Kabuflex Installation manual

Transcription

1 Kabuflex Installation manual ,5 1 1,5,5 3 3,5 4 4,5 5 Last modified: April 011 DRAINAGE SYSTEMS ELECTRICAL SYSTEMS BUILDING TECHNOLOGY INDUSTRIAL PRODUCTS

2 Table of contents Kabuflex cable ducts Preliminary remarks 1 Transport and storage 3 Trenching and bedding 3 3 Straight or evenly bent installation 3 4 Backfilling and compaction 4 5 Spacers 4 6 Change of direction of cable duct 5 7 Pulling string and cable insertion, insertion lengths 6 8 Cutting Kabuflex cable ducts to lengths 6 9 Connecting cable ducts and accessories 6 10 Connecting cable ducts to cable (laying) chutes 7 11 Standard statics for polyethylene (PE) cable ducts 7 1 Occupancy factor and dimensioning of cable duct 7 Instructions for correct installation of Kabuflex polyethylene (PE) cable ducts Structured wall pipe according to DIN EN FRÄNKISCHE Drainage SystemS

3 Preliminary remarks Adhere to applicable standards and regulations, such as DIN EN 1610, ZTV A-StB 97, DWA-A 139, and (in excerpts) A 535 of the Association of the Plastic Pipe Industry (Kunststoffrohrverband (KRV)) and additional rules and regulations of utility companies. For areas of the roadbed, also adhere to the guidelines for the backfilling of cable trenches ( Merkblatt für das Verfüllen von Leitungsgräben ) of the German Road and Transportation Research Association (Forschungsgesellschaft für Straßen- und Verkehrswesen (FGSV)). Coupling 1. Transport and storage of cable ducts and accessories Handle with care! Do NOT drop pallets, cable ducts and accessories! In general DIN EN 1610 applies. Prior to installation, check cable ducts and accessories for possible damage in transit. Make sure cable ducts are stored on a level and even surface! Do NOT stack loose cable ducts more than 1.5 metres high. (Pallets may be stacked to a maximum of high).. Trenching and bedding The provisions of DIN Earth works, DIN Timbering to trenchwork, DIN 414 Excavations and trenches and DIN EN 1610 apply. Bedding and backfill of the cable ducts (stoneless, compactable soil!) profoundly affects the deflection behaviour of the cable ducts! Thoroughly prepare bedding and backfilling according to DIN EN 1610, DWA-A 139 and KRV A 535! 0.15 m (Sand or fine gravel) In case of a compact, rocky surface, it is necessary to place a 0.15 m thick layer of stoneless material (sand, fine gravel) as base bedding layer (See DIN EN 1610 and KRV A 535). 3. Straight or evenly bent installation Lay cable ducts in straight lines on bedding and laterally embed the cable ducts. If cable ducts are not laid in straight lines, the maximum possible insertion length will be considerably reduced. Also, make sure to make a dent to accommodate the protruding coupling to accurately and evenly lay the cable duct. FRÄNKISCHE Drainage SystemS 3

4 4. Backfilling and compaction Backfill the cable duct simultaneously on both sides with stoneless, compactable soil (maximum grain size: 0 mm) in layers up to 30 cm. Overlay material directly above the cable duct must be hand compacted; mechanical compaction directly above the cable duct cannot commence until at least 30cm of cover are provided over the crest. The minimum depth of the cover directly above the cable duct, before mechanical compaction directly above the cable duct can commence, depends on the choice of compaction equipment. Prevent sideways movement of pipes during compaction operations. If necessary, secure the cable ducts in their horizontal position during backfill operations. If several layers of cable ducts are laid in a trench, each layer of cable ducts must be embedded (backfilled and compacted) separately, before the next layer is laid on top of it! Then conduct backfilling and compaction as described. If the minimum depth of cover of 50cm is not met in trafficked areas, measures must be taken to distribute the weight of the load (e. g. embedment in concrete), e. g. the trench fill is a mixture of sand and cement (See guidelines for the backfilling of cable trenches ( Merkblatt für das Verfüllen von Leitungsgräben ) of the FGSV). Make sure that the joints are watertight when embedding the cable ducts in concrete (with profile sealing ring, inserted into the second corrugation trough) and secure cable ducts against uplift! Make sure that the cable duct is not damaged by the choice of anti-uplift device. Determine spacing between spacers to make sure that the cable duct does not sag or deflect (approx. 1.5 m spacing). Preferrably use cable ducts in straight lengths to ensure correct axial alignment of the cable ducts during embedment in concrete. Note Please contact us to verify the product suitability of Kabuflex for their use in specialty applications or application in tunnel engineering. Sidewalk Sidewalk Ü < 50cm Trench Compactable backfill material Concrete B 15 Ü = cm Trench Construction steel mat Concrete B m Cable duct Cable duct Gravel sand mixture Sand Cover cable duct up to 30 cm over crest with stoneless, compactable soil by hand and compact trench. Cable ducts embedded in concrete where the minimum cover is not met (also See KRV A 515/A 535 for examples). Protect layer of cable ducts against deformation and mechanical damage if minimum depth of cover is not met (also See KRV A 515 for examples). 5. Spacers Use spacers to secure the cable ducts if cable ducts are laid in several layers in the trench. Plan spacing according to site requirements. Recommendation 1.5 m maximum spacing, for Kabuflex R also shorter spacing! Kabuflex DN 110/8 spacer 4 FRÄNKISCHE Drainage SystemS

5 6. Change of direction of cable duct Although Kabuflex R in coils can accommodate very small bending radii, we recommend that you avoid small bending radii in order not to prevent or make smooth cable insertion more difficult. Premanufactured 45 or 90 degree bends for Kabuflex S cable ducts in straight lengths (see table) serve as a reference for the smallest bending radii possible. L 45 and 90 degree bends of cable ducts, nominal diameter and radius R of the bend of the cable duct (inside bend) R degree DN R [m] Table: Kabuflex dimensions and bending radii However: Consider installing a cable chute after sharp turns! Kabuflex S pipes in bars D a [mm] 1 D i [mm] 1 R min [m] DN DN DN Kabuflex S DN DN DN DN Kabuflex R pipes in coils D a [mm] 1 D i [mm] 1 R min [m] DN DN DN DN Kabuflex R DN DN DN DN DN Production-related tolerances Minimum bending radius valid at an ambient temperature of 0 C. We recommended that you increase the minimum bending radii at lower temperatures (multiply by 1.5 x at approx. 10 C, multiply by x at approx. 0 C). FRÄNKISCHE Drainage SystemS 5

6 7. Pulling string and cable insertion, insertion lengths Pulling string Kabuflex R The factory-supplied pulling string in the Kabuflex R cable duct helps to insert the cable insertion wire or rope, NOT to insert the cable! A number of irregularities and bends in the routing increase the pull-in forces required and reduce the possible insertion length with the pulling string. Always loosen the cord ends that are attached to the cable duct before installing the cable duct. Never connect cable ducts and couplings with the cord ends attached to the cable duct. Remove the pulling string prior to installation if it is not needed! Tie two string ends together if the pulling string is needed to insert the cable insertion wire. Before uncoiling the cable duct (coil), only loosen the string at the duct end with extra string length (ball), open the ball and attach the end of the string to the outer wall of the cable duct. Then uncoil the cable duct. Cable insertion Kabuflex S and Kabuflex R The following factors are decisive for the insertion length possible: n Cable (type/weight/flexibility) n Routing (elevation profile, number/position/radii of turns/inaccuracies) n Friction coefficient (cable/duct wall) n Lubricant (type/amount) n Insertion method and velocity (also surface temperature) n Ratio of inside diameter of cable duct to diameter of cable n Installation quality (bedding/compaction of bedding material = affects deflection of cable duct, backfilling/compacting the backfill material around the cable duct bends/turns = also important for absorbing mechanical stress that occurs during cable insertion), also the permissible tensile forces (cable) Ensure thorough installation and small spacing between spacers, particularly for Kabuflex R (insertion forces)! Under the same conditions, larger insertion lengths are possible for Kabuflex S. Manufacturer is not able to make a statement on maximum insertion lengths due to the large number of factors that cannot be exactly determined. Always make sure that a sufficient amount of lubricant is used! 8. Cutting Kabuflex cable ducts to lengths If necessary, use a fine tooth saw or a suitable knife; make sure the cut is straight and exactly in the centre of the corrugation trough! It is important that the cut is exactly in the centre of the corrugation trough so that the coupling can be securely engaged to the cable duct! Use scraper, planer or file to remove burrs and irregularities. 9. Connecting cable ducts and accessories Sand tight joints SD: (IP-Code 54) EN 6059 n Clean spigot end and coupling. n Insert spigot end into coupling until it reaches the stop point. Water tight joints WD: (IP-Code 68) EN 6059 n Clean spigot end, inside of coupling and sealing ring. n Slide sealing ring onto spigot end (into second corrugation trough). n Lubricate sealing ring and coupling. n Insert spigot end into coupling until it reaches the stop point. Note In case of a water tight joints, ensure thorough and clean installation with sealing ring. The test requirements of the DIN EN 1610 apply. 6 FRÄNKISCHE Drainage SystemS

7 10. Connecting cable ducts to cable chutes Use our wall collars to connect cable ducts to cable chutes (shafts, etc.)! Take appropriate precautions when crossing other installations (e. g. required spacing according to A 515, A 535 of the KRV). Other installations High voltage cables/installations 0.3 Other telecommunication installations 0.3 Gas and water lines 1.0 Other supply and discharge lines 0.3 Long distance heating installations 1.0 Safety distance of telecommunication installations in crossing region/ approaching region [m] Table: Safety distances in the crossing or approaching region of other installations (acc. to A 515 of the KRV) 11. Standard statics for polyethylene (PE) cable ducts The chart shows the exemplary expected deflection values for Kabuflex S DN 110 (single cable duct installation) with an increasing depth of cover and taking into consideration the following installation conditions. It is assumed that the cable ducts were installed properly according to relevant guidelines Permissible deflection value Embankment, SLW 60 The following installation conditions apply: n Kabuflex S DN 110 n Single cable duct installation n Embankment n Cover m n Traffic load HGV 60 Note The calculation method according to ATV-DVWK-A 17 can be applied to single cable duct installation only! Refer to our installation manual and the A 535 of the KRV for multiple layers of cable ducts! Deflection in [%] G1, 95% DPr Cover in [m] n Trench: Soil class G1/ non-cohesive soil, degree of bedding 180, gravel/sand bedding n Surrounding soil and backfill G3 with 95 % D Pr 1. Occupancy factor and dimensioning of cable duct Chose occupancy factor or minimum inside diameter of the cable duct, taking into consideration the conditions prevailing at the installation site, and type and diameter of cable (See particularly Sections 6 and 7): Note If multiple strands of cables are inserted into a cable duct, take the below formula for dimensioning into consideration: Type of pipe Occupancy factor Kabuflex S 35 % 1.70 Kabuflex R 5 %.00 Ratio of inside diameter of cable duct to diameter of cable with single cable occupancy Kabuflex R Kabuflex S Occupancy factor Constant a R S 0 %.4 R S 5 %.00 S 30 % 1.83 S 35 % 1.70 d Ri = a d 1 + d... + d n d Ri...Inside diameter of Kabuflex cable duct d n...outside diameter of cable a...constant depending on the occupancy factor The information given in this document about possible applications is based on our present knowledge. Please contact our application engineering department if your application is not mentioned or in case of special installation techniques. Customer is, however, responsible for verifying the product suitability for their intended use; it is not our responsibility. Please read our general terms and conditions of sale. FRÄNKISCHE Drainage SystemS 7

8 Focused on the future FRÄNKISCHE is a third generation family owned business that was established in 1906 and is today run by Otto Kirchner. We are industry leader in the design, manufacturing and marketing of technically superior corrugated pipe systems for drainage, electrical, building technology and industrial applications. Sustainability, innovative thinking on products and customer focused service are at the heart of our business. At our corporate headquarters in Königsberg and at our domestic and foreign production facilities and sales offices, our employees are committed to developing innovative solutions. FRÄNKISCHE Your partner for sophisticated and technologically advanced solutions. Production facilities: Fränkische Rohrwerke/Königsberg (headquarters) Fränkische Rohrwerke/Bückeburg Fränkische Rohrwerke/Schwarzheide Fraenkische USA, LP (Anderson/SC, USA) Fraenkische CZ s.r.o. (Okřišky, CZ) Fraenkische Pipe-Systems (Shanghai) Co., Ltd. (Anting/Shanghai, CN) Fränkische Advanced Solutions AG (Rebstein, CH) Frankische Tunisie SARL (Ben Arous, TN) Sales offices: David Robbens Underfloor Heating Systems Ltd (St. Leonards-on-Sea, GB) OOO Fraenkische RUS (Moscow, RUS) Fränkische Ibérica, S.L. (Yeles/Toledo, E) Fraenkische France SAS (Nancy, F) Fraenkische Industrial Pipes India Private Limited (Pune, IN) FRÄNKISCHE ROHRWERKE Gebr. Kirchner GmbH & Co. KG Königsberg/Germany Phone Fax info.drain@fraenkische.de E.1170/ FRW Subject to change without notice Cat. no