PERFECT PIPE THE REVOLUTION CONTINUES

Transcription

1 PERFECT PIPE THE REVOLUTION CONTINUES

2 02 _ A new era My name is Mr. Perfect. I am an expert in pipe construction and will guide you through the world of Technology. The revolution continues A new era If you think about it, revolutions often mark the beginning of major changes. And just sometimes, they herald the beginning of a new era. The introduction of Technology sets a new quality standard in the pipe construction industry. The PERFECT system concept evolved from the idea of revolutionising the entire wastewater sector. As part of this, is representative of the qualitative breakthrough in pipe production and proves its worth due to the wide variety of benefits it offers, when compared with conventional wastewater systems. Welcome to the era of Technology! combines the product benefits of robust concrete pipe with resistant synthetic liners., therefore, marks the beginning of a new era in wastewater sewerage systems. Watertight from pipe to pipe, thanks to the internal PERFECT Connector. Concrete-HDPE composite pipe produced in a cost-effective process fulfil all the requirements of a modern, sustainable wastewater drainage system and it also offers significant benefits. Highest level of efficiency and eco- High corrosion resistance and static load capacity, even in the case of high traffic loads or extreme environments, enables to achieve an above-average life-cycle. A new era nomic viability, in both open construction and pipe jacking. Optimized use of resources and safety during planning, production, installation and operation _ 03

3 04 _ Technology Technology _ 05 Technology Because we are already planning more than 100 years ahead Laying new pipe systems is complex and costly. Therefore, it is important pipe installation is as quick and easy as possible and that the pipe have a long life-cycle. Pipe systems from stand out due to their optimum robustness and corrosion resistance regardless of whether they are used in trench construction or for pipe jacking. In addition to their long life-cycle, which can exceed 100 years, the fact that they are quick and easy to install is also a particularly important reason to use. Technology combines the positive material characteristics of robust concrete pipe and resistant synthetic liners. It also offers quick, safe and, most notably, a completely watertight installation thanks to the intelligent synthetic connectors. This equally applies to both open and closed installations. in wastewater sewerage systems, therefore, sets completely new standards in terms of quality and economic efficiency. Unbeatable in terms of life-cycle costs The concrete-hdpe composite pipe, which are produced in a precise process, fulfil the requirements of a modern, durable wastewater drainage system and are designed to have a life-cycle of more than 100 years. This results in low life-cycle costs and a high level of sustainability with regard to the use of resources and operations. PERFECT Shape made from selfor easy-compacting flowing concrete PERFECT Connector made from resistant polypropylene PERFECT Liner made from corrosion-resistant HDPE

4 A revolutionary symbiosis 1 Corrosion-resistant PERFECT Liner made from HDPE 2 Permanent connection: there is no separation of the liner from the surrounding concrete, even with temperature fluctuations during storage, transport and installation. 1 Wastewater pipe systems can now have a life-cycle of more than 100 years due to the perfect combination of concrete and synthetic liners in. _ 07 A revolutionary symbiosis Or how to withstand all adversities Wastewater pipe is subject to considerable external and internal influences. When required to withstand static loads or chemical attacks in the gas and liquid phase, only the best materials and material properties are good enough properties such as those of high-density polyethylene (HDPE) and concrete or reinforced concrete. consists of a synthetic liner, which is firmly anchored into a concrete shell. The tested pull-out strength for each anchor is more than 250 N. 2 A revolutionary symbiosis The PERFECT Liner is made from high-density polyethylene (HDPE) and stands out as a result of its ongoing resistance to all standard chemical loads. Additional notable characteristics of the liner include its high pressure flushing durability, its adhesive pull-out strength and its resistance to abrasion. During the Darmstädter Kipprinne abrasion test conducted in Europe, a moderate abrasion of only 0.22 mm was detected after 200,000 load cycles. This customary test simulates the actual load placed on a wastewater pipe over 100 years. The result clearly shows the high abrasion resistance of the PERFECT Liner. High static load-bearing Due to further developments in technology and, in particular, as a result of its combination with the PERFECT Liner, concrete, as a building material, which has been tried and tested for 0.7 Moderate abrasion a (absolute value) (mm) 06 _ CT Pipe PERFE , , , ,000 Abrasion curve (absolute value a) of different materials depending on the load cycles Concrete Polymer concrete GRP Stoneware (glazed) Ductile cast (CEM) PVC-Uv centuries, will continue to offer durable and watertight drainage for all types of wastewater in a broad range of applications, thanks to PERFECT Pipe Technology. When comparing materials, the static characteristics of concrete prove impressive, particularly since there is virtually no decrease in resistance as a result of ageing.

5 08 _ A perfect combination With the PERFECT Connector, a watertight connection from pipe to pipe can be made quickly and easily. A perfect combination _ 09 A perfect combination Advanced installation performance thanks to the PERFECT Connector Contracting companies are able to achieve considerable advances by using the PERFECT Connector. This connector makes it possible to connect pipe quickly, easily and, most notably, in a watertight manner, which means that welding of the PE corrosion protection is no longer required. The connector also takes into consideration all structural conditions on site. Watertight from pipe to pipe thanks to the internal PERFECT Connector In order to protect the pipe system from an aggressive chemical attack, the pipe connections are equipped with the PERFECT Connector, which is also resistant to corrosion. The connectors, each fitted with two gaskets, maintain a steady internal pressure of 2.5 bars. The lining system composed of the PERFECT Liner and PERFECT Connector is sealed up permanently inside and out without reducing the cross-section. Thanks to the PERFECT Connector, a watertight construction of corrosion-resistant pipe can be produced more quickly and therefore more economically than by welding synthetic pipe on the construction site. More importantly, this leads to a significant increase in the installation rate in the range of no-men-entry nominal widths, while at the same time resulting in a reduction in installation costs. 1 Position of the PERFECT Connector from pipe to pipe maximum water tightness due to a double tilting edge gasket.

6 10 _ Pipe jacking Pipe jacking with full drive Efficient micro-tunnelling starting at DN300 is ideal for pipe jacking. A big advantage of this wet cast pipe is its extremely low tolerance of both the inner and outer diameter and its tight and precise joint connections. Watertight pipe connection at a high rate of installation jacking pipes have a crucial advantage for trenchless construction: its higher jacking speed due to the quick and simple installation of the watertight PERFECT Connector in the starting pit. High level of economic efficiency The PERFECT Connector guarantees consistent internal corrosion protection with no lags in the launching pit. due to intelligent technology Before lifting a pipe into the manhole, the connector is already assembled in one end of the pipe. Upon reaching the target shaft, a durable, corrosion-resistant, operational and watertight pipe system is available in the form of a combination of PERFECT Liner and Connector, within the range of the nominal width DN300 to DN800, with no further processing steps. The economic efficiency of jacking measures is therefore significantly improved. Pipe jacking _ 11

7 12 _ Pipe jacking Pipe jacking _ 13 Ideal in pipe jacking Maximum watertightness with easy installation The robust concrete-hdpe pipe lined with an internal PERFECT Liner is ideal for pipe jacking, even in the case of difficult geodesic conditions, where high demands are placed on the load-bearing capacity of the material. This, in turn, increases efficiency in the production of sustainable pipe using the micro-tunnelling process. The watertight pipe connection is made by using PERFECT Connectors. These synthetic connectors are fitted with two double tilting edge EPDM gaskets that guarantee consistent protection of the system against corrosion. Jacking Pipe PERFECT Connector Plug-in connector Easy installation of corrosionresistant jacking pipe, including the no-men-entry nominal width spectrum efficiency due to the synthetic connector. Safe operation and installation synthetic connectors with double tilting edge EPDM gaskets for the permanently watertight concrete-hdpe composite pipe system. PERFECT PIPE (Jacking) Length 2000mm Wall Thickness Weight of Pipe Allowable Jacking Force DN300-DA mm approx. 720 kg approx. 180 Tons DN400-DA mm approx. 990 kg approx. 250 Tons DN500-DA mm approx kg approx. 270 Tons DN600-DA ,5 mm approx kg approx. 400 Tons DN700-DA mm approx kg approx. 420 Tons DN800-DA mm approx kg approx. 460 Tons

8 14 _ Optimised use of resources Safety in design and operation Stable pipe geometry for long-term use The easy inspection and maintenance of, in addition to its corrosion resistance and high static load characteristics, contribute to its long life-cycle of more than 100 years. s robust rigid concrete shell prohibits internal changes in the pipe cross-section, which enables easy inspection of the pipe using standard inspection equipment. 1 On the other hand, the position of the PERFECT Connector set-back in the pipe wall ensures that the internal cross-section also remains constant in pipe construction. low but constant gradients and ensures that deposits do not occur. For cleaning purposes, PERFECT PIPE is fully suitable for all common high pressure flushing. Production, installation and operation Optimised use of resources for concretehdpe composite pipe Installation and operation Economical due to rapid installation Economical due to longevity, easy inspection and maintenance, resulting in low life-cycle costs has a very favourable overall CO2 footprint, from its manufacturing and installation stages, all the way through to its ongoing operation and decommissioning stages. Removal and recycling Recycling of safe raw materials concrete and environmentally friendly thermoplastics, even after a hundred years of use. A constant gradient to prevent deposit-formation Especially in traditional pipelines with low overall gradients, sediment generally occurs. Prebed PERFECT Pipe, however, is ideal in supporting 2 1 A synthetic inner lining that is easy to inspect and maintain 2 High-pressure flushing conducted in Europe Optimised use of resources Because a longer life-cycle offers genuine benefits in terms of costs. _ 15

9 16 _ Industrial production Industrial production _ 17 Industrial production Tailor-made profitability Economically manufactured products due to optimised use of resources and intelligent technology. The minimal use of corrosion protective materials constitutes a significant basis for the economic production of. For the HDPE liner with a minimum wall thickness of 1.65 mm, the exact amount of required synthetics is used for reliable production and for its long-term use of more than 100 years. Various levels of automation ranging from full automation to batch production, in which only individual key processes operate in an automated way, constitute an additional factor that enables to be manufactured economically, taking into consideration project-specific and regional framework conditions. The production of includes the following processing steps: Trimming the HDPE liner to length in accordance with the pipe size Welding of the liner to form a cylinder and joint ends for the subsequent pipe connection Fixation of the liner cylinder to a dimensionally stable steel core Setting up the moulds with the PERFECT Liner fixed on the steel core as well as reinforcement and lifting anchors, if required Filling of the moulds with self-compacting concrete Curing and demoulding of the finished products 1 2 PERFECT Liner production In a fully automated process, the HDPE film is initially cut to size in accordance with the desired nominal pipe width and length, and welded to form a watertight cylinder. Next, the liner cylinder is applied to a supporting core and the ends undergo automatic thermoplastic moulding. In the subsequent pipe, the PERFECT Connector is also inserted in an automated process into the joint, without reduction to the pipe cross section. PERFECT Liner fixing and setting up the moulds The final outer contour of PERFECT Pipe is created by filling the moulds with self-compacting concrete. A number of different concrete mixes can be used for this purpose. In order to guarantee the dimensional stability of the corrosion protection, the liner is fixed to a steel core. Afterwards, the steel core and liner are inserted in a corresponding mould, which is then filled with self-compacting concrete. The dimensional accuracy of the pipe is guaranteed due to the outer steel formwork and its curing in the mould. 4a 5 4b 1 Trimming of the Perfect Liner film according to the pipe diameter 2 Thermoplastic forming of the Perfect Liner ends for the future connector position 4a Demoulding of a cured jacking pipe 4b/5 Secure product handling with a hydraulic gripper 3/6 Economic production on an industrial scale 3 6

10 18 _ Versatile and reliable Versatile and reliable _ 19 Versatile, available for different applications Reliable for generations 1 2a 2b provides consistent 5 and proven corrosion protection against chemical attacks ranging from PH 1 to PH 14. The PERFECT Liner permanently protects the concrete against chemical attacks and improves the pipeline flow rate. Due to the revolutionary combination of robust concrete pipe with the resistant PERFECT Liner, the concrete building material, which has been tried and tested for centuries, is still able to offer durable and watertight drainage for all kinds of wastewater thanks to Technology. The PERFECT Connectors 3 allow a certain deflection of the pipeline 6 and simple connections to the 1 Temporary storage of Perfect Jacking Pipe from Bilcon Industries manhole. Lateral connections can also 2-4 Preparation for pipe jacking at a building site be installed, either at the production in Singapore 5 Inserating a pipe into the starting pit plant or on the construction site. 6 Preparation of the jacking devices 4

11 05/2016, Subject to errors and changes. Bilcon Industries Pte Ltd. 12 Tuas Avenue 16 Singapore Telephone: (+65) Fax: (+65)