GRP non - circular Pipe Systems - Saudi Arabian … · GRP non - circular Pipe Systems for Construction and Renovation of Sewer Systems

GRP non - circular Pipe Systemsfor Construction and Renovation of Sewer Systems

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AMIANTIT – A winning combination

AMIREN pipe systems are manufactured in facilities owned by the AMIANTIT Group.

The Saudi Arabian AMIANTIT Company (SAAC) was established 1968 in Dammam in the Kingdom of Saudi Arabia to manufacture pipes for the local market.Since then, AMIANTIT has grown and developed into a major diversified industrial group with operations spanning the globe.

The Group’s core business activities comprise:

• Manufacture and sale of pipe systems and tanks made of GRP, GRE, PVC, HDPE, Ductile Iron and Concrete

• Ownership and sale of pipe technologies

• The provision of water management consultancy and engineering services

• Manufacture and supply of polymer products

Today AMIANTIT markets a wider range of pipe products than any other pipe manufacturer and provides a total solution to customers’ fluid transfer needs, designed to optimise the applied technology and costs. The Group serves municipal, civil engineering, industrial, energy and agricultural markets worldwide, supporting global infrastructure development.

The Group comprises approx. 30 manufacturing plants, 6 technology companies, 9 water management companies and 4 materials suppliers, In addition, an extensive sales and service network caters for the needs of customers in countries around the world.

AMIREN products are available through our international distribution network. If you require more details please contact us. A contact address can be found on the back page of this brochure.

AMIREN pipes are manufactured in a discontinuous process by helical filament winding of resin impregnated continuous and chopped fibreglass roving on a rotating oval mandrel with controlled sequences.

Using this technology, developed by material specialists, a very dense laminate is created that maximizes the contribution from the three basic raw materials: glassfibres, resin and sand. Both continuous glass fibre roving and chopped roving are incorporated for high hoop strength and axial reinforcement. A sand fortifier is used to provide increased stiffness by adding extra thickness. The unique manufacturing equipment allows the application of a special in-liner resin which can be modified depending on the expected chemical resistance of the pipes.

The unique advantages of the winding process also allow the use of other materials, such as a glass or polyester veil to enhance the abrasion resistance and the pipe finishing.

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Index of Content

1 Production Process .......................................................................................................................................5

2 Pipe Laminate ................................................................................................................................................5

3 Quality Standards and Test Procedures .....................................................................................................6

4 Product Benefits ............................................................................................................................................6

5 Applications ...................................................................................................................................................7

6 Product Description ......................................................................................................................................7

7 Product Range ...............................................................................................................................................87.1 Egg Shaped Profiles ........................................................................................................................................87.2 Mouth Shaped Profiles ....................................................................................................................................87.3 Parabolic Shaped Profiles ...............................................................................................................................97.4 Eliptical Shaped Profiles ..................................................................................................................................97.5 Pear Shaped Profiles .......................................................................................................................................9

8 Pipe Joining ..................................................................................................................................................10

9 Fittings ..........................................................................................................................................................10

10 Services ........................................................................................................................................................10

11 References ...................................................................................................................................................11

Appendix A ...................................................................................................................................................12 - Data Sheet - ................................................................................................................................................12

Appendix B ...................................................................................................................................................14 - Design samples - ........................................................................................................................................14

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2 Pipe Laminate

AMIREN pipes are manufactured in a discontinuous process by helical filament winding of resin impregnated continuous and chopped fibreglass roving on a rotating oval mandrel with controlled sequences.

Using this technology, developed by material specialists, a very dense laminate is created that maximizes the contribution from the three basic raw materials: glassfibres, resin and sand. Both continuous glass fibre roving and chopped roving are incorporated for high hoop strength and axial reinforcement. A sand fortifier is used to provide increased stiffness by adding extra thickness. The unique manufacturing equipment allows the application of a special in-liner resin which can be modified depending on the expected chemical resistance of the pipes.

The unique advantages of the winding process also allow the use of other materials, such as a glass or polyester veil to enhance the abrasion resistance and the pipe finishing.

1 Production Process

The basic raw materials used in the manufacture of AMIREN pipes are resin, fibreglass and silica sand. Usually unsaturated polyester resins are used since they give good performance for most applications. The combination of resin, endless glass fibre roving, silica sand and chopped glass fibres, forms a solid sandwich structure.

The figure shows a typical cross section of a pipe laminate. This cross section, as well as the method of applying and placing the different raw materials, can differ depending on the pipe application.

S1 - internal liner layer consisting mainly of resin with addition of quartz sand. Minimum 1 mm thickness.S2 - barrier layer made of resin and cut fibres. Minimum 1,5 mm thickness.S3 - structural layer made of resin, continuous and cut glass fibre and various additives (e.g. quartz sand).S4 - external liner layer consisting mainly of resin and quartz sand, covered with sand providing adequate adhesion to injection. Minimum 1 mm thickness.S5 - wall thickness

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AMIREN pipe systems provide the market with a product that provides low cost, long term piping solutions to all customers. The long list of features and benefits add up to provide an optimum system of installation and life cycle cost.

Outstanding Product Range

• Standard and non-standard shapes according to customer and project specification• Different joint solutions depending on project requirements

Corrosion and Chemical Resistant

• Long, effective service life • No need for linings, coatings, cathodic protection, wraps or other forms of additional corrosion protection• Hydraulic characteristics essentially constant over time• Resistant against many chemicals, acids and lyes

Light Weight (1/10 weight of concrete)

• Low transportation costs (nestable) • Eliminates need for expensive pipe handling equipment

Superior Hydraulic Characteristics

• Smooth inside surface• Minimal slime build-up due to high flow velocity in the lower narrow area of the pipe means lower cleaning costs• Excellent abrasion resistance

Precision Bell & Spigot Couplings with Elastomeric Gaskets

• Tight, efficient joints designed to eliminate infiltration or exfiltration• Ease of joining, reduces installation time• Accommodates small changes in line direction or differential settlements without additional fittings• Double gasket system that allows leakage tests executed on site by contractor

Installation, Handling and Maintenance

• Low maintenance costs due to less deposits and a good self-cleaning effect• Despite the narrow design, easy access due to the installation height• High intake capacity, especially at times of peak load• Pipe relining installation possible during operation, depending on diameter, flow amount and security requirements

4 Product Benefits3 Quality Standards and Test Procedures

The AMIREN system has passed the following standard tests:

• Abrasion test acc. to DIN EN 295 part 3/DIN19565 part 1, TU (Technische Universitat) Darmstadt, Germany

• Mechanical tests according to ISO 178, ISO 899-2, DIN EN ISO 527-4, DIN 53479, ISO 172

• Joint leak-proofness tests acc. to DIN 4060 MPA Dortmund, Germany

• High pressure setting resistance test according to draft DIN 19523, IRO Oldenburg, Germany

• Static buckling test MFPA Leipzig, Germany

• Joint leak -proofness tests acc. to ÖNORM B 5163

All the tests approved AMIREN pipe systems as the ideal solution for construction and renovation of sewer systems with non circular profiles. AMIANTIT is participating in the development of miscellaneous quality standards with representatives of most worldwide organisations, thereby ensuring that performance requirements will result in reliable products.

Our product manufacturing is distinguished by consistently high quality standards. The production facilities are regularly inspected by independent organisations and are certified according to ISO 9001. The factory has a dedicated quality control department, which ensures that:

• All products are manufactured according to the given specifications

• The quality of all products and services is continually improved

On request, quality certificates can be supplied with delivery.

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5 Applications

AMIREN pipe systems are designed and suitable for the transportation of miscellaneous polluted fluids. The non circular shaped pipes have proven to be the best solution in applications where reliability, excellent self-cleaning properties and low maintenance costs are key factors. You find AMIREN pipes executed as relining and open trench projects in:

• Storm water sewage applications • Sanitary projects• Chemical sewer applications

6 Product Description

AMIREN pipe systems are predominantly designed for the trench-less renovation of gravity sewage systems made of stoneware, concrete, brick, clinker, and plastic pipes with non-circular cross-sections.They are principally available in the following cross sections:

• Egg shaped • Mouth shaped• Pear shaped• Parabolic shaped • Elliptical shaped• Other non-standard shapes, designed in accordance to specifications and project requirements.

Depending on the application and operational conditions, AMIREN profiles are designed and manufactured in various classes of load-carrying capacity:

Carrying profiles

Designed for the renovation of sewer lines losing their load-carrying capacity and in need of construction reinforcement. The profile design withstands all current loads from the old sewer and also additional loads expected after renovation.

Non-carrying profiles

Designed for the renovation of sewer systems with sufficient mechanical load-carrying capacity. Design and profile is focused on inner surface modification, improving hydraulic characteristics and chemical resistance.

Samples of manufactured shapes

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The standard product range available includes pipe systems in various shapes and diameters. The tables below show the most common systems and diameters. The wall thicknesses of our pipes depend on installation/operational conditions and are determined by static calculations. However, the main strength of the AMIREN manufacturing system is the supply of individual, custom designed and tailor-made products. If you do not find a product listed below or in Appendix B, that is applicable to your requirements, please do not hesitate to contact us. Standard construction lengths of our pipes are 2 and 3m. Individual lengths up to 6m are available on request.

Egg shaped profiles 2/3

Internal diameter Radius Cross-

sectional areaTheoretical ID of round pipe

b/h [mm] r [m] A [m2] Ø [m]

400/600 0.200 0.184 0.484

470/705 0.235 0.254 0.568

500/750 0.250 0.287 0.605

580/760 0.290 0.386 0.701

600/900 0.300 0.413 0.726

700/1050 0.350 0.563 0.846

760/1140 0.380 0.663 0.919

800/1200 0.400 0.735 0.967

840/1260 0.420 0.810 1.016

900/1350 0.450 0.930 1.088

1000/1500 0.500 1.149 1.209

1100/1650 0.550 1.390 1.330

1200/1800 0.600 1.654 1.451

1300/1950 0.650 1.941 1.572

1400/2100 0.700 2.251 1.693

1600/2400 0.800 2.940 1.935



b/h [mm] r [m] A [m2] Ø [m]

500/625 0.250 0.239 0.551

1000/1250 0.500 0.956 1.103

1600/2000 0.800 2.446 1.765

2000/2500 1.000 3.822 2.206

Egg shaped profiles 2/2.5

Egg shaped profiles 2/3.5



b/h [mm] r [m] A [m2] Ø [m]

500/875 0.250 0.343 0.661

700/1200 0.350 0.673 0.926

1000/1750 0.500 1.373 1.322

1200/2100 0.600 1.977 1.587

1600/2800 0.800 3.515 2.115

Egg shaped profiles 2/4



b/h [mm] r [m] A [m2] Ø [m]

500/1000 0.250 0.391 0.706

650/1300 0.325 0.661 0.917

950/1900 0.475 1.412 1.341

Egg shaped profiles non-standard



b/h [mm] r [m] A [m2] Ø [m]

700/1200 0.350 0.653 0.912

750/1400 0.375 0.820 1.022

900/1200 0.450 0.785 1.000

1010/1370 0.505 1.050 1.156

1060/1414 0.530 1.190 1.231

1074/1674 0.537 1.290 1.282

1103/1824 0.550 1.470 1.368

Mouth shaped profiles 2/1.5



b/h [mm] r [m] A [m2] Ø [m]

1000/750 0.500 0.595 0.870

2000/1500 1.000 2.378 1.740

2100/1575 1.050 2.621 1.827

3000/2250 1.500 5.351 2.610

Mouth shaped profiles 2/2



b/h [mm] r [m] A [m2] Ø [m]

1200/1200 0.600 1.216 1.244

2000/2000 1.000 3.378 2.074

2800/2800 1.400 6.621 2.903

7.1 Egg Shaped Profiles

7.2 Mouth Shaped Profiles

7 Product Range

length

h

b

r

length

h

b

r

9




b/h [mm] r [m] A [m2] Ø [m]

1000/875 0.500 0.723 0.959

2000/1750 1.000 2.890 1.918

3000/2625 1.500 6.503 2.877




b/h [mm] r [m] A [m2] Ø [m]

1000/625 0.500 0.484 0,785

1400/875 0.700 0.949 1.100

2000/1250 1.000 1.936 1.570

3000/1875 1.500 4.356 2.355

Mouth shaped profiles 2/1



b/h [mm] r [m] A [m2] Ø [m]

1000/500 0.500 0.402 0.716

2000/1000 1.000 1.609 1.431

3000/1500 1.500 3.620 2.147

Mouth shaped profiles non-standard



b/h [mm] r [m] A [m2] Ø [m]

1800/1270 0.900 1.791 1.510

1905/1360 0.953 2.050 1.616

1905/1410 0.953 2.140 1.651

2200/1250 1.100 2.028 1.607

2290/1500 1.145 2.700 1.854

3000/2400 1.500 5.799 2.717

7.3 Parabolic Shaped Profiles

Parabolic shaped profiles 2/2



b/h [mm] r [m] A [m2] Ø [m]

1000/1000 0.500 0.752 0.978

1600/1600 0.800 1.924 1.565

2004/1965 1.002 2.97 1.944

2601/2590 1.300 5.07 2.541

2800/2800 1.400 5.894 2.739

7.4 Elliptical Shaped Profiles

Eliptical shaped 2/2.5



b/h [mm] r [m] A [m2] Ø [m]

1000/1250 0.500 1.036 1.148

1600/2000 0.800 2.651 1.837

2000/2500 1.000 4.142 2.296

Eliptical shaped profiles 2/3



b/h [mm] r [m] A [m2] Ø [m]

1000/1500 0.500 1.286 1.279

1500/2250 0.750 2.892 1.919

2000/3000 1.000 5.142 2.559

length

b

h

r

length

h

b

r

r

7.5 Pear Shaped Profiles

h

length

b

r



b/h [mm] r [m] A [m2] Ø [m]

1400/1750 0.700 1.948 1.575

1600/2000 0.800 2.545 1.800

1800/2250 0.900 3.221 2.025

2000/2500 1.000 3.976 2.250

Pear shaped profiles 2/2.5

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AMIREN pipe sections used for sewage media solutions are typically joined using a bell & spigot coupling with elastomer gaskets. It is a proven jointing system that ensures the system’s function through its whole estimated service life. The joint system is extensively tested and allows a defined maximum angular deflection at each coupling joint.For chemical industries as well as for acidic/basic fluid environment, glued and laminated connections are also available on request. It guarantees tightness and safe conditions for the environment in which the pipes are embedded. Length and thickness of the lay-up depends on diameter and application.

10 Services

8 Pipe Joining

Assistance

Specialists at our sales offices offer a wide range of products and product support. They will assist and advise on: Technical consultation for planning, installation and rehabilitation Local consultation and support for contractors Static and hydraulic calculation Solutions for special applications

Logistics

AMIREN Pipe Systems are supplied to many countries throughout the world. Working closely with our customers, experienced specialists in our Logistics Department develop the most efficient ways of transportation by rail, road, sea and air. Cost savings can often be obtained by nesting our pipes, which is possible due to their low weight and easy handling.

Please contact your local supplier for further information.

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Type A Rubber gasket

Test nozzle

Double rubber gasket

Polyurethane or epoxy glue

GRP laminate

Type B

Type B1

Type C

Type D

9 Fittings

The large production range of AMIREN system includes also segmented fittings produced on the basis of AMIREN pipes. The AMIREN fittings are produced acc. design specification , which are produced in whole or in parts and assembled on site by lamination. Dimensions and configurations of the fittings are establish directly with the customer. The product range of the AMIREN fittings contains: Elbows Tees Wyes Cylindrical and tangential manholes

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•

•

•

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11 References

Project Country Type of shape Diameter Length Year Application

Bamberg Germany egg 900/1350 193 m 2007 Relining

Bernburg, Schillerstraße Germany egg 900/1200 387 m 2007 Relining

Bonn Germany egg 600/900 207 m 2007 Relining

Hannover, Blumenauer Str. Germany mouth 1800/1270 169 m 2007 Relining

Schwandorf, Nabburg Germany mouth 2100/1575 41 m 2007 Relining

Szczecin Zalewskiego Poland egg 700/1200 126 m 2007 Relining

Bochum Germany egg 1000/1500 697 m 2008 Relining

Duisburg Germany egg 1000/1500 104 m 2008 Relining

Pabianice zadanie nr 8 Poland elliptical 750/1400 2008,8 m 2008 Relining

Siedlce Rondo Poland egg 1200/2100 42 m 2008 Open trench

Szczecin Dąbrowskiego Poland mouth 1905/1410 269 m 2008 Relining

Szczecin Zapadła Poland mouth 2200/1250 178 m 2008 Relining

Tübingen Germany egg 600/900 47 m 2008 Relining

Vocklabruck - Austria Austria egg 600/900 30 m 2008 Relining

Vocklabruck - Austria Austria egg 500/750 69 m 2008 Relining

Zielona Gora, ul. Kupiecka Poland egg 500/750 255 m 2008 Relining

Zielona Gora, ul. Kupiecka Poland egg 600/900 295 m 2008 Relining

Dresden Germany parabolic 2004/1965 344 m 2009 Relining

Dresden Germany parabolic 2601/2590 258 m 2009 Relining

Dresden, Tharandter Straße Germany egg 500/750 38 m 2009 Relining

Güstrow, RÜB Parumer Straße Germany mouth 1800/1270 24 m 2009 Relining

Köln Germany egg 700/1050 17 m 2009 Relining

Leipzig, Duforstraße Germany egg 800/1200 237 m 2009 Relining

Leipzig, Uferstraße Germany egg 1060/1414 327 m 2009 Relining

Nidderau, Niddertalstraße Germany egg 600/900 36 m 2009 Relining

Suhl, Gewerbepark Simson Germany egg 700/1050 72 m 2009 Relining

Wolimex Poland mouth 600/900 60 m 2009 Open trench

Wrocław, ul. Grabiszyńska Poland egg 700/1050 238 m 2009 Relining

Wrocław, ul. Krakowska Poland egg 800/1200 253,95 m 2009 Relining

58 Mannheim Q6,Q7 Germany egg 700/1050 96 m 2010 Relining

Austria, Waldrastobel Austria mouth 1800/1270 416 m 2010 Open trench

Dessau-Roßlau Germany egg 1000/1500 69 m 2010 Relining

Leipzig, Duforstraße II Germany egg 1010/1370 95 m 2010 Relining

Ludenscheid Germany mouth 1400/875 194,95 m 2010 Relining

Sak Invent Poland Poland egg 600/900 84 m 2010 Open trench

Troisdorf Germany egg 840/1260 166 m 2010 Relining

Weinsheim Germany mouth 1000/625 29 m 2010 Relining

GIGABLOK Poland mouth 3000/2400 104 m 2011 Open trench

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AMIREN Data Sheet for static calculations acc. to ATV M127 P-2

Design: Drawn up by:

Company: Phone/Fax:

Signature:

Data:

1. Technical characteristics of the pipeline subject to repair:

Material: Cross-section shape:

brick circular

concrete heightened circular

steel egg

cast iron bell

vitrified clay parabolic

other............ other............

Cross-section sketch

Dimensions:

Inner diameter (mm)

Width/height (mm)

Length of the section subject to repair (mm)

Technical sewer condition according to ATV M127P-2:condition II condition I condition III

Damages to the sewer:

Transverse scratches: hair cracks open

Longitudinal scratches on the roofing: hair cracks open

Sewer bending: partially totally

Max. narrowing comparing to the original shape: vertical (mm) horizontal (mm)

Leaks at joint Infiltration others

Defects, chippings Exfiltration

Chemical degradation Incustation

Appendix A - Data Sheet -

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Loads

Soil cover above the roofing of the repaired pipeline

hmax= hmin=

Underground water level above the bottom of the repaired pipeline

hwmax= hwmin=

Traffic loads

LKW 12 SLW 30 SLW 60 one-truck railway

Any other loads (N/mm2) multi-truck railway

Type of native soil in the zone of the repaired pipeline:

DPr compaction or EB module

G1 (%) (MPa)

G2 (%) (MPa)

G3 (%) (MPa)

G3 (%) (MPa)

Assembly conditions

Assembly chamber well working chamber

chamber dimensions (m)

Scope of the sewer renovation

invert channel the whole circumference unit panel length

straight section (m)

bend (m)

Specific gravity of the interpipe filling γ= filling pressure (bar)

Operational conditions Hydraulic conditions

Type of waste water:

domestic water sewer bottom gradient (%)

rain water

mixed water required flow rate (l/s)

mixed water

other............................

waste water temperature (oC)

Notes:

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Egg shape 2:3 Egg shape 2:4 Egg shape 2:3.5 Egg shape 2:2.5

3r

2r

r/2

3r

r

4r

2r

3.5r

r/2

r

2r

3.5r

3r

r/2

r

0.917r

0.583r

3r/2

2.5r

2r

r 3r/4 r/4

7r/4

r/2

A=4.594r2

lu=7.930rrhy=0.579r

A=6.254r2

lu=9.720rrhy=0.643r

A=5.492r2

lu=8.851rrhy=0.621r

A=3.822r2

lu=7.031rrhy=0.544r

Egg shape 2:2 Pear shape 2:2.5 Mouth shape 2:1.5 Mouth shape 2:2

2r

2r

11r/16r 5r/16

1.5r

r/2

21r/

16

2.5r

2r

r

1.3r

0.8r

2.4r

0.7r

1.5r

2r

rr/

23r/8 5r/8

2r

2r

2r

3r/8 5r/8

r2r

r/2

r/2

A=3.100r2

lu=6.283rrhy=0.493r

A=3.976r2

lu=7.148rrhy=0.556r

A=2.378r2

lu=5.603rrhy=0.424r

A=3.378r2

lu=6.603rrhy=0.512r

Mouth shape 2:1.75 Mouth shape 2:1.25 Mouth shape 2:1 Helmet shape 2:2

b=2r

h=1.

75r

0.41

9r0.

331r

2r

r/4

r

1.25

r

2r

r/3

3r/8 5r/8

r/6

3r/4

r

2r

2r

rr

0.44

2r0.

558r

3r

0.384r

3r/2

2.5r

2r

1.08

1r

r

r

2r

0.41

9r

r/4

A=2.890r2

lu=6.140rrhy=0.471r

A=1.936r2

lu=5.170rrhy=0.374r

A=1.609r2

lu=4.921rrhy=0.327r

A=4.389r2

lu=7.639rrhy=0.575r

Heightened circular shape 2:3

Heightened circular shape 2:2.5

Parabolic shape 2:2 Kite shape 2:2

2r

3r

r

r

r

2r

2.5r

r

rr/2 2r

2r

7r/4

r/2

r/4

1.5r

r/2

r

2r

2r

r

r/2

r/2

A=5.142r2

lu=8.283rrhy=0.621r

A=4.142r2

lu=7.283rrhy=0.569r

A=3.007r2

lu=6.283rrhy=0.479r

A=2.921r2

lu=6.127rrhy=0.477r

Appendix B - Design Samples -

other shapes on request

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Utmost care has been taken to ensure that all the contents of this brochure are accurate. However, AMIANTIT and its subsidiaries do not accept responsibility for any problems which may arise as a result of errors in this publication. Therefore customers should make inquiries into the potential product supplier and convince themselves of the suitability of any products supplied or manufactured by AMIANTIT and/or its subsidiaries before using them.

AP

-Am

iren

V3

09-1

0 E

NG

Distributed by:

AMITECH Service AG Turmstrasse 286300 Zug-SteinhausenSwitzerland Phone: + 41 41 748 07 20Fax: + 41 41 748 07 [email protected]

Documents

GRP non - circular Pipe Systems - Saudi Arabian … · GRP non - circular Pipe Systems for Construction and Renovation of Sewer Systems