Sewage and rainwater. Experience the leading G-PIPE system! G-PIPE system. PP system SN 8 DN/ID 150 mm DN/ID 1000 mm. With innovation from

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1 Sewage and rainwater Experience the leading G-PIPE system! G-PIPE system PP system SN 8 DN/ID 150 mm DN/ID 1000 mm With innovation from

2 ALPRO-ATT corrugated GIGAPIPE system Leading Pipe Technology for Convincing Solutions. The innovative approach, Corrugated Pipe Solutions, offered by ALPRO-ATT, is a contribution to solving the water problems caused by the world s rapidly increasing population and the consequences of global warming. Over the last few decades, ALPRO-ATT has gathered experience in the development and production of intelligent pipe systems and in doing so has accumulated competence offering process-optimised machines and services tailored to the pipe industry. These represent some of the foundations of successful cooperation with partners across the globe. On the one hand, the consequences of global warming, further industrialisation, strongly increasing tourism and progressive agglomeration are issues which require immediate efforts, although, on the other hand, these circumstances are establishing excellent chances at the same time. Invest in the growth markets of today for tomorrow: With ALPRO-ATT, the partner for sewage and rainwater drainage systems!»the ALPRO-ATT GIGAPIPE system offers me leading pipe technology with excellent advantages in quality, lifetime and profitability. «2

3 CORRUGA TED PIPE SOLUTIONS WIN-WIN PA RT NERSHIP AFTER SALES SERVICE WA TER- MANAGEMEN T ENGINEERIN G CONSUL TIN G MACHINER Y MARKETIN G PIPE SYSTEM S G-PIPE system All G-PIPE pipes are produced using ALPRO-ATT s own HD series corrugated plastic pipe machines. Customers profit from DROSS- BACH s innovation and technological expertise, especially in the production of large pipes, and benefit from the durable, quality controlled G-PIPE pipes with their improved corrugated pipe technology. TECHNICAL HIGHLIGHTS: Complete sewage and rainwater system with full fitting and manhole program from ID 150 mm up to ID 1000 mm Long-term watertightness thanks to SAFECONNEC Optimised pipe design for highly secure and flexible pipes Double-walled PP pipes high chemical resistance Long service life of approximately years Resistant to high pressure jet cleaning systems (180 bar) Excellent hydraulic properties thanks to k b = 0.25 mm No incrustation Easy to install Low life cycle cost 3

4 DIN EN 13476: ! AVAILABLE PIPE SIZES (DN/ID): 150 mm 200 mm 250 mm 300 mm 400 mm 500 mm 600 mm 800 mm 1000 mm DIN EN DIN PROFILE PIPE SERIES 5 DIN EN ISO 9969 SN AREAS OF APPLICATION Sewage Rainwater drainage Sewage and mixed water channels Various special solutions for industry and public sector Ground drainage Domestic drainage 2. STANDARDS The material PP guarantees a high E modulus and ring stiffness of SN 8 as per DIN EN ISO 9969 Profiled wall range 5 as per DIN kn/m2 Authorisation based on DIN 16961, DIN EN and DIN EN Suitable for all bedding materials as per DIN EN 1610 Suitable for all normal pressure tests as per DIN EN 1610 High pressure cleaning process as per CEN/TR EN TRADEMARK G-PIPE 4. MATERIAL Pipes and moulded parts made of polypropylene (PP) 5. QUALITY REQUIREMENTS General technical approval from the German Institute for Building Technology (DIBt) in Berlin. DIBt Z CHEMICAL RESISTANCE DIN 8061, leaflet 1 The pipes, moulded parts and sealing elements are all resistant to chemicals between ph 2 (acidic) and ph 12 (alkaline) G-PIPE pipes are resistant to all sewage and ground substances as per DIN THERMAL STRESS G-PIPE pipes and moulded parts made of PP are used to transport sewage and rain water. The requirements of DIN EN 476 concerning the long-term temperature stress levels. The temperature range is between -25 C and +90 C practicable. 8. COLOUR Black profile RAL turquoise blue inside (best colour for camera inspection) 9. IDENTIFICATION Pipe Identification as per DIN EN NOMINAL MEASUREMENTS (DN) Measurements in mm ID range = interior measurements or nominal measurements: 150; 200; 250; 300; 400; 500; 600; 800; LENGTHS Standard length (without in-line belling): app. 6 m Special lengths available on request 12. MARKINGS G-PPIPE system have co-extruded markings These show which type of drainage pipe has been laid Red sewage and mixed water drain Blue rainwater drain The co-extrusion process ensures durable markings 13. ROOT RESISTANCE Tests as per DIN /DIN EN 681 prove the watertightness and root resistance 14. RECYCLING Almost all thermoplastics, including PP, can be reused for processing new products

5 Lighter More solid Long-term watertightness Material comparison G-PIPE corrugated plastic pipes are lighter and at the same time more solid than common rigid pipes thanks to an improved corrugated pipe technology. The exceptional lightweight G-PIPE is the result of the fact that less material is used in comparison with when producing smooth plastic pipes. 30 % Deflection test Thanks to the remarkable elasticity and ring stiffness of the innovative corrugated pipe profile, G-PIPE corrugated plastic pipes are more resilient than regular pipes. Test of watertightness Special socket technology which ensures a short-term watertightness of 2.5 bar and a longterm watertightness for your reliability. SAFECONNEC: Innovative technology to secure long-term watertightness. SAFECONNEC Gasket The secret of the superior long-term watertightness of G-PIPE pipes is the innovative SAFECONNEC technology. It reinforces the plastic pipe joints at their most important and critical points to ensure their outstanding long-term resistance and watertightness. Moreover, an extraordinary strengthening process ensures the necessary long-term resistance of the joint against deformation and leaks with an externally welded reinforcement ring. It holds! SAFECONNEC reinforces the critical points on plastic belling joints to ensure a long-term watertight connection. The SAFECONNEC technology, a reinforcement process, provides the required permanent seal via a highly rigid reinforcement band welded to the pipe. Highlights Long-term watertight in-line belling joint Fulfils the latest standard (e.g. DIN EN Part 1-3) Insoluble special strengthening band welded onto external surface to eliminate typical long-term creeping of plastics The advanced SAFECONNEC technology for long-term watertightness. 5

6 Best abrasion values with PP! Sketch of Darmstadt method Silica sand/gravel/water with 45% silica sand/gravel particle size 0-30 mm Abrasion on pipes as per the Darmstadt method. Application and areas of use The construction of the pipe walls and the PP guarantee a perfect balance of ring stiffness and ring flexibility. The static verification comes from examples of static calculations. The G-PIPE system can therefore be used where traffic load is high. In the area of HLC 60, values were determined which allowed the problemfree laying of G-PIPE with low coverage of e.g. 0.5 m and high coverage of e.g. 6 m. Should an individual static verification be required, ALPRO-ATT can provide this via a static calculation. Abrasion behaviour The abrasion behaviour of G-PIPE pipes has been tested in comparison to pipes made of other materials as per the Darmstadt method. The results of this test have shown that sewage pipes made of plastic or PP always have the lowest abrasion values. PP in particular has the best abrasion values. Sewage Rainwater drainage Sewage and mixed water channels Various special solutions for industry and business Ground drainage Domestic drainage 6

7 Various applications, top abrasion values and durable ring flexibility! Dpr 92% Dpr 99% A A A A (kn/m 2 ) Low tension in the ground --> Low vertical stress above the pipe High tension in the ground --> Pipe is supported sideways by the ground Effective mean stresses Extreme effective mean stress kn/m 2 Effective mean stresses Extreme effective mean stress kn/m 2 Ring flexibility The relaxation capacity of G-PIPE in sewage systems means that when under pressure, e.g. through wrong loads caused by movement or ground slippage, the pipes remain elastic and stay in shape. The load is carried back to the ground. Should this deformation occur over a longer period, the tension in the pipe relaxes until there is virtually no tension left. Rigid pipes, on the other hand, accept the load and cracks begin to form, which can lead to the pipe s not functioning at all. Difference between rigid and flexible pipes: Rigid pipes: All loads (static and dynamic) are accepted by the pipe. Flexible pipes: All loads transferred to the soil around the pipe; pipe is stress-free. 7

8 Watertightness, approved under tough conditions! Watertightness of pipes, moulded parts and connections: Watertightness with internal pressure Pipes and moulded parts: All tested pipes and moulded parts must be watertight. Bent pipes: All connections on bent pipes must be long-term watertight at an internal excess water pressure of min. 0.5 bar and must also display a short-term watertightness at an internal pressure of 2.5 bar. Deformed pipes: All connections on deformed pipes must be long-term watertight at an internal excess water pressure of min. 0.5 bar and must also display a short-term watertightness at an internal pressure of 2.5 bar. Bent and deformed pipes: All pipe connections must be watertight. Flexible pipe: deformed, especially in the pipe shaft The graphic shows that flexible pipes adapt to uneven ground or displacement. The G-PIPE system remains undamaged the system remains tight. Rigid pipes: the pipe joints do not bend Rigid pipes react to uneven ground or displacement as a whole unit. The lack of flexibility combined with a relatively small joint can lead to leaks. 8

9 Hydraulic behaviour at its best! The pipe wall roughness of G-PIPE, as with all plastic pipes due to their very smooth pore-free internal surface, is between and 0.05 mm. The influence of connections, diversions, shafts, etc must be taken as a correction value in the regulatory roughness calculation kb for streaming technology. Comprehensive information about this can be found in the datasheet ATV-DVWK-A 110 Hydraulische Dimensionierung und Leistungsnachweis von Regenabwasserkanälen und leitungen (hydraulic dimensions and performance of rainwater channels and pipes) (3rd edition 09/2001). The flow amounts for G-PIPE for a roughness value of 0.25 mm corresponding to the ATV-A 241 requirement for e.g. transport channels with shafts can be seen below. Diagram of flow amounts for G-PIPE pipes for kb = 0.25 mm Flow in l/s DN/ID 1000 DN/ID 800 DN/ID 600 DN/ID 500 DN/ID 400 DN/ID 300 DN/ID 250 DN/ID 200 DN/ID Bed slope in 9

10 Technical details of the system parts! ALPRO-ATT offers complete sewage and rainwater systems with a full fitting and manhole program from ID 150 mm up to ID 1000 mm, which is shown below. Due to the secure and fast installation of all the different system parts, construction times can be reduced to a minimum and costs can be cut. SAFECONNEC Gasket DN/ID Ø de Ø di Ø Di L The transition to smooth pipe (KG) is in nominal sizes up to ID 600 possible. α Bend 15 α Bend 30 L L L L α Bend 45 α Bend 90 L L L L Diversion 45 with reducer Diversion 45 same nominal measurements 10 L L L L

11 T-piece L L Bracket (post connector) Shaft feet Ø di Ø di L DN/ID D1 L1 L2 L Twin-seal coupler Sleeve coupler Ø Di L Ø Di L End piece Reduction joint (SS) Ø D z S DN/ID 200/ / / / / / / /800 Ø D z z S End piece Reduction joint (MM) Ø D z S DN/ID 200/ / / / / / / /800 Ø D z z S S

12 Easy and simple jointing! Application: G-PIPE sewage and rainwater pipes are used as underground gravity lines, as well as for other, similar non-pressure purposes, which must not exceed: ph-value 2 (acidic) to ph-value 12 (alkaline), with a continuous operating temperature of maximum 60 C. General installation rules and standards: DIN EN 1610 (10/97): Installation and examination of sewer pipes and channels (earlier DIN 4033) ATV - worksheet A 139 (10/88): Guideline for production of drainage lines and channels DIN in 1986/1 to part 4: Drainage systems for buildings and plots ZTV A-StB 97 (1997): Additional technical contract conditions and guidelines for excavations in areas with traffic DIN 4124 (08/1981): Excavations and slopes, trench widths and shuttering requirements G-PIPE pipes installation: The jointing of G-PIPE pipes is very easy and simple. G-PIPE pipes have an integrated in-line belling joint on one end and a flat end on the other end. The pipes are jointed by simple insertion (no need for welding). Special tools have been developed; designed with an easy and time-saving assembly in mind. 1 2 Apply lubricant to the inside of the belling joint. Insert the flat end of the pipe into the belling joint Position the second part of the tool between the ribs on the other pipe. Position the tool so that the first notch enters the stud. Operate the levers backwards and forwards. The pipes are jointed when the inserted pipe reaches the end of the belling joint.

13 Bedding layers for perfect pipe support! Together with the lower bedding layer [a], the upper bedding layer [b] forms the pipe support, see picture below, which requires careful implementation and compacting in accordance with the load calculations. The thickness [b] of the upper bedding results in the bedding or support angle. This term is still widespread and characterises the bearing capacity of the bedding in an easily conceivable manner. For G-PIPE-PP, the following table shows the relation between the easily measurable thickness [b] of the upper bedding and the bedding angle. The main compression directly above the pipe should be placed with a minimum coverage c of cm above the pipe end at first. The sewage pipe system G-PIPE-PP must be secured sideways at a high level in front of the compression. Upper bedding layer b in mm for G-PIPE-PP Creation of pipe trenches as per DIN EN 1610 Nominal Bedding angle [ ] width in (mm) ID OD K 90 = 0.15 K 90 = 0.25 K 90 = K = the quotient from the bedding layer and the OD of the pipe c b a Our sample static calculation is based on the following initial values: Load: HLC 60 with asphalt or concrete road, no additional surface loads Solid ground: G3 / 97% Pipe bedding (pipeline zone): G2 / 95% Cover (main backfill): G3 / 92% Single trenches, slope angle 90 or dam yield No groundwater Cover condition A1: Trench backfill compacted in layers against the undisturbedsoil without proof of the degree of compaction; applies to beam planking (Berlin-type sheeting) or insulating yield. min. 20- cover pipeline zone Bedding condition B1: Bedding compacted in layers against the undisturbed soil or compacted in layers against the dam yield without proof of the degree of compaction; applies to beam planking (Berlin-type sheeting). Used on foundation such as solid soil. Not to be placed on concrete! (This applies in principle to all flexible pipes, i.e. all plastic pipes). 13

14 G-PIPE manholes with cone top! Areas of application G-PIPE manholes are integral parts of wastewater collectors in gravity systems of wastewater, rainwater and mixed water drainage. They are employed as inspection manholes, cascade manholes or for sewage system cleaning. Production technology G-PIPE manhole bottom (base) and top (cone) are manufactured using rotational mould technology. The manhole body is a G-PIPE polypropylene corrugated pipe made by extrusion. G-PIPE manholes are manufactured as complete units (monolithic construction). Manhole elements are interconnected by extrusion welding according to the DVS 2207 working sheet. Features and benefits G-PIPE manholes have the following advantages: excellent resistance to high traffic loads excellent crack resistance even at low temperatures high temperature resistance (temperatures up to 60 C, short-term up to 90 C) excellent chemical resistance (suitable for household and industrial wastewater drainage) G-PIPE manhole with cone top G-PIPE manhole cone (top) Type d1 [mm] H [mm] D1 [mm] CONE DN 1000 mm CONE DN 800 mm G-PIPE manhole body G-PIPE-PP corrugated pipe; DN/ID 1000 mm or DN/ID 800 mm. Height adjustable directly at the construction site. D1 (mm) D2 (mm) H (mm) Max G-PIPE manhole bottom (base) INLET/OUTLET DN/ID α D1 H1 [mm] [mm] [ ] [mm] [mm]

15 Installation guidelines! During the installation guidelines given in EN 1610, the technical regulations for construction of sewers and drainage lines should be followed. After connecting the manhole and the pipeline, the backfill is performed. The backfill material may be Class I or II. It should be installed gradually in layers of 30 cm, taking care to ensure complete and uniform filling of all voids on the outside layer of the manhole. When placing and compacting embedment soil, care should be taken to employ methods that will not disturb or damage the manhole. The compaction of the backfill material must be performed using hand-held compaction equipment or by low weight mechanical equipment in order to avoid manhole deformation. The backfill material must be compacted to a minimum of 95% standard Proctor for localisation in green areas and % in areas with traffic. The final backfill is performed with the material excavated during trench preparation, following the removal of all sharp stones or cobbles which might damage the manhole. The final backfill must satisfy loading, pavement and other requirements in addition to those of the manhole. During the installation of G-PIPE manholes, the guidelines given in EN1610 must be observed. G-PIPE PP manhole body Internal diameter: DN/ID 1000/800 mm Ring stiffness: SN 8 Material: polypropylene (PP-B) Construction: smooth inside, corrugated outside Final Backfill Material Backfill Material Bedding Required compaction 15

16 21220 TROGIR, Plano bb, p.p.3, CROATIA Tel.: ; Tel/Fax: Branch offices PROIZVODNO-SKLADIŠNI CENTAR ZAPREŠIĆ ZAPREŠIĆ, Krapinska bb Tel.: ; Tel/Fax: alpro-att@zg.t-com.hr RIJEKA, Luki 19 Tel.: ; Tel/Fax: alpro-att@ri.t-com.hr OSIJEK, Dubrovačka 7a Tel.: ; Tel/Fax: alpro-att@os.t-com.hr ZADAR, Vlahe Paljetka 2/I Tel.: ; Tel./Fax: alpro-att@zd.t-com.hr With innovation from