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Drainage for road construction and civil engineering works

Agrosil 2500

DrainagesystemPE-HD - DIN 4262-1and shaftsystems

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WPS – drainage system AGROSIL 2500Leading pipe technology for convincing solutions

Corrugated Pipe Systems, in established composite construction offered by WPS, are a contribution to solve the water problems caused by the world’s rapidly increasing population and the consequences of global warming. In result of the long-year experience of our employees in the fields of Developing, Production and Sales of intelligent pipe systems, today we can offer our customers tailor-made services in pipe business.

Today our employees’ know how is building the foundation of successful cooperation with customers across the European continent.

The consequences of global warming, further industrialization and the increasing heavy rainfalls are challenges of our time, which require immediate efforts.

“Think of tomorrow and invest in the growth markets of today...

WPS – Water Pipe System GmbH - Your partner for multifarious solutions in corrugated pipe business

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General information 2

Drainage system AGROSIL 2500 3Types of Perforation 4Technical specifications 5Drainage pipe range 6

AGROSIL-CONTROLLER 8Shaftsystems 9

VARIODRÄN 10Shaftsystems 11

Transport – Laying – Maintenance 12

Planning Information 14

Quality and Safety 15

INDEX

General information

AGROSIL 2500

The safety and functionality of traffic installations and construction sites demand that surface water is drained away safely. In addition, water that has infiltrated into the soil as percolating and stratum water must be collected in drainage pipes and kept away from the building structure by being diverted into a drainage ditch, channel or a drainage system. For many years, perforated plastic pipes have been the pipes of choice and have proven their efficiency and long service life in various construction forms.

The DIN 4262-1 (10/2009) “Piping systems for civil engineering subsoil drainage, Part 1; Plastic pipes” standard defines the pipe types, perforation types, materials and other properties and quality characteristics.Under this standard, all perforated pipes must have a minimum water inlet surface of ≥ 50 cm²/m, independent of the nominal width and type of perforation.

DIN standards:S DIN 4262-1S DIN EN ISO 9969S DIN EN ISO 9967

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WPS – Drainage system AGROSIL 2500Types of Perforation

FULL DRAINAGE PIPE (TP)

S DN 100/150/200/250/300/350S In accordance with DIN 4262-1, type R2S Colour: blackS Cellular design - smooth on inside, corrugated on outsideS With a factory-fitted double socketS Perforation distributed evenly around the pipeS Perforation width 0.8 to 1.4 mmS Minimum water inlet surface: 50 cm²/mS Pipe length (without joint): 6 m

PARTIAL DRAINAGE PIPE (LP)

S DN 100/150/200/250/300/350S In accordance with DIN 4262-1, type R2S Colour: blackS Cellular design - smooth on inside, corrugated on outsideS With a factory-fitted double socket S Perforation in the upper area symmetrical to the ver- tical circumference pipe axis over an angle of 220°S Coloured crown markingS Perforation width 0.8 to 1.4 mmS Minimum water inlet surface: 50 cm²/mS Pipe length (without joint): 6 m

MULTI-PURPOSE PIPE (MP)

S DN 200/250/300/350 S In accordance with DIN 4262-1, type R2S Colour: blackS Cellular design - smooth on inside, corrugated on outsideS Delivered with a profile sealing ring at each end in the second trough as well as a factory - fitted double socketS Perforation in the upper area symmetrical to the vertical circumference pipe axis over an angel of 120°S Coloured crown markingS Perforation width 0.8 to 1.4 mmS Minimum water inlet surface: 50 cm²/mS Pipe length (without joint): 6 m

UNPERFORATED PIPE (UP)

S DN 100/150/200/250/300/350S In accordance with DIN 4262-1, type R2S Colour: blackS Cellular design - smooth on inside, corrugated on outsideS Delivered with a profile sealing ring at each end in the second trough as well as a factory-fitted double socketS Pipe length (without joint): 6 mS With a specially developed sealing ring for increased water resistance as per DIN 19537

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WPS – Drainage system AGROSIL 2500Technical specifications

MATERIAL

AGROSIL 2500 pipes are made of PE-HD in accordance with DIN 4262-I (Annex B). PE-HD is a high-quality plastic with excellent mechanical properties (high impact strength), good chemical-biological resistance and first-class abrasion values. Its many years of proven efficiency make it a safe and reliable material for drainage technology.Chemical resistance in accordance with leaflet 1 of DIN 8075. Sealing rings for MP and UP pipes made of EDPM.

QUALITY REQUIREMENTS

AGROSIL 2500 drainage pipes are subjected to continuous quality monitoring in accordance with DIN 4262-1:S Internal monitoring and documentation of the results by our on-site laboratoryS External monitoring through SKZ (Süddeutsches Kunststoffzentrum – „South German Plastics Centre“) in Würzburg.

SOCKET JOINT

All AGROSIL 2500 pipes are supplied with a factory-fitted double socket. The moulded fittings for AGROSIL 2500 pipes have factory formed joints. The joints are fixed onto the drainage pipes by means of snap-in studs.

A profile sealing ring is fitted in the factory onto the second trough of the tapered end of the multipurpose pipes (MP) and unperforated multipurpose pipes (UP). They can be laid as watertight pipelines thanks to the moulded parts with welded joint in combination with the sealing ring on the pipe.

AGROSIL 2500 DRAINAGE PIPE RANGE

APPLICATION

Drainage tasks for the entire spectrum of traffic engineering (road and motorway construction, railway construction, road building for farms and woodlands) and for civil engineering works, in landfill construction for covering and remediation on the edges.

MARKING

Every AGROSIL 2500 pipe has at least once the following markings:S DIN 4262-1S Typ R2S WPS AGROSIL 2500S SKZS Production year/QuarterS PE-HDS Nominal width

*Delivery length with double socket (working length: 6 m)

DN Perforation Palletcontents

No. of pipeseach 6 m

Internaldiameter

Externaldiameter

Draincross-section

Deliverylength*

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WPS – Drainage system AGROSIL 2500Drainage pipe range

End cover Bend 90°

Branch 45° with reducer Branch 45°

Double socket Bend 45°

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T-piece

Transition to KG

Profile sealing ring

T-piece with reducers

Reduction joint

Shaft lining

Frog flap

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WPS – Shaft systems AGROSIL-CONTROLLERCollection and drainage of seepage water at road construction sites

SHAFT BODY

S Shaft body, DN 400, with continuous PE-HD channel.S Welded construction with a 3-layer cellular design. S With up to 4 connection pieces in freely selectable nominal widths for connection pipes, type R2, in accordance with DIN 4262-1 and joint for connector pipe.S Where required, DN 100 to DN 300 joint can be welded on for the connection of KG pipes.S Optional joint for AGROSIL 2500 DN 100, DN 150, DN 200, DN 250, DN 300, DN 350 with DN 100 to DN 300 KG joint possible.

APPLICATION

The AGROSIL CONTROLLER is employed in systems for collecting and discharging seepage water in road construction (motorway, road and rail construction), in general civil engineering works for connecting several pipe runs and for checking, cleaning and carrying out camera inspection and high-pressure cleaning measures.

S Continuous channelS Easy to installS No heavy-duty laying equipment necessaryS The body is in the earth away from traffic loadsS Easy to cleanS Camera inspections possibleS Tested quality - monitored internally and by outside agenciesS Optimum chemical resistance (PE-HD)S Outstanding ageing resistanceS Optimum abrasion resistanceS Variable connections possibleS Rinsing pressure 130 bar

AGROSIL-CONTROLLER

HIGHLIGHTS

Main body with

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WPS – Shaft systemsShaft versions:

CUSTOMISED PRODUCTION

1 to 4 outlets DN 100/150/200/250/300/350 with sleeves for AGROSIL 2500 or KG can be supplied on request.

The welded construction means that any nominal width and connection configuration is possible!

Ask about our special customised production- short delivery periods are possible!Telephone: + 49 9090 / 923 99 - 19

STANDARDSection A-A 2 Outlets 180°

Section A-A 2 Outlets 90°

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WPS – Shaft systems VARIODRÄN

The VARIODRÄN is employed in systems for collecting and discharging percolating water in road construction (motorway, road and rail construction), in general civil engineering works for connecting several pipe runs and for checking, cleaning and carrying out camera inspection and high pressure cleaning measures.

S Shaft body, DN 400, with continuous PE-HD channel

S Welded construction with a 3-layer cellular design

S With up to 4 connection pieces in freely selectable nominal widths for connection pipes, type R2, in accordance with DIN 4262-1 and joint for connector pipe

S Where required, DN 100 to DN 300 joint can be welded on for the connection of KG pipes

S Optional joint for AGROSIL 2500 DN 100, DN 150, DN 200, DN 250, DN 300, DN 350 with DN 100 to DN 300 KG joint possible

S Continuous channelS Easy to installS No heavy-duty laying equipment necessaryS The body is in the earth away from traffic loadsS Easy to cleanS Camera inspections possibleS Tested quality - monitored internally and by outside agenciesS Optimum chemical resistance (PE-HD)S Outstanding ageing resistanceS Optimum abrasion resistanceS Variable connections possibleS Cleaning pressure 130 bar

VARIODRÄN

HIGHLIGHTS

SHAFT CONNECTOR PIPES Made of PE-HD DN 400S 1 m; 1.5 m; 2 m; 6 m (to be cut to size on site)

DIRT TRAPS Made of PE-HD, for Class B and Class D shaft covers

SHAFT COVERClass B/DS Cast, DN 400 with/without ventilation, including cast frame and concrete ring

SHAFT ACCESSORIESINLET COVER S For overflow shaft, cast, DN 400, including cast frame and concrete ring

VARIODRÄN ACCESSORIES

Article

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INFORMATION:

S The DN 100 sleeves have a slightly conical shape and enable KG pipes (Da = 110 mm) to be connected.

S The DN 150 sleeves enable the connection of KG pipe (Da = 160 mm).

S DN 200 spigot ends (Da = 200 mm) enable KG sleeves to be slid on as well as connecting sleeves.

MAIN AND CONNECTION DIMENSIONS

Sand trap

Art.-No. 621 52 200

Sand trap

Art.-No. 621 52 160

Sand trap

Art.-No. 621 52 110

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Drainage system AGROSIL 2500Transport – Laying – Maintenance

DELIVERIES

AGROSIL 2500 is supplied in 6 m lengths packed in wooden frame pallets. The pallets must be packed exactly on top of one another on transport vehicles and secured against slipping.On the site, use suitable lifting gear to unload and transport the pallets, such as fork-lift trucks or a crane with cushioned slings. Do not unload by tipping or throwing. The storage site should be firm and free of any foreign bodies that might damage the pipes. Stack max. 2 pallets on top of each other and make sure that the wooden frames of the pallets are placed exactly. Stack loose pipes on a level place with displaced sleeves to a max. height of 1.5 m and secure at the sides. Because of the low weight, single pipes can easily be transported by hand and lowered into the trench without being thrown. Shaft material and fittings are supplied loose or on nonreturnable pallets.

MACHINING

Check pipes and fittings before machining. Damaged parts must be separated. The limit temperatures for transport and laying AGROSIL 2500 PE-HD pipes are between -20°C and +40°C. Use a fine-toothed saw to cut lengths by sawing in the troughs without cutting the profile. With full and partial drainage pipes, after cleaning the sleeves are pushed together dry; with larger nominal widths use a lever where necessary, with a board between the lever and the end of the pipe to protect the surface. With multipurpose pipes and unperforated multi-purpose pipes clean the sleeves, tapered end and sealing ring carefully and use WPS lubricant.When laying the pipes, make sure that the layout is in accordance with the function. AGROSIL 2500 partial drain and multi-purpose pipes have a lengthways coloured marked on the crown. This marking must be exactly uppermost. The filter and backfill material must be inserted carefully and gradually without being tipped from a height. Compacting in the pipeline zone must be done by hand and with lightweight apparatus only. When doing this, make sure that the pipe is not pushed at the sides or upwards out of its correct position (e.g. sand cone, rods, etc.).

PIPE TRENCHES AND PIPELINE ZONE

The pipe trenches must be excavated taking account of the relevant laying and safety provisions, including

S DIN EN 1610 (01/2010): Laying and Testing Sewer Pipes and Conduits (replaces the previous standard DIN 4033)

S ATV DVWK-A 139 (01/2010): Installing and Testing Sewer Pipes and Conduits

S ZTV A-StB 97 (2006). Additional Technical Contractual Conditions and Directives for Excavations in Traffic Areas

S Accident Prevention Regulations issued by Trade Associations

The pipe support must be implemented with the planned gradient and degree of compacting. For reasons to do with the static, in the pipeline zone use material from soil group G1 or G2 that is capable of being well compacted and is filter stable (see the section entitled “Filter stable installation”). Frequently, for leading percolating water to the perforations of partial drain or multipurpose pipes the lower area of the pipeline zone is to be consist of dense material through which the water cannot seep. For this purpose, use cohesive soil or foil on non-cohesive soil with a gradient to the perforations. For pipe static reasons, with drainage pipes made of plastic the use of concrete for the support and bedding to the perforations is not recommended. Flexible plastic pipes require a supporting layer in a compactable elastic soil material, so that the pipe/soil interplay and the necessary bedding reaction pressure can develop.

compact soil

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FILTER STABLE CONTRUCTION

Drainage pipes must be laid with suitable filter materials. If this is not done, malfunctions and restrictions on the service life may occur as a result of blocked perforations or deposits of fine soil particles in the pipe. The following general information shows the fundamental background. It is not intended to replace concrete measures based on the local situation, which have to be made where necessary by a specialist planner or in a soil survey. The choice of the filter material and the dimensions of the filter layer depends on the soil in place and the perforation width of the pipes used.

The gravel filter layer must be at least 200 mm thick on all sides, even if multiple graduated material is used.If this condition cannot be complied with, a suitably structured geotextile must be used (see “Leaflet on using geotextiles and geogrids in civil engineering works for road construction”).

S Perforation width of the drainage pipe

The grain distribution curve of the filter gravel that is used must have a grain Ø at 85% by weight that is greater than the perforation width of the pipe. The perforation widths of AGROSIL 2500 are between 0.8 mm and 1.4 mm in accordance with DIN 4262-1.

INSPECTION AND MAINTENANCE

Drainage pipes are inspected and maintained through the appropriate shafts. With its smooth flat bottom, the AGROSIL-CONTROLLER enables inspection cameras and high-pressure flushing nozzles to be easily inserted into the pipe holders. In contrast, VARIODRÄN shafts retain a certain amount of dirt in the collecting space and this can be sucked out easily during cleaning work. When the drainage installation is handed over to the operator there is usually an initial inspection and the system is cleaned as well, if necessary.

Following this, inspections and cleaning measures should be carried out at regular intervals to keep drainage pipes ready for use permanently.AGROSIL 2500 drainage pipe and the AGROSIL- CONTROLLER and VARIODRÄN shafts have been verified

as being able to withstand the usual flushing pressure of max. 130 bar used in pipe cleaning today. If rotating chains are to be used as mechanical cleaners only round link chains should be used. The pipe cleaners must choose the right apparatus and method of working to ensure that the drainage pipes are not damaged.

INSTALLING THE SHAFTS

Shafts made by WPS for drainage pipes are constructed as follows:A shaft body with welded sleeves for the inlets and outlets and a sleeve for the shaft pipe, which is inserted into the shaft body. The shaft pipe is to cut to length in the field for the exact installation height (delivery lengths: 1 m, 1.5 m, 2 m or 6 m). The shaft pipe then leads in a single nominal width through to the surface just below the cover.A fine-toothed saw must be used for cutting. The shaft pipes have a 3-Iayer wall construction. Make the cut in the trough at a right angle to the pipe axis so that the result is a straight end without the webs being cut. The position of the corrugations can be seen on the outer surface of the pipes. We recommend marking the cut with a wide marking tape.

Heavy duty covers, designed for vehicular traffic (Class B 125 and D 400) These lie on concrete rings outside the shaft pipes. Their weight and the load from the covers must be transferred through the concrete rings into the soil without the shaft pipes experiencing a vertical load either in the installed position or through settling. With covers that are designed for vehicular traffic cut the shaft connector pipe so that there is a minimum clearance of 50 mm between the upper edge of the shaft pipe and the lower edge of the cover. With heavy duty covers, make sure as well that loads cannot be transmitted into the Connector pipes through the substructure.

Class D 400Lay the concrete foundation at least 20 cm thick so that the cover does not lie on the connector pipe. A sliding and separating layer of film or a similar material must be located between the concrete foundation and the connector pipe.

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Drainage system AGROSIL 2500Guaranteed quality and safety throughout.

PLANNING INFORMATION

Pipes and shafts for collecting and discharging seepage and surface water must, among other things, conform to the following requirements:

RESISTANCE Resistance of the material to water and soils:S For its pipes and shafts WPS uses proven and

reliable materials: PE-HD is resistant to surface and seepage water and with its resistance in the range of pH 2 to pH 11 is in extreme cases, also resistant to water contaminated in industrial catastrophes or to water used in fire-fighting activities. On the other hand, it is stable against erosion and the leaching of ingredients and does not pass on any substances to the seepage water or the surrounding soil.

FLOW DIAGRAMAGROSIL 2500

COLLECTING WATER FOR DISCHARGE

S For collecting the water from the soil, the water inlet surface of AGROSIL 2500 drainage pipes is greater than or equal to 50 cm²/m in accordance with DIN 4262-1 and is independent of the type of perforation. The water inlet surface of a meter length of drainage pipe therefore corresponds to at least the outflow cross-section of a DN 80 pipe!

S The profile geometry of AGROSIL 2500 pipes, whichhas been optimised for use as drainage pipes, provides the inflowing water with secure and permanent flow paths to the inlet perforations in the troughs. The filter-stable bedding of the pipes is absolutely essential for guaranteeing the long-term water collection capacity of drainage pipes. The correct choice and dimensioning of the filter materials depend on the local soil and the hydrological situation at each project site and require great care in the planning stage.

GUARANTEE OF MAINTENANCE FACILITIES

Standard inspection methods using cameras and cleaning with high-pressure machinery are possible without any problems with the pipes and shafts shown in this catalogue.

The drainage pipe AGROSIL 2500 as well as the AGROSIL-CONTROLLER and VARIODRÄN are demonstrably resistant to commonly used high pressure cleaning systems using a cleaning pressure of 130 bar.

After clarifying the concrete requirements, it may be necessary to draw up application-based special solutions for particular application and load conditions, for example, those encountered in tunnel construction, with landfills or in industrial and process engineering.

Please contact our Engineering department.Telephone: +49 90 90 / 923 99 - 25

DN 350

DN 300DN 250

DN 200

DN 150

DN 100

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DIMENSIONING

Outflow of the expected volume of water without damming up:

S For calculating drainage pipes check the possible through flow volume for a selected nominal width, given an available pipe gradient, or determine the required nominal width for a volume to be discharged.The internal roughness of the pipes is an important factor for flow losses. Like all plastic pipes with very smooth non-porous inner surfaces, AGROSIL 2500 pipes made of PE-HD have an absolute pipe wall roughness of 0.5 mm. The perforation has only a slight effect on the outflow performance. Partial drainage pipes and multi-purpose pipes are unperforated in the lower area and UP pipes used purely for transport purposes do not have any perforations at all.

To take account of socket joints, shafts, positional deviations and perforations, in general a value of 0.5 mm is assumed for the operating roughness kb, and this can be used for dimensioning using the flat rate concept (RAS EW: kb = 0,4 mm).

The outflow as a function of the pipe gradient for AGROSIL 2500 can be seen in the diagram (page 14).

‘The basic principles are found in the worksheet ATV-DVWKA 110 “HydraulischeDimensionierung und Leistungsnachweisvon Abwasserkanälen und -leitungen”(Hydraulic Dimensioning and PerformanceRecord of Sewer Conduits and Pipes), whichwas revised and published in a new editionin August 2006 (ISBN 3-935669-22-4).Important information and standards are alsocontained in the “Richtlinien für die Anlagevon Straßen (RAS)” (Directive for HighwayProjects (RAS)), Part Drainage RAS-Ew.

DURABILITY AND DIMENSIONALITY

Thanks to their material and geometrical parameters, drainage pipes made by WPS display excellent properties for use in road construction and civil engineering projects. The material PE-HD provides a high degree of toughness at cold temperatures and extreme deformation capability without failure, even under dynamic loads. The corrugated wall design ensures maximum stability.

In accordance with DIN 4262-1, the ring stiffness of AGROSIL 2500 drainage pipes is tested under DIN EN ISO 9969 and compliance with the standards in the category “SD” is guaranteed:

DN 80/100 ring stiffness ≥ 8 kN/m² SN8DN > 100 ring stiffness ≥ 4 kN/m² SN4

However, these ring stiffnesses are measured values from laboratory tests to verify defined quality criteria. They only provide conditional information on the behaviour of a pipe under concrete installation and load conditions and on permanent suitability for the planned application.

The pipe static verification for drainage pipes under the expected load and the soil and installation conditions of a project can be carried out using the relevant calculation provision ATV-DVWK-A 127. Where required, ask for our “Project questionnaire for the static calculation of WPS pipes”. With the help of a calculation program, your data are used to check compliance with the verification criteria strength, stability and deformation. In general, it is not difficult to carry out this verification for the drainage pipes even under the highest load class SLW 60 and shallower cover. However, a firm support and bedding for the pipes is necessary in accordance with DIN EN 1610 “Construction and testing of drains and sewers”, RAS-Ew (drainage), ATV/DVWK-A 139, ZTVA-StB 97 as well as ZTV-Ew-StB 91.

WPS delivery programmeS Drainage – Agrosil 2500S Percolation – Sicadukt / DrossduktS Sewage - GigapipeS Rainwater – Agro-RainS Cable protection - KabuplastS Prestressing technology – Metal-, duct-, anchorpipes / injection-, venting-tubesS Special-purpose solutions

Mittelstetter Straße 22aD-86641 Rain am Lech

Telephone: +49 (0)9090 / 923 99 - 0Telefax: +49 (0)9090 / 923 99 - 39E-mail: info@wps-gmbh.comInternet: www.wps-gmbh.com

WPS - Water Pipe System GmbH

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