Composite Pipe Solution

COMPOSITE PIPE SOLUTION
STEEL REINFORCED PE SPIRAL- CORRUGATE PIPE
KONTI KAN - SRP

- HIGH RING STIFNESS PIPE
SN 10- SN 16 New solution
ISO 9001:2008 No. 01442/0 ISO 14001:2004 No. 00211/0
There are big demands of large diameter drain pipes at the global market, especially for infrastructure projects. Nowdays in contemporary projects concrete pipes are used as the only solution with all its minuses, only because so far the plastic corrugated pipes as well as the pipes with spiral wall havent met the requirements for high stiffness yet. The outcome of this common problem was our work on developing the new product KONTI KAN-SRP composite and steel reinforced PE spiral and corrugated pipe, which can reach high ring stiffness from SN10 up to Sn16.
DESCRIPTION OF THE PRODUCT
Steel reinforced PE spiral and corrugated pipe SRP- KONTI KAN COMPOSITE PIPE has three layered reinforced structure. The pipe is composed by HDPE layers (inner and outer) and U shaped steel band, The inside HDPE tube is formed by wrapping of the PE sheet, and the steel band is pre-coated with adhesive resin.The steel and the HDPE are wrapped around the mandrel and bond together so that they can form one integrated spiral-corrugated pipe. The steel provides outstanding stiffness and the outer PE layer protects the steel out of corrosion. The advantages as high rigidity and strength of the steel as well as the uniqueness of this pipe come from the combination of different organic materials.
REINFORCED STRUCTURE
The elastic modulus of carbon steel is 200 times higher than polyethylene, by combining the advantages of both steel and plastic we developed a composite pipe suitable for application in buried sewage pipe systems, with outstanding anti-corrosive properties and easy installation process.
www.konti-hidroplast.com.mk
contact@konti-hidroplast.com.mk
STEEL AND POLYETHYLENE BONDING

The mechanical bond between the steel U-shaped plate and the polyethylene is stronger then the tensile strength of the polyethylene resin, and this is the major reason why this pipe came out to be so successful option. The bonding between the steel and the polyethylene layer is extremely strong and there is absolutely no chance of separation of any two layers in any way. The process of the bonding is developing in that way so the steel band is pre-coated with a special bond resin in order to create a medium layer between the steel and the plastic, meanwhile the processing temperature, pressure an press-cooling time are strictly controlled, to ensure that the fusion and the bonding are developing under the best proper conditions. The other process point is to protect the metal layer out of corrosion. In SRP pipes, the steel i completely covered with polyethylene so the liquids, air and soil can not contact with the steel reinforcement which guarantees the anti-corrosive performance of the SRP pipe. With the new wall structure, the pipe system can easily reach high ring stiffness up to SN 16 (based on testing by ISO 9969), in other hand when it comes to the weight of the pipe its obiously lighter than other competitive pipes.
Polyetylene Stell Reinforce Vee Shape Plate Polyetylene
FLEXIBLE VERSUS RIGID PIPE

Pipes on the market are generally fall into two categories : flexible pipe and rigid pipe. There is a classification of type of pipe according to performance during interaction with soil ( before permanent damage to the structure , as follow: Pipe classification rigid Semi-rigid flexible % of deflextion before damage 0.1% <0.3% >3.0%
Flexible pipe are manufactured from plastic, metal or their combination. These materials have different mechanical characteristics. Metal present with elastic properties whereas plastic present with viscoelastic properties, where the influence of time is noticeable. In case of combination of metal with plastic, our SRP pipe, make collection of their properties which gave one stable flexible pipe with balance of elastic and viscoelastic properties of both material. Flexible pipe benefit from their capacity to move or modify under loads without structural damage. The principal materials of flexible pipe are HDPE, Steel, SRP and aluminum.. Flexible pipes are generaly defined as those pipes that accept a certain deflection without structural damage. This deflection or distortion enables the pipe to adapt to the shape of the outside casing, the vertical loa is thus transferred for the most part to the outside casing, which is the backfield and the soil. Rigid pipe materials such as glazed clay, GRP, reinforced or non reinforced concrete have a minimum deflection tolerance before reaching the acceptable limit of cracking. To illustrate, figure below show the difference of ultimate performance of flexible and rigid pipe under load.
Cracking
under application of ultimate load with time
Flexible igid
Both , flexible and rigid pipes required and appropriate backfield , even though the interaction of the pipe with the backfield is different. That is, the flexible pipe works with the backfield , and the load is transferred by the wall to the foundation. For both types of material ,the choice of good backfield, and the load is transferred and carried bt the backfield . In the case of the rigid pipe, the load is transferred by the wall to the foundation. For both types of material, the choice of good backfield and compaction material is very important to enable this transfer of load. Figure below( strana 5) show the interaction between backfield and pipe as well as the transfer of load.
Flexible
Rigid
Flexible pipe offers significant structural offers significant structural advantages to the project designer. In many situation, a flexible pipe correctly installed can be buried much deeper than a rigid pipe installed in a similar manner, because of the interaction pipe/backfield. A rigid pipe is often stronger that the surrounding backfield material, leading to the necessity to support soil loads much greater then the prism load over the pipe. On the other hand, flexible pipe is not as strong as the surrounding backfield, thereby forcing a mobilization of the surrounding backfield casing in order to sustain the dead weight and the live weight. The interaction between flexible pipe and the backfield is extremely efficient in maximizing the structural characteristics of pipe, permitting the installation of pipe in very deep installation, many times superior to the covering admissible for rigid pipe in an identical installation.
STRUCTURAL ACTION
When flexible pipes is submitted to vertical pressure, the soil surrounding the pipe is compressed and the circular shape of the pipe becomes and ellipsis with a horizontal increasing of the diameter of Dx and a decrease of the diameter of Dy. These distorsion are desirable up to certain point beyond whichthe pipe /soil system can no longer accomplish the task for which it was designed. The vertical deflection is generally limited to 7% for a flexible pipe.
F (kN/m) Y/2 (mm)
/2 (mm) dint dext
/2 (mm)
The distorsion of the pipe is linked in part to its rigidity and to its casing. The first factor is determined by its own structure without support and the second factor is linked to the relationship/soil.
PIPE IN BACKFIELD
Flexibility is a desirable attribute of buried pipe. As previous indicated , the flexible pipe connects with the surrounding soil to establish a structure/pipe unit, which is the principal key to as successful design. A buried pipe and the adjacent casing of soil will support the dead load and the live load according to the fundamental principle of structural analysys: the stiffest element attract a larger proportion of shared load than those that are more flexible.This principal is illustrated in figure below (slika strana 9) which show the effect of load bearing of the soil surrounding a flexible pipe,properly embanked and compacted. For the flexible , the soil is more rigid , which creates a lateral support , reducing the possibility of deflection and thereby enabling the development of soil stopper, a necessary condition for the formation os a structural arch on the pipe. A second condition required for the formation of the arch is achieved when the resistance to intergranular cutting of soil correctly compacted for a certain distance over top of the pipe is mobilized to maintain its geometry . The direct load on the crown of the pipe is mobilized to maintain its geometry. The direct load on the crown of the pipe is the part between the crown an dthe soil arch.See the dotted line. The rectangular prism of the soil stretches from over the surface of the pipe to over the top of the backfield , with a base exactly equal to the width of the external dimensions of the pipe.In contrast, a rigid pipe by its structure incorporates a column of load into the prism load,mwhich gives a triangular prism and leads to a greater load.
ADVANTAGES
SRP pipe technology provides clients and contractors with the following key benefits: Strenght - :Long-term high ring stiffness Stronger than usually expected ring stiffnes SN10, SN16and Sn20 Durability:Unique combination of HDPE and steel Flexibility: Structurally flexible, yet with outstanding long-term stiffness High deformation resistance and mechanical strength High impact resistance Installation: Easy and fast installation Environment: Significant reduction in material consumption and transport Cost benefit: Reduced installation and whole life spand costs Anticorrosive and wear proof properties of plastics Large diameter available up to ID 2200mm Long life spand
The newly developed process of plastic-steel bonding, and formig technology makes the pipe reliable composite and with high performance. The specially designed steel bending device can form the reinforced layer easily. When it comes to the production line itself it is flexible and adjustable which means the dimensions can easily be changed to different size. This is the most economical solution for large size sewage pipeline systems. The innovative pipe provides high stiffness, less weight and low cost.
MATERIAL
The material used for production of SRP-KONTI KAN COMPOSITE PIPE contains the following: Inner Layer: 100% Polyethylene pipe grade, without the presence of any form of recycled material. Outer Layer: 100% Polyethylene pipe grade, without the presence of any form of recycled material. Middle Layer: Steel according EN 10130-1991, steel grade FE PO1, coated with polyethylene based adhesive.
DIMENSION RANGE
e2 de di
e1 P
Specification
OD
de
ID
di
Inner wall thick

e1
Out wall thick

e2 4.00.3 4.00.3 4.20.3 4.30.3 5.30.3 5.30.3 5.30.3
SN 10
1300 1400 1500 1600 1800 2000 2200 14147 15257 16407 17407 19647 21857 23887 13056 14136 15106 16106 18146 20156 22186 4.50.5 4.50.5 4.50.5 4.50.5 50.5 50.5 50.5
APPLICATION RANGE
- Civic buried drainpipe, sewage pipeline - Industrial waste - Seawater, rainwater pipeline - Water collection system - Water treatment works
HYDRAULIC PROPERTIES OF SRP - KONTI KAN COMPOSITE PIPE

The hydraulic characteristics are extremely good providing maximum efficiency and durability.
ROUGHNESS (KS)
The roughness coefficient of HDPE for calculation using Colebrook White formula is 0.03ks. However Sewer and Adoption and certain other standards or codes of practice state that a general roughness figure of 0.6ks should be applied, irrespective of pipe material. Where this figure is applied, SRP will in all cases function much more efficiently than the calculated design flows. If the Manning equation is used, a roughness coefficient of 0.01ks should be applied.
ABRASION RESISTANCE
Polyethylene is extremely resistant to abrasion if compared with alternative pipe products, offering much greater resistance to abrasion caused by larger solid particles and fines that are present in all sewerage systems. For this reason, polyethylene pipes are routinely used in mining and quarrying applications, and for conveyance of slurry. Testing abrasion resistance generally aims to compare relative performance of ppe materials under specific conditions which are usually more severe than those encountered in normal stormwater applications. The empirical testing used to produce the graph below consisted of charging a 0.5m long section of pipe with a quartz sand/ gravel mixture and rocking it backwards and towards. After 600.000 cycles the abrasion of the polyethylene pipe was 0.3mm compared to a value of 1.2mm of concrete.
FLOW RATE TABLE PIPE FILLING 90%

Flow calculation Flow: Q=A*C*R1/2*I1/2 (l/sek) Chezy coefficient: C =1/n*R2/3*I1/2 Q=A*1/n*R2/3*I1/2 where: A- circular section of the pipe (m2) R - hydraulic radius (m) I -slope of trench (m/m) Velocity calculation Velocity:V =C*R1/2*I1/2(m/s) C =1/n*R2/3*I1/2 V = 1/n*R2/3*I1/2 where: R - hydraulic radius (m) R- hydraulic radius for full pipe =ID/4 I - slope of trench (m/m) Manning number n=0.010
SLOPE m/m
1/1000 0,001 2/1000 0,002 3/1000 0,003 4/1000 0,004 5/1000 0,005 6/1000 0,006 7/1000 0,007 8/1000 0,008 9/1000 0,009 10/1000 0,01 15/1000 0,015 20/1000 0,02 30/1000 0,003 40/1000 0,04 50/1000 0,05
DN ID
Q (l/s) V (m/s) Q (l/s) V (m/s) Q (l/s) V (m/s) Q (l/s) V (m/s) Q (l/s) V (m/s) Q (l/s) V (m/s) Q (l/s) V (m/s) Q (l/s) V (m/s) Q (l/s) V (m/s) Q (l/s) V (m/s) Q (l/s) V (m/s) Q (l/s) V (m/s) Q (l/s) V (m/s) Q (l/s) V (m/s) Q (l/s) V (m/s)
1300 1300
1848,60 1,39 2614,32 1,97 3201,88 2,41 3697,21 2,79 4133,60 3,12 4528,14 3,41 4890,95 3,69 5228,64 3,94 5545,81 4,18 5845,80 4,41 7159,61 5,40 8267,21 6,23 10125,22 7,63 11691,60 8,81 13071,60 9,85
1400 1400
2252,52 1,46 3185,55 2,07 3901,49 2,54 4505,05 2,93 5036,80 3,27 5517,53 3,59 5959,62 3,87 6371,10 4,14 6757,57 4,39 7123,11 4,63 8723,99 5,67 10073,59 6,55 12337,58 8,02 14246,21 9,26 15927,75 10,35
1500 1500
2707,52 1,53 3829,01 2,17 4689,56 2,66 5415,03 3,07 6054,19 3,43 6632,03 3,75 7163,42 4,06 7658,01 4,34 8122,55 4,60 8561,92 4,85 10486,17 5,94 12108,38 6,86 14829,68 8,40 17123,84 9,70 19145,04 10,84
1600 1600
3215,99 1.60 4548,09 2,26 5570,25 2,77 6431,97 3,20 7191,16 3,58 7877,53 3,92 8508,70 4,23 9096,18 4,53 9647,96 4,80 10169,84 5,06 12455,46 6,20 14382,33 7,16 17614,68 8,77 20339,69 10,12 22740,46 11,32
1800 1800
4402,72 1,73 6226,38 2,45 7625,73 3,00 8805,43 3,46 9844,77 3,87 10784,41 4,24 11648,49 4,58 12452,76 4,90 13208,15 5,19 13922,61 5,47 17051,64 6,70 19689,54 7,74 24114,67 9,48 27845,22 10,95 31131,90 12,24
2000 2000
5830,96 1,86 8246,23 2,63 10099,52 3,22 11661,93 3,71 13038,43 4,15 14282,88 4,55 15427,28 4,91 16492,45 5,25 17492,89 5,57 18439,12 5,89 22583,22 7,19 26076,86 8,30 31937,50 10,17 36878,25 11,74 41231,14 13,13
2200 2200
7518,32 1,98 10632,50 2,80 13022,10 3,43 15036,63 3,96 16811,46 4,42 18416,04 4,85 19891,59 5,24 21265,01 5,60 22554,95 5,94 23775,00 6,26 29118,31 7,66 33622,93 8,85 41179,51 10,84 47550,00 12,52 53162,52 13,99
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CHEMICAL RESISTANCE
The HDPE bore of SRP-KONTI KAN COMPOSITE PIPE offers excellent resistance to all substances that would routinely be discharged into sewerage systems, including water with high saline contents,fuels,acids and most chemicals. Additionlly, unlike concrete based products, polyethylene is completely resistant to sulphates and can therefore provide significantly better long term performance. Further information related to chemicals resistance and performance against a comprehensive list of specific chemicals is available on our web site.
200,000 400,000
Asbestos cement
Fibr eglass
concrete Vitrihed Clay PVC HDPE

600,000
Number of Lload Cycl es
DELIVERY, HANDLING AND TRANSPORTATION ON SITE

Pipes, pipeline component and joint accessories shall be inspected immediately after delivery to ensure that they are appropriately marked and comply with the desired requirements.Product shall be examined both on delivery and immediately prior installation to ensure that they are free from damages. SRP PIPE is robust, reltive light and easy to handle, however care must be taken to prevent damage during handling and unloading. Pipes should not be dropped, thrown or dragged. Pipes that require mechanical lifting should be supported in two evenly spaced positions, adequate protection should be placed between chains and the pipe. In that case the external corrugation will prevent pipes from slipping. See picture.
STORAGE
Pipes should be placed or stacked on flat surface free of protrusions and large debris, oe in built boxes. Important: Pipes shall be secured to prevent rolling. Excessive stacking height should be avoided so that pipes in the lower part of the stacks are not overloaded. See picture.
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INSTALATION
Lightweight Pipes and tanks manufactured using SRP technology are significantly lighter then conventional plastic, concrete or clay products. Robust- The combination of polyethylene and steel provides extremely robust products that can easily withstand routine site handling. For construction, installation and testing after drain and sewer pipelines has been installed normally buried in the ground and normally operating under gravity is applicable standard En1610.
INSTALATION GUIDE
Standard trench
BEDDING
Bedding material should be laid Evenly along the trench bottom.
h1
DN
Granular material
b
b = (DN/10)+10 b : Height of bedding (cm) DN: Nominal diameter (cm) h1= DN/2 h1 : Height of embedment (cm) (Max. 30 cm)
WORK AREA DN (mm) L (mm) 200-350 150 400-500 200 600-900 300 1000-1600 450 1800-2600 600
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PIPE LAYING
Pipes should be laid to the correct line and level on the bedding material, taking care to ensure that there are no voids underneath any part of the pipe. The backfill materials must be coated in layers, in filling both sides of the pipe in trench. Compacting the native soil for the backfill is not required except for the road crossings (30cm from the crown) Damaged (crushed, punctured, scratched, etc.) pipes should not be used. The water in the soil should be drained during installation. If there is any risk of flotation or movement of the pipes occurring prior to backfilling the trench, the pipes should be fixed in place with pegs or other suitable holding devices. The backfill height should be min h=100cm considering the regional frost affects. The granular materials with high ability of compaction should be preferred in the bedding zones and for the material surrounding the pipe. If the excavated material is suitable for use as backfill material, the pipe can be directly laid on the cleared trench bed. If the soil contains mud and clay, it should be compacted with fine, coarse grained materials. In extremely loose grounds, the trench wall should be either sloped or sheeting shoulf be applied to the trench walls for workmanship safety.
MRP pipes(Metal reinforced polyethylene pipes) are manufactured in SN 10kN/m2-SN 20kN/m2 stiffness classes. The metal reinforcement elements in polyethylene parts of MRPpipes provides extra ring stiffness to the pipe. MRP pipes are economic solutions compared to other arge diameter or HDPE, PP stiffness to the pipe. MRP pipes are economic solutions compared to other large diameter or HDPE, PP (polypropylene) corrugated pipes and RC (reinforced concrete) pipes. Dependable of the national regulative it is possible not to backfill material properties and compacting capabilities to be required.
13
CONNECTION
The connection of the pipe could use various joint like plastic welding, electrofusion and welding, different solution of socket and gasket connection, stainless steel couple or heat shrinkable couple dependable on the installation conditions but as most reliable and most efficient solution with strong watertightness is our solution:
INCORPORATED SOCKET AND GASKET CONNECTION

Multiple connecting methods, strong connecting: Electro thermal welding, thermal shrinkage, internal and external extruding,welding or different connecting methods can be used at the same time, the strong connection ensures no leakage of the pipes.
1. First ensure that the spigot ends of both pipes, that are about to be jointed are clean of any kind of dirt or remains of debris. 2. Place the flexible coupling over the end of the receiving pipe making sure that the fixings (screws of bolts) are positioned about 30 around from thw top of the pipe.The coupling should be placed such that the end of the pipe spigot meets the centere point of the width of the coupling. The easiest way to do this is to mark an appropriate line on the spigot prior of placing the coupling. Gently tightnen the fixings on that half of the coupling so that the coupling will retain its position. 3. Carefully lift the adjoining pipe slightly and locate the spigot inside the coupling until the two spigot ends are approximately 10mm apart (to allow for a small amaunt of movement)ll retain its position.
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JOINT & MANHOLE

There are available range of bends that can be used with MRP pipe. They ae manufactured with cutting and welding pieces of SRP. Solution for connection with ipe can be done on no one of the above mentioned jonting solution.
STANDARDS
Specific standards for SRP pipe have been developed ASTM F 2435-05 and it is intended that a similar standard will be eveloped for the European market. In the absence of a specific, appropriate standard for SRP pipe in Europe, to provide complete confidence in relation to comparative performance against exsisting, recognized standards for structural wall plastic pipes, SRP KONTI KAN CMPOSITE PIPE has been independally tested in accordance with the following standards: EN13476 Thermoplastic piping systems for non-pressure underground drainage and sewerage. Structured wall piping system. DIN 16961 Plastic pipes and fittings with profiled outer and smooth inner surface. EN 9969 Determination of ring stiffness EN 744 Resistance of External blows by the round clock method. EN 1446- Determination of Ring Flexibility.
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Tel: 00 389 34 212 064 00 389 34 211 757 00 389 34 215 225 00 389 34 215 226 Fax: 00 389 34 211 964 e-mail: contact@konti-hidroplast.com.mk e-mail: hidropl@t-home.mk www.konti-hidroplast.com.mk Industriska bb 1480 Gevgelija MACEDONIA
Representatives
Bulgaria: 00 359 287 081 48 00 359 296 590 77 Serbia: 00 381 21 444 662 00 389 71 315 210 Kosovo 00 389 02 246 846 00 389 70 244 291 Albania 00 355 67 2022 043 00 389 75 221 043 00 355 42 419 304 e-mail: info@kontihidroplast-al.com B i H Montenegro 00 389 71 315 210 Croatia 00 385 91 3234 335
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Composite Pipe Solution

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Composite Pipe Solution

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COMPOSITE PIPE SOLUTION

STEEL REINFORCED PE SPIRAL- CORRUGATE PIPE

KONTI KAN - SRP

DESCRIPTION OF THE PRODUCT

STEEL AND POLYETHYLENE BONDING

FLEXIBLE VERSUS RIGID PIPE

F (kN/m) Y/2 (mm)

/2 (mm) dint dext

Inner wall thick

Out wall thick

HYDRAULIC PROPERTIES OF SRP - KONTI KAN COMPOSITE PIPE

FLOW RATE TABLE PIPE FILLING 90%

concrete Vitrihed Clay PVC HDPE

Number of Lload Cycl es

DELIVERY, HANDLING AND TRANSPORTATION ON SITE

INCORPORATED SOCKET AND GASKET CONNECTION

JOINT & MANHOLE

desing PRINT CHAOS 2011

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