cooperation
within the urban water industry. It is proud of the collegiate attitude of its members which
has led to industry-wide approaches to national water issues.
WSAA can demonstrate success in the standardisation of industry performance monitoring
and benchmarking, as well as many research outcomes of national significance. The
WSAA Executive retains strong links with policy makers and legislative bodies and their
influences, to monitor emerging issues of importance to the urban water industry. WSAA is
regularly consulted and its advice sought by decision makers when developing strategic
directions for the water industry.
WSAA was formed in 1995 as a non-profit organisation to foster the exchange of
information relating to the provision of urban water services between industry, government
and the community, and to promote sustainable water resource management.
The Association’s main activities focus on four areas:
1.
Influencing national and state policies on the provision of urban water services and
sustainable water resource management;
2.
Promoting debate on environmentally sustainable development and management of
water resources and the community health requirements of public water supplies;
3.
Improving industry performance and establishing benchmarks and industry leading
practices for water service processes; and
4.
Fostering the exchange of information on education, training, research, water and
wastewater management and treatment and other matters of common interest
Copyright
This document is copyrighted. Apart from any use as permitted under the Copyright Act
1968, no part of this document may be reproduced or transmitted in any form or by any
means, electronically or mechanical, for any purpose, without the express written
permission of Water Services Association of Australia Limited.
© Copyright 2014 by WATER SERVICES ASSOCIATION of Australia Limited All rights
reserved.
COPYRIGHT
4
CONTENTS
ERROR! HYPERLINK REFERENCE NOT VALID.
1 EXECUTIVE SUMMARY ............................................................................................................................................. 6
1.1 Recommendation .................................................................................................................................................. 7
2 THE APPLICANT ......................................................................................................................................................... 7
2.1 The Manufacturer .................................................................................................................................................. 7
3 THE PRODUCT ........................................................................................................................................................... 8
3.1 General.................................................................................................................................................................. 8
3.2 Manufacture of the HOBAS® CC-GRP jacking pipes............................................................................................. 8
3.2.1 Manufacturing process .................................................................................................................................... 8
3.2.2 Joints .............................................................................................................................................................. 9
3.2.2.1 Filament Wound GRP coupling (Non-jacking application) ........................................................................ 9
3.2.2.2 Stainless Steel Coupling for Jacking Pipes .............................................................................................. 9
3.2.2.3 GRP Coupling for Jacking Pipes .............................................................................................................. 9
3.2.2.4 Filament Wound Couplings for Jacking Pipes ........................................................................................ 10
3.2.3 HOBAS CC-GRP Jacking Pipe Composition ................................................................................................ 10
3.2.3.1 Reinforcement ........................................................................................................................................ 10
3.2.3.2 Resin ...................................................................................................................................................... 10
3.2.3.3 Aggregate and Fillers ............................................................................................................................. 10
3.2.4 Elastomers - Type test .................................................................................................................................. 10
3.3 Nominal Sizes ..................................................................................................................................................... 11
3.4 Jacking Load and Nominal Stiffness ................................................................................................................... 11
3.5 Nominal Pressure ................................................................................................................................................ 11
3.6 Nominal Pipe lengths........................................................................................................................................... 11
3.7 HOBAS® Joint Properties (couplings) ................................................................................................................. 11
3.8 Allowable Angular Deflection ............................................................................................................................... 12
3.9 Straightness ........................................................................................................................................................ 12
3.10 Pipe Fittings and Accessories ........................................................................................................................... 12
3.11 Flanges.............................................................................................................................................................. 12
4 SCOPE OF THE APPRAISAL ................................................................................................................................... 13
5 APPRAISAL CRITERIA ............................................................................................................................................. 13
5.1 General................................................................................................................................................................ 13
5.2 Quality Assurance Requirements ........................................................................................................................ 13
5.3 Performance Requirements................................................................................................................................. 13
6 COMPLIANCE WITH APPRAISAL CRITERIA........................................................................................................... 13
6.1 Compliance with Quality Assurance Requirements ............................................................................................. 13
6.2 Compliance with Performance Requirements ..................................................................................................... 14
6.2.2 Mechanical Characteristics ........................................................................................................................... 14
6.2.2.1 Initial specific ring stiffness - Batch release test ..................................................................................... 15
6.2.2.2 Long-term specific Creep Stiffness - Type test ...................................................................................... 15
6.2.2.3 Initial resistance to failure in a deflected condition - Batch release test.................................................. 15
6.2.3 Resistance of pressure pipes internal pressure - Type test .......................................................................... 16
6.2.4 Resistance to strain corrosion - Type test ..................................................................................................... 16
6.2.5 Joint performance - Type test ...................................................................................................................... 17
6.2.6 Longitudinal compressive strength................................................................................................................ 19
6.2.7 Permissible Jacking Forces .......................................................................................................................... 19
COPYRIGHT
5
6.2.8 Specific initial longitudinal compressive modulus.......................................................................................... 19
6.2.9 Abrasion resistance ...................................................................................................................................... 20
6.2.10 Temperature and pressure re-rating ........................................................................................................... 20
6.2.11 Resistance to Ultraviolet degradation ......................................................................................................... 20
6.2.12 Other Technical Data .................................................................................................................................. 20
7 FITTING INSTRUCTIONS, TRAINING AND INSTALLATION ................................................................................... 21
8 REPAIR FOR NON-PRESSURE CC GRP JACKING PIPE FOR SEWERAGE APPLICATIONS.............................. 21
9 PRODUCT MARKING ............................................................................................................................................... 21
10 PACKAGING AND TRANSPORTATION ................................................................................................................. 22
11 PRODUCT WARRANTY .......................................................................................................................................... 22
12 WATER AGENCY EXPERIENCE WITH THE PRODUCT OR FIELD TESTING REPORT ..................................... 22
13 DISCUSSION........................................................................................................................................................... 22
14 LIFE EXPECTANCY ................................................................................................................................................ 23
15 REPORT RECOMMENDATION .............................................................................................................................. 23
16 DISCLAIMER ........................................................................................................................................................... 24
16.1 Issue of Report .................................................................................................................................................. 24
16.2 Limits on Reliance on Information and Recommendations................................................................................ 24
16.2.1 Disclaimer of liability ................................................................................................................................... 24
16.2.2 Need for independent assessment ............................................................................................................. 24
16.3 No Updating ...................................................................................................................................................... 25
16.4 No Warranty ...................................................................................................................................................... 25
APPENDIX A – TECHNICAL MANUALS BROCHURES / REPORTS .......................................................................... 26
AVAILABLE FROM GLOBAL PIPE AUSTRALIA PTY LTD OR THE GLOBAL PIPE WEBSITE .................................. 26
OTHER REPORTS AND TECHNICAL DOCUMENTATION - WSAA MEMBERS ONLY ............................................. 27
APPENDIX B - QUALITY CERTIFICATIONS ............................................................................................................... 29
APPENDIX C – PRODUCT SCHEDULE ...................................................................................................................... 38
APPENDIX D – WSAA PRODUCT SPECIFICATION................................................................................................... 43
WSA PS – 205J CENTRIFUGALLY CAST GLASS REINFORCED PLASTICS (CC-GRP) PIPES FOR PRESSURE
AND NON-PRESSURE APPLICATIONS – WATER SUPPLY AND SEWERAGE - INSTALLED USING TRENCHLESS
INSTALLATION METHODS.......................................................................................................................................... 43
205j.1 Scope ............................................................................................................................................................. 43
205J.2 Requirements ................................................................................................................................................ 43
205J.3 Quality Assurance ......................................................................................................................................... 43
205J.4 AGENCY or project SPECIFIC REQUIREMENTS ........................................................................................ 43
APPENDIX E - SUPPLIER CONTACTS ....................................................................................................................... 45
APPENDIX F – HOBAS® ENGINEERING LABORATORY ACCREDIATION ............................................................... 46
APPENDIX G – OTHER DETAILS (CARBON NEUTRAL HOBAS) .............................................................................. 47
APPENDIX H – PIPE MARKING .................................................................................................................................. 48
APPENDIX I – TRANSPORTATION / PACKING .......................................................................................................... 49
COPYRIGHT
1
6
EXECUTIVE SUMMARY
This appraisal applies to HOBAS ® Centrifugal Cast (CC) Glass Reinforced Plastic (GRP)
jacking pipes, for non-pressure systems, joined using flexible non-end-load-bearing joints
with elastomeric seals, intended to be installed using various trenchless installation methods
e.g. Slip Lining, Micro Tunnelling and Pipe Jacking.
This appraisal assesses the HOBAS Jacking pipe suitability to sewerage applications in
accordance with ISO 10467 in addition to assessing its structural suitability for installation by
jacking methods in accordance with ISO 25780.
Global Pipe Australia Pty Ltd has been appointed the exclusive Agent and Distributor for the
range of HOBAS® CC-GRP jacking pipes for the Australasia region.
HOBAS® CC-GRP pipes and fittings for this region are manufactured in Germany/Austria by
HOBAS® Rohre GmbH. This company was founded in 1957 and is a major manufacturer and
exporter of GRP pipes and fittings and their associated accessories within Europe, USA,
Middle East and other countries across the World. HOBAS® has 15 manufacturing plants
around the World. HOBAS® Rohre GmbH is a part of The Wietersdorfer Group who plays a
large role in the commercial and industrial sectors of Europe.
Global Pipe Australia imports HOBAS® CC-GRP jacking pipes with nominal pipe diameters
ranging from OD 272 to OD 3600. HOBAS® CC-GRP jacking pipes are manufactured with
jacking loads ranging from 204 kN (approx. 20T) to a maximum of 20,462 kN. (approx.
2045T)
HOBAS® CC-GRP jacking pipes are manufactured with a nominal pressure class ranging
from PN 1 to 16 and stiffness rating ranging from SN 32,000 to SN 1,000,000.
Note: HOBAS CC-GRP pipes marked PN 1 are designated for non-pressure applications. For the purposes of
this appraisal CC-GRP pipes are manufactured with nominal pressure rating of PN 1 to PN 16 and are typically
used in pressure and non-pressure applications. It should be noted that although the ISO 25780 standard
requires a minimum stiffness of SN 20,000 for a jacking pipe, the min. stiffness that HOBAS recommends and
manufactures a jacking pipe, is SN 32,000.
GRP fittings used with HOBAS® CC-GRP jacking pipe are fabricated from sections of straight
pipe, cut to length, joint wrapped externally and internally with additional fibre reinforcement
in accordance with ISO 10467 for sewerage system. GRP fittings are supplied with spigot
ends suitable for connection to the HOBAS CC-GRP jacking pipe stainless steel or GRP
couplings.
The HOBAS® CC-GRP jacking pipe system is manufactured to comply with ISO 25780 –
Plastic piping systems for pressure and non-pressure, water supply, irrigation, drainage or
sewer - Glass-reinforced thermosetting plastics (GRP) systems based on unsaturated
polyester (UP) resin – Pipe with flexible joints intended to be installed using jacking
techniques.
The TÜV SÜD Confirmation Certificate confirms the manufacturing capability of HOBAS
Pipes to produce HOBAS® CC-GRP jacking pipes with flexible joints intended to be installed
using jacking techniques according to ISO 25780 and it also satisfies the more extensive
requirements pursuant to MUC-KSP-A 2000.
The declared external and internal diameters of the HOBAS® CC-GRP jacking pipe are
provided in Global Pipe Australia’s HOBAS Technical Product Data – Gravity Pipe Systems
and Pressure Pipe Systems.
This appraisal submission is in three parts and this report focuses on Part 3 only:
PA 1014 Part 1
HOBAS® CC GRP centrifugal cast pipes and fittings manufactured in
accordance with ISO 10467 – Plastic piping systems for pressure and
non-pressure drainage and sewerage - Glass-reinforced thermosetting
plastics (GRP) systems based on unsaturated polyester (UP) resin.
COPYRIGHT
7
PA 1014 Part 2
HOBAS® CC GRP centrifugal cast pipes and fittings manufactured in
accordance with ISO 10639 – Plastic piping systems for pressure and
non-pressure water supply - Glass-reinforced thermosetting plastics
(GRP) systems based onunsaturated polyester (UP) resin.
PA 1014 Part 3
(This part) HOBAS® CC-GRP jacking pipes and fittings manufactured in
accordance with ISO 25780:2011 Plastics piping systems for pressure
and non-pressure water supply, irrigation, drainage or sewerage -- Glassreinforced thermosetting plastics (GRP) systems based on unsaturated
polyester (UP) resin -- Pipes with flexible joints intended to be installed
using jacking techniques.
1.1 Recommendation
It is recommended that WSAA members and associates, subject to any specific requirements
of the member or associate, accept or authorise the HOBAS® CC GRP jacking pipes and
couplings as detailed in this report for use in non-pressure sewerage applications subject to
the design, installation and commissioning in accordance with specifications provided by
being HOBAS Rohre GmbH and relevant WSAA Sewerage Code or WSAA Members or
Associated Members integrated WSAA Code editions.
2
THE APPLICANT
Global Pipe Australia was established in 2007 and has since become a major supplier of pipe
products to infrastructure projects throughout Australia. Global Pipe’s focus has been to
import and distribute premium quality products from the World’s best manufacturers to
companies throughout Australasia. With a focus on technical support, the Global Pipe team
has supplied pipe to some of Australia’s most technically demanding projects.
Global Pipe Australia Pty Ltd has been appointed the agent and distributor for a wide range
of HOBAS ® CC GRP pipes and fittings, for water supply, recycled water and sewerage
applications for Australia and New Zealand.
With a focus on internationally and domestically accepted standards, state of the art
manufacturing and on-time delivery, Global Pipe is becoming Australia’s supplier of choice
for projects with significant requirements of glass-fibre-reinforced plastics pipe system.
HOBAS® products have been installed in Australia by a variety of methods such as open
trench, jacking, microtunneling, sliplining and above ground.
As the exclusive Australian supplier of the World’s biggest brands and producers of
®
composite pipe; HOBAS Pipe Systems, Austria; Global Pipe is proud to have Australia’s
most comprehensive portfolio of glass-fibre-reinforced plastics pipe system.
2.1 The Manufacturer
HOBAS® is a part of the Wietersdorfer Group and produces GRP pipe systems with state of
the art production technologies and markets them for pressure and non-pressure applications
like water supply, sewer, drainage, hydropower and etc. With the services and support it
offers; from dimensioning and routing pipelines through calculations to consultancy on site,
HOBAS® products have been installed by a variety of methods such as open trench, jacking,
micro tunnelling, slip lining and above ground in more than 50 countries and for over 50
years. Totalling thousands of kilometres of pipe, the line would span the Globe several times.
HOBAS® is a major manufacturer and exporter of pressure and non-pressure pipes and their
associated accessories. HOBAS® currently manufactures glass-fibre-reinforced plastics pipes
in accordance with a variety of International Standards. Their modern factories are equipped
with the latest process control equipment which allows them to produce a range of pipes to
exacting standards and makes them one of the major players in the pipe production industry
across the world.
COPYRIGHT
8
The HOBAS® Pipe company has been operating for over 50 years, has 15 manufacturing
plants worldwide and is operating in more than 50 countries.
HOBAS® attaches great importance to ensuring that continuous improvement of
environmental protection measures is a major part of their corporate social responsibility.
The whole lifecycle of their pipe systems and strong commitment to conservation can be
seen throughout the entire product life cycle.
HOBAS® CC-GRP pipe systems are currently the only pipes that can be offered “Carbon
Neutral” in Australia. (Please refer the Certificate from CRI, Appendix G)
3
THE PRODUCT
3.1 General
HOBAS® CC-GRP pipe is a flexible, structurally strong, centrifugally cast composite pipe that
is designed to be used in buried and above ground applications for the transport of drinking
water, sewage, sea water, storm water and aggressive chemicals under both pressure and
gravity flow conditions. The pipes and fittings are manufactured under strict quality standards
and are distinguished by their high strength, chemical and corrosion resistance and relatively
low weight.
The “HOBAS® Technical Product Data – Gravity Pipe Systems” provides a more complete
description of the range of pipe and fittings available (Refer to Appendix A).
3.2 Manufacture of the HOBAS® CC-GRP jacking pipes
HOBAS® can design CC-GRP Jacking pipes to meet the different needs of many nonpressure applications (pressure applications omitted from appraisal scope) by varying the
resin, sand and glass proportions, orientation and configuration.
3.2.1 Manufacturing process
HOBAS® CC-GRP is a special compound made of unsaturated polyester resins (UP),
chopped glass and mineral reinforcing agents. These raw materials are progressively fed into
a rotating mould, thus building up the wall structure from its exterior surface.
Raw materials undergo stringent quality inspection and laboratory testing before being
approved for use. They are then stored in special tanks to ensure that sufficient quantities
are available at all times.
Computer-controlled pumps and high-precision metering systems guarantee that the right
amounts of raw materials for the relevant product go to the HOBAS ® Feeder. A 100% control
of production process is assured. Fiberglass Roving stored on spools is chopped to the
required length and added. The feeder then deposits the predefined quantities of raw
materials layer by layer with each pass of the feeder arm in the six-meter-long rotating
mould.
Centrifugal casting is important for the quality of HOBAS® Pipes. The preset mould speed
with centrifugal acceleration of up to 70 g causes the layers to be bonded into a compact,
void free fibre composite. The high compression of the wall layers caused by centrifugal
forces also removes all air bubbles from the wall of the pipe which makes CC-GRP pipe more
resistant to delimitation than manufacturing by filament winding.
Spraying hot water onto the outside of the mould accelerates the polymerization process.
Resin solidification is irreversible as a result of the three-dimensional chemical bonding. GRP
is thus a thermosetting plastic which retains its dimensional stability in any environment.
Cold water is used to cool the mould and after the pipe is removed, finishing includes
trimming and bevelling the pipe ends. Finally a coupling is mounted onto one end of each
pipe.
COPYRIGHT
9
The HOBAS® Group plants only use approved raw materials from qualified suppliers which
meet detailed specified requirements.
The product standards for pipes – ISO 10639, ISO 10467, EN 1796 and EN 14364 – state
the requirements for GRP (glass reinforced unsaturated polyester resins), irrespective of the
manufacturing process used (e.g. centrifugal casting or filament winding). However, to define
the product properties in more detail, a special quality specification for centrifugally cast GRP
pipes was subsequently introduced which is the MUC-KSP-A2000 by TUV. The requirements
in this quality specification do not contradict the minimum ones given in the latest versions of
the ISO and EN pipe system standards but define requirements over and above them for
ensuring a higher level of quality.
The specification for MUC-KSP-A2000 standard can be downloaded from the WSAA
Members only portal using link provided in Appendix A.
3.2.2 Joints
Ref: Clause 7.5 of ISO 25780:2011
HOBAS have three types of joints available for HOBAS® CC-GRP jacking pipes, each with a
coupling mounted onto one end of the pipe and an elastomer which seals the pipe. Global
Pipe Engineer will provide instructions/recommendations for the selection of the 3 available
types of joints (Stainless Steel, GRP and Filament Wound) for the pipe sizes and project
specifics for Jacking pipes.
Refer to Section 3.7 (Joint properties), 3.8 (Allowable angular deflections) and 6.2.5 (Type
tests) for additional information on couplings.
The scope of this appraisal covers HOBAS couplings with Stainless Steel, GRP and Filament
wound GRP sleeves.
3.2.2.1 Filament Wound GRP coupling (Non-jacking application)
Ref: Clause 4.2.6 of ISO 10467:2004
The standard pipe jointing system (non-jacking application) is the HOBAS double socketed
coupling. The couplings comprise a full face EPDM rubber membrane encased in a GRP
collar.
Plain ended GRP pipes are joined with a sleeve coupling, factory fitted to one pipe end.
Deflections permitted at joints vary in accordance with Table 2 in draft WSAA Product
Appraisal Report No 1014 Part 2 (currently being appraised).
EPDM rubber rings are supplied pre-moulded to HOBAS specifications, and are in
accordance with the requirements of BS EN 681.1. Refer to Section 6.2.13 for elastomeric
seals.
3.2.2.2 Stainless Steel Coupling for Jacking Pipes
These HOBAS couplings have a stainless steel sleeve with an EPDM seal firmly attached
and are used for trenchless installations only.
Refer to HOBAS CC-GRP Jacking Pipe Brochure, Appendix A for a diagram of the Stainless
Steel Coupling.
3.2.2.3 GRP Coupling for Jacking Pipes
These HOBAS couplings have a GRP sleeve with an EPDM ring and are used for trenchless
installations only.
Refer to HOBAS CC-GRP Jacking Pipe Brochure, Appendix A for a diagram of the GRP
Coupling.
COPYRIGHT
10
3.2.2.4 Filament Wound Couplings for Jacking Pipes
HOBAS offer couplings with a glass fibre reinforced plastic sleeve that is flush fitted and used
for trenchless installations where the pipeline is under pressure.
Refer to HOBAS CC-GRP Jacking Pipe Brochure, Appendix A.
3.2.3 HOBAS CC-GRP Jacking Pipe Composition
HOBAS can select the jacking pipe constituents-including ECR, E or a mixture of ECR/E
glass fiber, resin or reinforcement fillers to meet the user or specifier needs confirmed by
Global Pipe. The glass fibers, resin, fillers etc are sourced from approved suppliers across
Europe are checked for specific quality parameters in the HOBAS QC laboratory prior to use
in the pipe manufacturing.
For further information regarding the jacking pipe constituents please refer the TÜV Quality
specification for centrifugally casted - GRP Pipe Systems MUC-KSP- A 2000, in Appendix A.
3.2.3.1 Reinforcement
HOBAS use any combination of glass material (Full ECR, full E or mixture of E & ECR glass)
in production in accordance with the customer request and application area. Global Pipe
Australia provides the necessary information to HOBAS so that they are able to determine if
their standard glass mix is satisfactory or if it needs to be modified to meet the application.
HOBAS are able to meet any request for pipes to be manufactured with either ECR, E or
mixed.
The glass used in the manufacture of pipes for water and sewer industry is type E or ECR
glass. The glass is supplied by approved suppliers of HOBAS ® and must conform to
international standards for the manufacture of fibreglass. Depending on the application, fluid
handled, the appropriate glass can be used.
Standard roving tests are performed on every batch delivered (tex no., roving stiffness,
moisture content, size content, etc.) to check the quality and uniformity of an approved glass
fibre.
3.2.3.2 Resin
The HOBAS® pipes are manufactured using orthophthalic polyester resin supplied by
approved suppliers. All resin orders are required to meet detailed specific quality
requirements specified by HOBAS® and samples of all batches are checked in the QC
laboratory on delivery. Different resins are purchased as required for specialized
applications.
3.2.3.3Aggregate and Fillers
Silica sand is used as filler in the HOBAS® CC-GRP pipes. The sand is required to meet
specified grading and quality requirements. All the sand samples are checked in the quality
lab before unloading in the silos.
3.2.4 Elastomers - Type test
The HOBAS pipe coupling for jacking applications comprises a full-face EPDM rubber
membrane encased in a Stainless Steel 316 collar or rubber rings inside the GRP sleeve.
HOBAS requires the elastomeric joint sealing materials meet the requirements of EN
681:1996 (equivalent to AS681.1:2008).
COPYRIGHT
11
3.3 Nominal Sizes
HOBAS® CC-GRP jacking pipe is manufactured for the Australian market to ISO 25780, in
nominal sizes ranging from OD272 (DN 250) to (OD3600) DN 3600.
The declared external diameters are closely aligned with ISO 10467/10639 Table 6 Series B2
up to DN 500 and with Table 5 Series B1 for DN 600 to DN 2400 jacking pipe. For application
in Australia, these align closely with the external diameters required by AS3571 Appendix ZZ
Table 5 (Series B1, B2, B3 and B4) for DN400 and DN900 to DN2400 jacking pipe. DN 500
to 800 HOBAS jacking pipe connections with AS3571 Appendix ZZ Table 5 GRP and other
DN 500 to 800 pipes, may require the use of non-standard tapered or stepped adaptor fittings
HOBAS declared external and internal pipe diameters are specified in the Global Pipe
Australia’s HOBAS GRP Technical Product data for Gravity Pipe Systems. Refer to
Appendix C.
3.4 Jacking Load and Nominal Stiffness
Ref: Clause 4.2.2 and 4.2.3 of ISO 25780:2011
HOBAS® CC-GRP jacking pipes can be supplied in the following jacking loads and stiffness
classes.
TABLE 1 JACKING LOAD (KN/TONNES) AND NOMINAL STIFFNESS (SN)
Jacking Load (kN/Tonnes)
Nominal Stiffness (N/m²)
From 200kN (~20T) to 20000kN (~2000T >SN 20,000
The nominal stiffness in Table 1 above, correspond to the min. nominal stiffness values
specified in Clause 4.2.3 of ISO 25780.
Based on years of experience in supplying GRP Jacking pipes across the world, the
minimum stiffness recommended by HOBAS® for GRP jacking pipes is SN 32,000 with a
safety factor of 3.5; although the international standard ISO 25780 requires a minimum
stiffness of SN 20,000 for jacking applications. This is to account for any unexpected ground
conditions, point loads etc encountered in the real world.
3.5 Nominal Pressure
The HOBAS® CC-GRP jacking pipe intended for use in non-pressure and pressure sewerage
applications can be supplied with a nominal pressure rating ranging from PN1 to PN16, which
relates to components pressure rating in bars. A pressure Jacking pipe can be used as a
pressure pipe for trenchless installations.
3.6 Nominal Pipe lengths
Ref: Clause 5.1.3 of ISO 25780: 2011
HOBAS moulds are capable of producing HOBAS® CC-GRP jacking pipe lengths up to 6 m.
The HOBAS® CC-GRP jacking pipe can be supplied in 1m, 2m, 3m or 6m lengths.
Intermediate pipe lengths are available upon request.
The total length of each pipe is equal to the specified nominal length with a tolerance of ±25
mm.
3.7 HOBAS® Joint Properties (couplings)
Ref: Clause 4.7.2 of ISO 25780: 2011
The standard jacking pipe jointing system is the HOBAS double socketed coupling. The
couplings comprise a full face EPDM rubber membrane encased in a stainless steel collar,
COPYRIGHT
12
GRP sleeve or Filament wound coupling for Pressure Jacking pipes. Rebated spigots are
used to accommodate flush couplings.
Plain ended GRP pipes are joined with a sleeve coupling, factory fitted to one pipe end.
Deflections permitted at joints vary in accordance with Table 2 in Section 3.8.
Refer to Section 3.2.5 for elastomeric seals.
3.8 Allowable Angular Deflection
Ref: Clause 4.7.3.1 of ISO 25780: 2011
In accordance with ISO 25780, HOBAS has declared:
(a) the maximum allowable deflection between adjacent pipes in the installed condition.
(b) the maximum allowable deflection at which each joint is designed to operate when
subjected to either internal or external pressure and the
(c) the maximum angular deflection permitted during pipe jacking operations
(d) For parts (a) and (b), the above values are not less than the values required by ISO
25780, Table 2 for sizes < DN1000 and as calculated for sizes >DN1000.
Table 2 below specifies the maximum allowable angular deflection, at which each joint is
designed to operate when subjected to either internal or external pressure, including the
maximum allowable angular deflection permitted during pipe jacking operations.
TABLE 2 MAXIMUM ALLOWABLE INSTALLED DEFLECTION FOR PIPE JOINTS
External Diamete Maximum allowable
installed deflection
dOD
a
mm
mm/m
Maximum allowable
200<dOD ≤500
15
200<dOD ≤500
degrees
𝜹
Maximum allowable
Maximum allowable
a
mm/m
degrees
0.8594
15
0.8594
10
0.5729
10
0.5729
1000=dOD
a=10 x 1000/d OD
Derive from value a
9
0.5156
1200=dOD
a=10 x 1000/d OD
Derive from value a
8
0.4583
1400=dOD
a=10 x 1000/d OD
Derive from value a
7
0.4010
𝜹
3.9 Straightness
Ref: Clause 5.1.5 of ISO 25780: 2011
The maximum permissible deviation from straightness of a surface line shall not exceed the
values given in Table 3 in ISO 25780, based on a 6m length. HOBAS conforms to the
requirements of Table 3 in ISO 25780.
3.10 Pipe Fittings and Accessories
The Global Pipe Australia’s HOBAS GRP Technical Product Data Gravity Pipe Systems
provide a more complete description of the range of products covered by this appraisal.
3.11 Flanges
Flanges for the Australian market are manufactured to be compatible with sizes according to
AS 4087, Figure B5 for Class PN 16 flanges.
Ancillary products such as jointing lubricant are also available from Global Pipe Australia on
request.
COPYRIGHT
4
13
SCOPE OF THE APPRAISAL
The scope of this product appraisal applies to the HOBAS® CC-GRP jacking pipe and
specified in Section 3, for non-pressure sewerage using various trenchless installation
methods such as Slip Lining, Micro Tunnelling and Pipe Jacking. Refer to Global Pipe
Australia’s Schedule of imported certified products attached to Appendix ‘C’.
5
APPRAISAL CRITERIA
5.1 General
Appraisal criteria is determined by the WSAA Infrastructure Products and Materials (IPAM)
Network and regularly reviewed to ensure that the criteria reflect the requirements of WSAA
members.
5.2 Quality Assurance Requirements
The WSAA product appraisal network accepts GRP pipes and fittings manufactured under
cover of a third party certified management system complying with AS/NZS ISO 9001 and
having ISO Type 5 product certification in accordance with ISO 25780 by a JAS-ANZ
accredited Certification Assessment Body (CAB) or by a CAB accredited by international
accreditation system recognised by JAS-ANZ.
5.3 Performance Requirements
HOBAS GRP jacking pipe and fittings have been appraised for compliance with the
requirements of ISO 25780 – Plastic piping systems for pressure and non-pressure drainage
and sewerage - Glass-reinforced thermosetting plastics (GRP) systems based on
unsaturated polyester (UP) resin Pipes with flexible joints intended to be installed using
jacking techniques.
The following Product Specifications are also relevant to this application:
WSA PS – 205J Centrifugally Cast Glass Reinforced Plastic (CC-GRP) Pipes and Fittings
(ISO Sized) for Pressure and Non-Pressure Applications - Sewerage
A copy of the above Product Specification can be found in Appendix D or downloaded from
the WSAA website.
6
COMPLIANCE WITH APPRAISAL CRITERIA
6.1 Compliance with Quality Assurance Requirements
The HOBAS ® Group Plants have quality management systems designed to satisfy the
requirements of the ISO 9001:2008 standard. Each pipe manufactured by the computer
controlled production process is marked with a unique number that permits complete
traceability of the product with respect to the origin, quality and quantity of raw materials, the
manufacturing conditions and batch conformance test results. Even before the pipe is
produced, the quality approved raw materials are tested in the laboratory in order to ensure
that they meet the strict internal standards.
HOBAS Rohre GmbH plant in Germany is a Quality Endorsed Company and holds an ISO
9001:2008 Certificate of Registration No. 12 100 7194 TMS issued by TÜV SÜD
Management Service GmbH for development, production and sale of pipeline systems for
sewers, drinking water and industry lines, shafts and buildings produced of glass fibre
reinforced synthetic materials in the centrifugal casting process.
TÜV SÜD Management Service GmbH is a CAB accredited by a member of the International
Accreditation Forum (IAF) Multilateral Recognition Agreement (MLA) recognised by JASNZS, which is also a signatory IAF MLA.
TUV SUD Industrie Service GmbH has also confirmed that HOBAS® produces CC-GRP
pipes, pipe connectors and fittings (DN150 to DN3600; PN1 to PN32; SN500 to SN10000)
that meet the requirements according to ISO 10467.
COPYRIGHT
14
6.2 Compliance with Performance Requirements
The HOBAS® CC-GRP jacking pipe system is manufactured to comply with ISO 25780 –
Plastic piping systems for pressure and non-pressure, water supply, irrigation, drainage or
sewer - Glass-reinforced thermosetting plastics (GRP) systems based on unsaturated
polyester (UP) resin – Pipe with flexible joints intended to be installed using jacking
techniques.
The TÜV SÜD Confirmation Certificates (No’s 13 02 90258 001-1 and 13 02 90253 003-1),
issued to following HOBAS Rohre manufacturing plants confirms the manufacturing capability
of HOBAS Rohre GmbH to produce HOBAS® CC-GRP jacking pipes with flexible joints
intended to be installed using jacking techniques according to ISO 25780 and it also satisfies
the more extensive requirements pursuant to MUC-KSP-A 2000.
(a)
Wietersdorf 1 9373 Klein St. Paul Austria and
(b)
Gewerbepark 1 Hellfeld 17034 Neubrandenburg Germany,
TUV SUD Industrie Service GmbH, Institute for Plastics was commissioned by HOBAS®
Engineering GmbH to witness the qualification tests of HOBAS® CC-GRP pipe systems
according to the international product standards ISO 10467, ISO 10639 and ISO 25780. For
auditing/witnessing the above mentioned GRP pipe system, TUV SUD was on-site on three
different appointments at the HOBAS Rohre GmbH factory. TUV SUD performed third party
tests based on the product standard ISO 10467, ISO 10639 and ISO 25780 on randomly
chosen pipe samples.
All tests were carried out at HOBAS® Tech Centre, which is certified on the basis of ISO
17025 in conjunction with so called “VdTUV Leitfaden fur Unterauftragnehmer” (“VdTUV
Guide for Subcontractors”) by TUV SUD, Institute for Plastics.
The HOBAS® Tech Center in Wietersdorf, Austria is an independent and officially accredited
testing laboratory. The official Confirmation of Accreditation was issued by the Austrian
Federal Ministry of Economy in accordance with ISO/IEC 17025 – General requirements for
the competence of testing and calibration laboratories.
Austrian Federal Ministry of Economy is a signatory to the International Laboratory
Accreditation Co-operation (ILAC) with mutual recognition arrangements (MRA) within the
Asia Pacific Laboratory Accreditation Cooperation (APLAC).
WSAA accepts the results from testing and calibration laboratories that are accredited by
accreditation bodies that are signatories to the ILAC Arrangement.
Copies of the Certificates can be found in Appendix B.
Global Pipe Australia Pty Ltd has provided a copy of the report for the same named
“Summary of qualification tests of HOBAS® CC-GRP Pipe System according to international
product standards ISO 10467, ISO 10639 and ISO 25780 for GRP Pipe Systems” (Order no.:
600009627).
Summary of the qualification tests of HOBAS® CC-GRP Pipe System according to
international product standards ISO 10639, ISO 10467 and ISO 25780 for GRP Pipe systems
has been submitted to WSAA and can be reviewed by contacting the Product Appraisal
Manager.
All the HOBAS® CC-GRP pipes are manufactured for a design pressure of 4 times the rated
pressure so that even after 50 years of service life it can have a safety factor of 2.
6.2.2 Mechanical Characteristics
The HOBAS® Group Plants only use approved raw materials from qualified suppliers which
meet the detailed specified requirements. Each type of raw material has to pass process,
compound and service relevant requirements set up in the central research department.
COPYRIGHT
15
All pipes are subjected to a range of quality control checks including the following:
6.2.2.1 Initial specific ring stiffness - Batch release test
Ref: Clause 5.2.1 of ISO 25780: 2011
The HOBAS® pipe design program provides for an initial ring stiffness value higher than the
minimum stiffness values specified in the relevant ISO standard. Initial stiffness testing is
part of the daily quality control program. First pipe piece for every new project is checked for
stiffness before commencing production.
The initial specific ring stiffness is determined using a special test method, as it cannot be
accurately obtained by calculation using the nominal values for elastic modulus (E) and wall
thickness (e).
Please refer HOBAS® CC-GRP Pipes Features, Tests and Benefits brochure, Chapter 2.
HOBAS provided batch release test results for a typical initial ring stiffness test performed on
test specimens cut from a section DN2000, PN1, SN32000 and DN2000, PN6, SN40000
pipe. For the SN 32000 N/m2, the initial specific ring stiffness, the average of the test results
was 35706 N/m2 and for the PN6, SN40000 N/m2 it was 53787 N/m2 .The values are way
higher than the required SN values, so the results were satisfactory. The batch release test
results detailed in “Summary of qualification tests of HOBAS CC-GRP Pipe System according
to international product standards ISO 10639, ISO 10467 and ISO 25780 for GRP Pipe
Systems” confirms the testing system used and shows the pipe met the ISO standards
requirement, as specified in ISO 25780. This document has been submitted to WSAA and
can be reviewed by contacting the Product Appraisal Manager.
6.2.2.2 Long-term specific Creep Stiffness - Type test
The long-term specific ring stiffness of HOBAS® CC-GRP pipe is checked using the long-term
creep stiffness method in accordance with ISO 10467:2004 and ISO 10639:2004 by HOBAS®
Engineering GmbH. The documentation for the ongoing long-term tests, initial type tests and
raw material assessments were checked during the audits by TUV SUD.
The long-term ring stiffness tests were performed on various CC-GRP-UP pipes DN 200 –
DN 1400 PN 1 – PN 16 SN 5000 – SN 40000 by independent certification bodies (TÜV, Det
Norske Veritas, Austrian Polymer Institute). Compliance of the long-term ring stiffness with
the requirements was assessed and confirmed according to the most relevant national and
international standards: EN 1796, EN 14364, ISO 10467, ISO 10639, DIN 19565, DIN 16869,
BS 5480, ASTM D3262, ASTM D3517, ASTM D3754, AS 3571, AS 3572.
The creep factors for HOBAS® CC-GRP Pipes resulting from the time-dependent, reversible,
visco-elastic material behaviour were determined and reported. Comparisons between
laboratory tests according to EN 1225 and ISO 10468 and pipes tested after several years in
operation indicate significantly lower creep for buried pipes. Using creep factors for static
calculations determined in the laboratory therefore ensure additional safety, as the decrease
in the specific ring stiffness of the pipe when properly buried is considerably lower than
predicted by the creep test.
Please refer HOBAS® CC-GRP Pipes Features, Tests and Benefits brochure Chapter 2, for
further details.
6.2.2.3 Initial resistance to failure in a deflected condition - Batch release test
The test procedure used is based on ISO 10466 as nominated in ISO 10467. The QC testing
involves deflecting the samples as shown in the Table 3 below and conducting a visual
inspection for cracks, de-lamination, buckling or failure.
COPYRIGHT
16
TABLE 3 INITIAL RESISTANCE TO FAILURE
Stiffness Class (SN)
Initial ultimate ring deflection (%)
Measured mean value
DN2000, PN1, SN32,000
7.6
Required
>6
Testing of pipes on a regular basis has shown that pipes produced in the HOBAS factory
meet the initial resistance to failure requirements of the ISO product standards. Where a pipe
fails to comply with this requirement, it is rejected, the cause of failure is identified and
production processes reviewed to prevent recurrence.
6.2.3 Resistance of pressure pipes internal pressure - Type test
Ref: Clause 5.7 of ISO 25780:2011 - (Specifies ISO 15306 test procedure within ISO 10467 and ISO 10639)
The resistance of HOBAS pipes to cyclic internal pressure up to 1 million pressure cycles has
been verified through ongoing testing. The requirements of ISO 10639 and ISO 10467 are
fulfilled.
• Subjecting HOBAS® CC-GRP pipes to 1 million cyclic pressure variations between
(0.75 x PN) and (1.25 x PN) and even 0.75 times (1.5 x PN) and 1.25 times (1.5 x
PN) did not lead to leakage or any signs of failure.
The DN 200 and DN 400 PN 10 as well as the DN 300 PN 16 pipe types show a residual
pressure safety of more than 4 after 1 million cycles between (0.75 x PN) and (1.25 x PN). A
safety factor of 3 was even measured after 1 million cycles between 0.75 times (1.5 x PN)
and 1.25 times (1.5 x PN).
Please refer HOBAS® CC-GRP Pipes Features, Tests and Benefits brochure, Chapter 5 for
details.
6.2.4 Resistance to strain corrosion - Type test
Ref: Clause 5.3 of ISO 25780:2011 - Specifies ISO 10467 test procedure
The test procedure follows the above mentioned standard. The results are used to calculate
the ultimate ring deflection and flexural strain under combined mechanical and chemical
attack.
A series of strain corrosion tests with acidic and alkaline chemicals was conducted on pipes
of different types and manufactured at various production plants to establish the long-term
®
(50, 60, and 100 years) resistance of HOBAS CC-GRP Pipe Systems to acid strain
corrosion.
The results of the various strain corrosion test series are presented in Fig. 36 in HOBAS®
CC-GRP Features, Tests and Benefits brochure. The long-term regressions were calculated
according to method A in EN 705 and ISO 10928 including failure points of all pipes and led
to the following long-term flexural strain at break (Table 14 in HOBAS® CC-GRP Pipes
Features, Tests and Benefits brochure).
The requirements of product standards ISO 10467, EN 14364 and ASTM D3262 are fulfilled
for acidic and alkaline environments.
After more than 12 years of strain corrosion testing, HOBAS® CC-GRP Pipe Systems,
including the standard joint (see also couplings chapter) prove their superior behaviour under
combined mechanical loading and chemical attack. The highly advanced design of the
HOBAS® CC-GRP Pipe System leads to significant advantages compared to other products.
The results of the various strain corrosion test series are presented in HOBAS® CC-GRP
Pipes Features, Tests and Benefits brochure, Chapter 8.
COPYRIGHT
17
The test results show HOBAS pipe complies with the minimum requirement shown in ISO
10467 Table 17:
TABLE 4 INITIAL RESISTANCE TO FAILURE
Stiffness
Calculated deflection %
SN 40000
SN32000
7.05 %
7.6 %
5.11 %
6%
Allowable
Minimum Deflection,%
6.2.5 Joint performance - Type test
®
Leak tightness and pressure type tests on HOBAS joints/couplings were carried out in the
material development department. These tests were witnessed by TUV Industrie Service
Germany. The test sequences complied with the requirements of following standards: ISO
8639, EN1119 and based on ASTM D4160.
Type tests comply with ISO, EN and ASTM D4161 requirements. The test series under draw,
hydrostatic and cyclic pressure were positive. No leakage could be observed during the test
with angular deflection and misalignment by shear load. The tests with negative pressure
were positive (0.2 bar absolute pressure), no increase in pressure was detected during the
test period.
The HOBAS® FWC joint meets the compliance requirements of EN 691-1, ISO 8639, EN
1119, and DIN 4060, which ensures that they remain sealed even when deflected and
subjected to externally applied lateral loading and/or internal and external hydrostatic
pressure, or a combination of those loads. The high contact pressure of the seal on the pipe
also may also prevent tree root penetration.
Please refer HOBAS® CC-GRP Pipes Features, Tests and Benefits brochure Chapter 7 for
details.
HOBAS CC GRP Jacking pipes are joined using flexible joints with elastomeric seals.
Chapter 7 of the HOBAS® CC-GRP Pipes Features, Tests and Benefits brochure details the
performance testing of the HOBAS couplings. Clauses 7.5.2, 7.5.3, 7.5.4 and 7.5.6 requiring
leak tightness when subjected to an external pressure differential, internal positive pressure,
angular deflection, misalignment and draw under static and positive cyclic pressures. All
tests performed pass and met the requirements of ISO 25780. Refer to Table 5 for results.
COPYRIGHT
18
TABLE 5 SUMMARY OF TEST RESULTS
Summary of test requirements for flexible joints
ISO 25780
clause
7.5.3
7.5.2
7.5.5
7.5.6
7.5.4
7.5.4
Testing Std.
Clause and
Description
Initial leaktightness test
(ISO 8639:2000,
7.2)
External pressure
differential
(ISO 8639:2000,
7.3)
Misalignment and
draw under static
pressure (ISO
8639:2000, 7.5)
Misalignment and
draw under cyclic
pressure (ISO
8639:2000, 7.6)
Angular deflection
and draw
(ISO 8639:2000,
7.4)
Test
Initial positive
pressure
Negative
pressure a
Test Conditions
Duration
1,5 × PN
– 0,8 bar (– 0,08 MPa)
Result
Conforms
15min
No leakage during test sequence
YES
>
YES
1 hour
Positive static
pressure
2,0 × PN
24 hours
YES
Positive cyclic
pressure
Atmospheric to 1,5 × PN
and back to atmospheric
10 cycles of 1.5
to 3min each
YES
Initial pressure
1,5 × PN
15 min
YES
Positive static
pressure
2,0 × PN
24 hours
YES
Relative to atmospheric pressure, i.e. approximately 0,2 bar (0,02 MPa) absolute.
COPYRIGHT
19
6.2.6 Longitudinal compressive strength
Longitudinal compressive test was performed to determine the longitudinal compressive
stress at break for sample DN350 HOBAS CC-GRP jacking pipe. For the DN350 HOBAS CCGRP jacking pipe sample the minimum compressive stress at break is 90 N/mm2. Results
obtained were 145 N/mm2 which is much higher than the minimum, proving the sample fulfils
the requirements of ISO 25780.
6.2.7 Permissible Jacking Forces
Ref: Clause 5.5 ISO 25780:2011
6.2.7.1 General
Permissible jacking forces are calculated to determine the force that can be applied to a pipe
during the jacking operation. Therefore the declared jacking load, ultimate longitudinal load,
the theoretical jacking load (concentric) and the eccentric jacking loads are to be determined.
HOBAS used a DN2000, SN 32000, PN1 Jacking Pipe for these results.
Therefore the theoretical jacking load (Fj) for the jacking pipe sample used was 26,249kN.
Material safety factors (γ) of 1.75 and 3.5 have been used for assessment.
6.2.7.2 Ulitmate Longitudinal Load
The ultimate longitudinal load is the calculated value of the concentric longitudinal load that
the pipe withstands just before it breaks. This calculated value is used to determine the
permissible jacking forces of a jacking pipe.
HOBAS tested a DN2000, SN32000 jacking pipe and calculated its ultimate longitudinal load
to be Fult =26,249 kN.
Therefore the jacking pipe sample tested can withstand a concentric longitudinal load of
26,249kN just before the pipe breaks.
6.2.7.3 Designed Jacking Load and permissible eccentric jacking forces
HOBAS has calculated that the theoretical design jacking load as;
•
Fj,calc = 6549 kN, which gives a Safety Factor of >3.5
HOBAS have calculated the permissible eccentric jacking force on the pipe using the
estimated angular deflection to be;
HOBAS have declared that the permissible eccentric longitudinal force that the system can
withstand during a jacking operation is 6549kN, taking into account the material safety
coefficient (γ 1.75) and the estimated angular deflection.
Permissible jacking forces were calculated using the methods described in Annex C of ISO
25780 using minimum compression stress at break as 90 N/mm²
Fperm = 6549 kN and declared as 6549 kN for sample DN2000, SN32000 Jacking Pipe
6.2.8 Specific initial longitudinal compressive modulus.
Clause 5.6 ISO 25780:2011
HOBAS used a DN2000, SN32000, PN1 Jacking Pipe for these results.
The specific initial longitudinal compressive modulus expressed as Ec,m is the ratio of the
applied stress to the resulting strain below the elastic limit, both measured concurrently
during a short term compression test.
The specific initial longitudinal compressive modulus, Ec,m, is determined by selecting any
point from the performed quality control test data and using strain gauge at the tested
specimens.
COPYRIGHT
20
A test piece taken from the pipe wall is compressed, at a uniform rate of strain in the
direction parallel to the longitudinal axis of the pipe, until failure occurs.
The ratio of the applied stress to the resulting strain below the elastic limit was calculated to
be 113 N/mm2 and is greater than the required 100 N/mm2
6.2.9 Abrasion resistance
Ref: DIN 19565
This appraisal assesses the HOBAS CC-GRP pipe system suitability for sewerage
applications in accordance with ISO 10467. Pipe systems for sewer and pressure sewer
applications can be stressed continuously by mechanical abrasion. In order to determine the
abrasion resistance of HOBAS® CC-GRP Pipe Systems, several Darmstadt rocker tests were
performed. The Darmstadt Rocker test is based on DIN 19565.
TABLE 6 AVERAGE ABRASION OF HOBAS ® CC-GRP PIPES.
No. of Cycles
Abrasion, mm
Abrasion safety factor
100,000
0.31
4.3
200,000
0.49
2.6
500,000
0.9
1.5
®
The test results show that the abrasion resistance requirements for HOBAS CC-GRP
Systems are fulfilled. The minimum abrasion safety factor is 4.3 after 100,000 cycles, which
is considered to be equivalent to an operational lifetime of 50 years according to DIN 19565.
Even after 200,000 and 500,000 cycles, the reinforced structural layers are still entirely
covered by the liner resin.
®
Ref. HOBAS CC-GRP Pipes Features, Tests and Benefits Ch. 9
Note: The abrasion resistance of individual pipeline materials is difficult to determine because test methods do
not duplicate the varied abrasion conditions found in sewers. Comparative Darmstadt rocker test results often
show performance ratings of plastic pipe materials exceed other harder pipe materials.
6.2.10 Temperature and pressure re-rating
This appraisal assesses the temperature and pressure de-rating of HOBAS® CC-GRP pipe
systems in accordance with ISO 10467. Temperature and pressure re-rating requirements
vary according to the pipeline application and HOBAS ® can provide special resins and rerating for abnormal applications. In general, pipelines carrying liquids up to 35°C and below
require no pressure re-rating, but for temperatures above 35°C it is recommended that the
design be checked by a HOBAS® Application engineer.
6.2.11 Resistance to Ultraviolet degradation
This appraisal assesses the requirement for resistance to ultraviolet degradation of HOBAS
CC-GRP pipe systems, in accordance with ISO 10467. For further information refer to PA
Report 1014 Part 2 (currently being appraised).
6.2.12 Other Technical Data
For additional information refer to Global Pipe Australia’s HOBAS GRP Jacking Pipe
Brochure in Appendix A.
The characteristic short-term material constants for HOBAS® CC-GRP Pipe wall laminates
and summary of important pipe/material parameters for structural design and static
calculations are given in “HOBAS® CC-GRP Features, Tests and Benefits”. These include the
following:
(a) Tensile/compressive strength
COPYRIGHT
(b)
(c)
(d)
(e)
(f)
7
21
Sound celerity
Poisson’s ratio
Thermal conductivity
Ultimate ring deflection
Apparent flexural modulus
FITTING INSTRUCTIONS, TRAINING AND INSTALLATION
The Australasian Society Trenchless Technology has developed Trenchless Guidelines,
Standards and Specifications to assist industry users in Australia and New Zealand in
utilising these technologies. These documents are not intended not replace any existing
relevant manuals or standards. It remains the users responsibility to ensure that all relevant
laws, standards and specifications are adhered to during the course of a Works with use of
these trenchless technologies.
These Guidelines, Standards and Technical specifications are available from the
Australasian Society Trenchless Technology (ASTT) website. (http://astt.com.au).
Comprehensive technical specifications are available from the ASTT (Australian Society for
Trenchless Technology) website. (http://astt.com.au) and www.globalpipe.com.au
8 REPAIR FOR NON-PRESSURE CC GRP JACKING PIPE FOR SEWERAGE
APPLICATIONS
In service repairs can be easily carried out using standard Stainless Steel mechanical repair
couplings.
Pressure pipes must not be repaired. Gravity pipes can be repaired with help of special
laminate kits on site. On site lamination should be done only by trained and experienced
laminators. Stainless steel repair bands can also be used. Please contact Global Pipe for
specific projects. The HOBAS repair procedure document mentions about GRP repair
methods & procedures.
9
PRODUCT MARKING
Ref: Clause 6 in ISO 25780:2011
HOBAS pipes are labelled in accordance details to Clause 6 of ISO 25780: 2011, (similar to
ISO 10467 /10639, AWWA C-950 and BS5480):
All products are branded with a serial number (enabling product traceability even after many
years of service), the nominal diameter, series, pressure and stiffness class as well as
specific quality marks relating to approvals by various associations and third party
certifications (DVGW, SVGW, TUV etc.)
The
(a)
(b)
(c)
(d)
(e)
(f)
(g)
number of this International Standard i.e. ISO 25780
Manufacturers name or identification
Nominal Size (DN/OD)
Stiffness rating, SN
Pressure rating, PN
It also includes:
GP Australia (for Global Pipe)
Individual pipe number
The marking is digitally printed on the pipe as shown in Appendix H.
COPYRIGHT
10
22
PACKAGING AND TRANSPORTATION
Transportation / Shipment is done by trucks, train or ships all around the world by HOBAS®.
For Australia and NZ, Global Pipe will supply the pipes in shipping containers. Storage and
handling instructions are mentioned in the HOBAS® Pipeline Textbook.
Typical packaging arrangements are given in Appendix I.
11
PRODUCT WARRANTY
This product is covered by the normal commercial and legal requirements of the Competition
and Consumer Act 2010, which covers manufacture to relevant standards. Additional
warranties may be negotiated on a project specific basis.
12 WATER AGENCY EXPERIENCE WITH THE PRODUCT OR FIELD TESTING
REPORT
HOBAS® CC-GRP pipes have been used by Australian Water Authorities for more than 25
years. No issues with the pipe quality have been encountered. Global Pipe has supplied
HOBAS® CC-GRP Jacking pipes to all the major water authorities like Melbourne Water,
Yarra Valley Water, South East Water, City West Water, Power and Water (NT), Sydney
Water, Water Corporation of WA, Queensland Urban Utilities etc.
Details of many international GRP Pipe projects have been supplied by Global Pipe. Details
of these projects can be provided upon request.
High-pressure water jetting of sewers and drains is being undertaken in the Australia using
equipment which, under certain circumstances, can damage the internal surface of the pipe.
It is recommended that Operators of high-pressure water jetting equipment comply with
HOBAS guidelines while undertaking water jet cleaning of HOBAS® CC-GRP jacking pipes.
HOBAS has proved its resistance during water jet studies carried out by Department of
Water, Germany. The nozzle impacts did not cause any damage to the pipes.
A report titled “Water jet cleaning” submitted to the Program Manager at WSAA is available
for WSAA members only. Refer to Appendix A for further information.
13
DISCUSSION
Q.1 What fittings and accessories are available to be used with Jacking pipes?
Ans. It is common to have transition fittings which are used to connect to the start and end of
the pipe to be jacked. Transition fittings may have a filament wound coupling and a stainless
steel coupling where one end joins to the jacking pipe and the other to an open trench pipe.
HOBAS Transition pipes can be supplied such that there is no step between the Jacking pipe
ID and the open trench pipe ID and there is a smooth transition.
Rocker pipes/manhole connectors have spigot/spigot connections and a puddle flange
fabricated onto the pipe. The puddle flange position can be fabricated in accordance with the
pipeline design requirements.
All fittings can be supplied with either the Stainless Steel couplings or GRP filament wound
couplings.
Q.2 What safety factors are used for calculating the allowable Jacking loads on the Superlit
CC-GRP Jacking pipes? Why are the safety factors important?
Ans from HOBAS: Safety factors are intended to account for any eccentric or point loading
that may occur during Jacking. HOBAS uses a safety factor of 1.75 for Relining/sliplining
applications due to the fact that these trenchless applications do not require the pipe to take
a major compressive load. Based on over 30 years of experience as the developer of CCGRP jacking pipe, HOBAS has determined that a safety factor of 3.5 is needed. This high
safety factor is very useful to accommodate ‘unanticipated’ deviations in the jacking
alignment which result in eccentric loads and point loads on the jacking pipe. Experience
COPYRIGHT
23
dictates that not all bores will be perfectly straight. This may be due to changes in geology
(hard ground to softer ground), inconsistencies in ground conditions (eg boulders in soft
ground), steering or oversteering of the TBM or planned curves. HOBAS determined very
early in their development of CC-GRP jacking pipe that a safety of 1.75 was not adequate.
14
LIFE EXPECTANCY
Global Pipe had engaged GHD for a Durability assessment of HOBAS® pipe, and it infers that
a HOBAS® CC-GRP pipe will have a design life of 100+ years. Long term testing results have
also been extrapolated to 100+ years design life.
Refer to Appendix A for information on how to access a copy of the GHD Report for HOBAS
Pipe Durability Assessment.
In addition the ISO 7509 tested regression characteristics of GRP (as used by HOBAS to
manufacture CC-GRP jacking pipe) together with the long term safety factors applied to the
probability of failure at 50 years at a lower confidence level of 97.5% suggest that the pipe is
likely to perform successfully beyond a 100 year operating life.
15
REPORT RECOMMENDATION
It is recommended that WSAA members and associates, subject to any specific requirements
of the member or associate, accept or authorise the HOBAS® CC GRP jacking pipes and
couplings as detailed in this report for use in non-pressure sewerage applications subject to
the design, installation and commissioning in accordance with specifications provided by pipe
manufacturer and relevant WSAA Sewerage Code or WSAA Members or Associated
Members integrated WSAA Code editions.
COPYRIGHT
16
24
DISCLAIMER
This Product Appraisal Report (Report) is issued by the Water Services Association of
Australia Limited on the understanding that:
This Report applies to the product(s) as submitted. Any changes to the product(s) either
minor or major shall void this Report.
To maintain the recommendations of this Report any such changes shall be detailed and
notified to the Product Appraisal Manager for consideration and review of the Report and
appropriate action. Appraisals and their recommendations will be the subject of continuous
review dependent upon the satisfactory performance of products.
WSAA reserves the right to undertake random audits of product manufacture and installation.
Where products fail to maintain appraised performance requirements the appraisal and its
recommendations may be modified and reissued. Appraisal reports will be reviewed and
reissued at regular intervals not exceeding five (5) years.
The following information explains a number of very important limits on your ability to rely on
the information in this Report. Please read it carefully and take it into account when
considering the contents of this Report.
Any enquiries regarding this report should be directed to the Program Manager, Carl
Radford, Phone: 08605 7601 email [email protected].
16.1 Issue of Report
This Report has been published and/or prepared by the Water Services Association of
Australia Limited and nominated Project Manager and peer group of technical specialists (the
Publishers).
The Report has been prepared for use within Australia only by technical specialists that have
expertise in the function of products such as those appraised in the Report (the Recipients).
By accepting this Report, the Recipient acknowledges and represents to the Publisher(s) and
each person involved in the preparation of the Report that the Recipient has understood and
accepted the terms of this Disclaimer.
16.2 Limits on Reliance on Information and Recommendations
16.2.1 Disclaimer of liability
Neither the Publisher(s) nor any person involved in the preparation of the Report accept(s)
any liability for any loss or damage suffered by any person however caused (including
negligence or the omission by any person to do anything) relating in any way to the Report or
the product appraisal criteria underlying it. This includes (without limitation) any liability for
any recommendation or information in the Report or any errors or omissions.
16.2.2 Need for independent assessment
The information and any recommendation contained (expressly or by implication) in this
Report are provided in good faith. However, you should treat the information as indicative
only. You should not rely on that information or any such recommendation except to the
extent that you reach an agreement to the contrary with the Publisher(s).
This Report does not contain all information that a person might require for the purposes of
assessing any product discussed or appraised within it (Product). The product appraisal
criteria used in preparing this Report may not address all relevant aspects of the Product.
Recipients should seek independent evidence of any matter which is material to their
decisions in connection with an assessment of the Product and consult their own advisers for
any technical information required. Any decision to use the Product should take into account
the reliability of that independent evidence obtained by the Recipient regarding the Product.
COPYRIGHT
25
Recipients should also independently verify and assess the appropriateness of any
recommendation in the Report, especially given that any recommendation will not take into
account a Recipient’s particular needs or circumstances.
WSAA has not evaluated the extent of the product liability and professional indemnify
insurance that the provider of the product maintains. Recipients should ensure that they
evaluate the allocation of liability for product defects and any professional advice obtained in
relation to the product or its specification including the requirements for product liability and
professional indemnity insurance.
16.3 No Updating
Neither the Publisher(s) nor any person involved in the preparation of this Report [has] [have]
any obligation to notify you of any change in the information contained in this Report or of
any new information concerning the Publisher(s) or the Product or any other matter.
16.4 No Warranty
The Publisher(s) do[es] not, in any way, warrant that steps have been taken to verify or audit
the accuracy or completeness of the information in this Report, or the accuracy,
completeness or reasonableness of any recommendation in this Report.
COPYRIGHT
26
APPENDIX A – TECHNICAL MANUALS BROCHURES / REPORTS
AVAILABLE FROM GLOBAL PIPE AUSTRALIA PTY LTD OR THE GLOBAL PIPE
WEBSITE
Technical Manuals Brochures Manuals Documents Referenced
HOBAS® CC-GRP Jacking Pipe 2010
Brochure
HOBAS Trenchless Applications
Compendium
HOBAS® Technical Product Data-Gravity Pipe
Systems 2014
HOBAS® Pipeline Electronic textbook
COPYRIGHT
Hyperlinks to the
Global Pipe’s
Website
http://hobas.com.au/file
s/HOBAS%20Jacking%
20Pipe%202010%20Br
ochure.pdf
http://hobas.com.au/file
s/HOBAS%20Trenchle
ss%20Applications%20
Compendium%202009.
pdf
Refer to the Global
Pipe’s Website;
otherwise a copy is
available from the
WSAA IPAM member’s
only website.
Refer to the Global
Pipe’s Website
otherwise a copy is
available from the
WSAA IPAM member’s
only portal website.
27
OTHER REPORTS AND TECHNICAL DOCUMENTATION - WSAA MEMBERS
ONLY
Hyperlinks to the
WSAA Website
HOBAS® CC-GRP Pipes Features, Tests
and Benefits
TÜV Quality specification for centrifugally
casted - GRP Pipe Systems MUC-KSP- A
2000
Report for HOBAS Pipe Durability
assessment by GHD.
Report: Summary of qualification tests of
HOBAS® CC-GRP Pipe Systems according
to international product standards ISO
10639, ISO 10467 and ISO 25780
Certificate MUC-KSP A2000.
COPYRIGHT
Refer to the WSAA
Product Portal Site
28
Hyperlinks to the
WSAA Website
DBU report Water Jet Cleaning.
HOBAS® Pipeline Electronic textbook
HOBAS® Technical Product Data-Gravity
Pipe Systems 2014
COPYRIGHT
Refer to the WSAA
Product Portal Site
29
APPENDIX B - QUALITY CERTIFICATIONS
Copies of the following Quality Certification Certificates are available for downloading from
the WSAA ‘Members Only’ IPAM Portal Website.
TABLE B1 HOBAS Rohre GmbH – MANAGEMENT SYSTEMS
Applicants Business HOBAS Rohre GmbH Wietersdorf 9373 Klein St. Paul AUSTRIA
Quality Systems Standard
ISO9001:2008
Certification license no.
12 100 7194 TMS
Certifying agency
TUV SUD Management Service GmbH
Current date of certification
3/3/2014
Expiry date of certification
24/2/2017
Applicants Business HOBAS Rohre GmbH GEWERBEPARK 1 HELLFELD 17034
NEUBRANDENBURG GERMANY
ISO9001:2008
12 100 7194 TMS
Certifying agency
20/12/2013
22/10/2015
Applicants Business HOBAS Rohre GmbH GEWERBEPARK 1, 17039 TROLLENHAGEN GERMANY
ISO9001:2008
12 100 7194 TMS
Certifying agency
20/12/2013
22/10/2015
Applicants Business HOBAS Rohre GmbH EICHHORSTER Straße 5,, 17034 NEUBRANDENBURG
GERMANY
ISO9001:2008
12 100 7194 TMS
Certifying agency
20/12/2013
22/10/2015
COPYRIGHT
30
TABLE B2 HOBAS Rohre GmbH – PRODUCT CERTIFICATION
Manufacturing Plant HOBAS Rohre GmbH GEWERBEPARK 1 HELLFELD 17034
Product Standard/Spec.
EN 1796, EN 14364, ISO 10639, ISO 10467, and ISO 25780,
including MUC-KSP-A 2000
Confirmation No.
13 02 90258 001-1
Issuing certification body
TUV SUD Industrie Service GmbH
Manufacturing Plant HOBAS Rohre GmbH WIETERSDORF 1 9373 KLEIN ST. PAUL AUSTRIA
EN 1796, EN 14364, ISO 10639, ISO 10467, and ISO 25780,
including MUC-KSP-A 2000
Confirmation No.
13 02 90253 003-1
Manufacturing Plant HOBAS Rohre GmbH GEWERBEPARK 1 HELLFELD 17034
EN 1796, EN 14364, ISO 10639 and ISO 10467
Confirmation No.
D-PL-14153-02-01
Manufacturing Plant: HOBAS Rohre GmbH WIETERSDORF 1 9373 KLEIN ST. PAUL AUSTRIA
EN 1796, EN 14364, ISO 10639 and ISO 10467
Confirmation No.
D-PL-14153-02-01
TABLE B4 HOBAS ENGINEERING – PLASTICS TEST LABORATORY
Plastics Test Laboratory: HOBAS ENGINEERING PISCHELDORFER STR. 128 A – 9020
KLAGENFURT STANDORT: WIETERSDORF (KLEIN ST.PAUL)
Din EN ISO/IEC 17025:2005
Confirmation No.
Attached with this application.
NOTE: The registration covers TÜV SÜD Management Service GmbH is a CAB accredited by a member of the
International Accreditation Forum (IAF) Multilateral Recognition Agreement (MLA) recognised by JAS-NZS, which is
also a signatory IAF MLA.
COPYRIGHT
31
COPYRIGHT
32
COPYRIGHT
33
COPYRIGHT
34
COPYRIGHT
35
COPYRIGHT
36
COPYRIGHT
37
COPYRIGHT
38
APPENDIX C – PRODUCT SCHEDULE
Please refer the HOBAS “Technical Product Data – Gravity Pipe Systems” and “Technical
Product Data – Pressure Pipe Systems” for the complete product range for HOBAS CC-GRP
Jacking Pipes.
COPYRIGHT
39
COPYRIGHT
40
COPYRIGHT
41
COPYRIGHT
42
COPYRIGHT
43
APPENDIX D – WSAA PRODUCT SPECIFICATION
WSA PS – 205J CENTRIFUGALLY CAST GLASS REINFORCED
PLASTICS (CC-GRP) PIPES FOR PRESSURE AND NON-PRESSURE
APPLICATIONS – WATER SUPPLY AND SEWERAGE - INSTALLED
USING TRENCHLESS INSTALLATION METHODS
205J.1 SCOPE
2-
1
This specification covers CC GRP pipe for:
3,4.
Gravity stormwater/sewerage
3,4
5.
Pressure sewerage /water
205J.2 REQUIREMENTS
7
(a) CC-GRP pipes shall comply with ISO 25780:2011 .
(b) CC-GRP pipes shall be manufactured using the following glass reinforcement types:
(i)
Type “C”
(ii)
Type “E” glass
(iii)
The “ECR” glass and/or a
(iv) Combination of (i), (ii) and (iii) above.
Elastomeric joint seals shall be EPDM complying with AS 1646:2007 and
AS 681.1:2008 (EN 681-1:1996).
Jointing
lubricants
shall
have
product
certification
(ISO Type 1)
to
AS/NZS 4020:2005.
CC-GRP pipes shall be manufactured with an opaque inner resin liner layer.
(c)
(d)
(e)
205J.3 QUALITY ASSURANCE
(a) CC-GRP
pipes
shall
have
product
certification
(ISO Type 5)
to
ISO 25780:2011.
(b) Elastomeric joint seals shall have product certification (ISO Type 5) to AS 1646:2007
and AS 681.1:2008 (EN 681-1:1996).
(c) All products shall be marked in accordance with the conformity assessment body’s
requirements.
205J.4 AGENCY OR PROJECT SPECIFIC REQUIREMENTS
Nominal size, DN
3
Pressure Class , PN
4
Stiffness Class , SN
Design Jacking Load (kN)
Joints SS Sleeve / FW GRP couplings
Alternative elastomeric material for joint seals8
Pipe lengths
Alternative glass type
NOTES:
1
The use of this specification requires approval by the Water Agency.
COPYRIGHT
44
2
Manufactured using centrifugally casting process for GRP pipe useful in managing the compressive
loads during jacking.
3
Pipes for gravity sewerage are classified by nominal stiffness, SN.
4
Pipes for pressure sewerage are classified by nominal stiffness, SN and nominal pressure, PN.
5
Includes source water, drinking water and recycled water supply.
6
ISO 25780:2011 – Plastics piping systems for pressure and non-pressure water supply, irrigation,
drainage or sewerage – Glass-reinforced thermosetting plastics (GRP) systems based on
unsaturated polyester (UP) resin – Pipes with flexible joints intended to be installed using jacking
techniques.
COPYRIGHT
45
APPENDIX E - SUPPLIER CONTACTS
Kunal Bhagwat
Technical Manager
Global Pipe Australia Pty Ltd
1/27 Metrolink Circuit
Campbellfield, VIC 3061
Ph. (03) 9305 0600
Email:
[email protected]
[email protected]
Website:
www.globalpipe.com.au
COPYRIGHT
46
®
APPENDIX F – HOBAS ENGINEERING LABORATORY ACCREDIATION
COPYRIGHT
47
APPENDIX G – OTHER DETAILS (CARBON NEUTRAL HOBAS)
®
1. Certificate for Carbon Neutral HOBAS CC-GRP Pipes from Carbon Reduction Institute
(Attached below)
COPYRIGHT
48
APPENDIX H – PIPE MARKING
All products are branded with a serial number (enabling product traceability even after many
years of services), the nominal diameter, series, pressure and stiffness class as well as specific
quality marks relating to approvals by various associations and third party certifications (DVGW,
SVGW, ÖVGW, GRIS, KIWA, TÜV, CSTB, etc.)
The below pipe marking is for OD427, SN640,000
FIGURE H1 HOBAS CC-GRP JACKING PIPE MARKING
FIGURE H2 HOBAS® GRP COUPLING
COPYRIGHT
49
APPENDIX I – TRANSPORTATION / PACKING
Below is a photo of how the pipes are packed and transported from Germany/Austria to
Australia. Location: Lorimer Street, Melbourne
FIGURE I1 PIPE PACKING FOR TRANSPORTATION
FIGURE I2 PIPE NESTING
COPYRIGHT
50
FIGURE I3 PIPE NESTING
COPYRIGHT
51
Melbourne Office
Suite 8.02, Level 8
401 Docklands Drive
Docklands Vic 3008
P: (03) 8605 7601
F: (03) 8605 7612
Sydney Office
Level 11, 39 Martin Place
Sydney NSW 2000
GPO Box 915
Sydney NSW 2001
www.wsaa.asn.au
APPENDIX H PIPE MARKING
COPYRIGHT

Global Pipe Australia Pty Ltd - Water Services Association of Australia

Transcription

Similar documents

Fernco Flexible Coupling Installation - Fernco

Hymax Couplings 1.5

Fernco Flexible Coupling Installation - Fernco

Aviva Stadium

QUIET-RIOT - rocky mountain performance

VIDEO SCANNER LASER FOR TV INSPECTION AND

Drainex - Incledon

Chart L4: Details (sidewalks, stormwater management)

The New American Home

GV650 Exhaust Mod - Alternative Cruisers