GEONFLEX - GEONDUR New double structured wall conduits (HDPE) for underground networks
05 facts 07 GEOΝFLEX - GEOΝDUR 08 GEOΝFLEX - GEOΝDUR characteristics 09 fittings 11 application field 12 installation guide Leading
environmentally friendly throughout their life cycle 3
4 Our company is the leading wholly Greek-owned company producing conduits for buried underground power and telecommunication networks.
5 facts Our company s new double structured wall conduits are 100% eco-friendly and 100% recyclable GREEN PRODUCT The production of double structured wall plastic conduits for underground networks by our company marks a new era for the sector of cable protection conduit systems. Their capability of integrating characteristics of pliable and rigid conduits, through the advanced technology of co-extrusion, makes them ideal for a whole host of underground networks for the distribution of electricity and telecommunications. In all developed countries public utility networks are installed below ground due to the significant advantages that this provides, such as safety, minimization of exposure to extreme natural phenomena, reduced electromagnetic radiation and better aesthetics since they are not an eyesore. GREEN PRODUCTS In an age when huge sums are invested in alternative forms of energy, energy distribution through eco-friendly materials is an issue that should concern us all. In this case the use of intelligent climate-friendly networks is essential.
6 Ø40 Ø50 Ø63 Ø75 Ø90 Ø110 Ø125 Ø160 Ø200 GEOΝFLEX GEOΝDUR
7 - The new GEONFLEX - GEONDUR conduits are the perfect solution for protecting cables in underground distribution networks. Substitutes from other application fields, e.g. drainage/irrigation/ water supply conduits do not meet the requirements of the safety standards for electrical installations. The new double structured wall conduits GEOΝFLEX (pliable) - GEOΝDUR (rigid) are made from high density polyethylene (HDPE) in line with the requirements of LVD and European standards ΕΝ 50086-2-4 & ΕΝ 61386-24. Their external surface is corrugated (spiral), light grey colour RAL 7035, whereas the inner surface is smooth, black colour RAL 9004. 10 decisive advantages: 1. They have exceptional resistance to compression (min 500Nt) and impact (Normal duty) due to the high quality of the pure raw materials (HDPE) from which both walls, internal and external, are made. 2. They incorporate a special material (slip) on their internal smooth surface to facilitate easier introduction and guiding of cables thanks to the significant (up to 50%) reduction in friction. 3. They are not destroyed by rodents due to the particular ecological additive they contain in their internal layer. 4. Are resistant to ultraviolet radiation (UV stability) due to special stabilizers (>5years). 5. They guarantee stability and high watertightness ΙΡ 44 when connected to their couplers. 6. They facilitate the smooth running of a steel cable guide or of the cables themselves inside the conduits thanks to the preinstalled guide (pull cord), with minimum tensile strength 650Nt (65 kg). 7. They come with special caps that protect their interiors during storage, installation or while awaiting future use. 8. Are 100% recyclable since they are made from 100% eco-friendly materials, halogen free and low-smoke, and comply with the requirements of the European RoHS directive and REACH regulation. 9. They are available in a choice of packs: 25m or 50m to meet different installation requirements. 10.They are tested and certified by the independent German VDE laboratory.
8 GEONFLEX Normal 450 Nt GEONDUR Normal 750 Nt - c a acte istics PACKAGING All conduits are packaged with special safety straps in order to ensure their safe distribution and storage. Their waterproof, indelible labels help in providing reliable technical information. GEOΝFLEX Comes in packs of 25m coils for diameters from Ø40 to Ø200, and in 50m coils for diameters from Ø40 to Ø125. In 50m coil packs an internal safety strap is placed on the 25 th meter to keep the initial shape of the coil unchanged when its external straps are snipped off. Comes with cable guide (pull cord) and protective caps which are mounted at coil s edges during the packaging procedure. GEOΝDUR Comes in packages of 9m (3m rigid bars) of diameters Ø75, Ø90, Ø110 & Ø125 which are bound with special safety straps. The following dimensions are available by order Ø40, Ø50, Ø63, Ø160 & Ø200. Different lengths (other than 3m) can be produced subject to prior agreement. USE GEONFLEX & GEONDUR conduits are relatively easy to load and transport due to their reduced weight and proper packaging, while they can be stored in outdoor areas thanks to their exceptional UV stability. Thanks to their special geometry they are quick and easy to cut using basic professional cutting tools. Conduits intended to be used in buried underground network installations are categorized according to their mechanical strength, thus their impact and compression resistance (EN 61386-24). For more information see page 14.
9 fittings GEONFLEX & GEONDUR conduits are produced by the most state-of-theart, fully automated, production lines in Europe, with special technical characteristics that highlight their uniqueness. All fittings that compose the GEOΝFLEX - GEOΝDUR conduit system are made from halogen and heavy metals free raw materials, in black colour RAL 9004, and are available in all dimensions from Ø40 up to Ø200. Their engraved marking remains unaltered over time and they are 100% recyclable. GEONFLEX couplers Made from high density polyethylene (HDPE) in accordance with European standards EN 50086-2-4 & ΕΝ 61386-24 and have the same mechanical strength as the GEONFLEX - GEONDUR conduits. They have exceptional UV stability. They carry three perimetric internal double hooks on each side guaranteeing proper retention of the conduits. An inner end lip ensures the correct assembly of GEONFLEX - GEONDUR conduits. Their design facilitates the introduction of the conduits (protruding entry lip) and maximises their retention (conical inner slope). They guarantee IP 44 ingress protection against solid objects and water. GEONFLEX caps Made from low density polyethylene (LDPE) and packaged together with GEONFLEX - GEONDUR conduits. They have a ventilation hole which prevents the coupler from coming away from the conduit if the air inside it happens to expand due to an increase in temperature, while at the same time retaining the guide (pull-line) that runs through the conduit. They keep the inside of the conduit clean protecting it from the entry of dry and liquid bodies and live organisms guaranteeing smooth passage of the conduits. They have exceptional UV stability. Guide (cable pull-line) The guide is installed in the interior of the conduits during production; is made from high quality polyester material (PET) and it is black in colour. It has minimum tensile strength 650Nt in accordance with European standard ΕΝ ISO 2062. Its thickness is 1.2 mm and its special surface configuration protects the user from unexpected injuries.
10 Photovoltaic parks Wind power parks Construction projects Roadway lighting Telecommunications Outdoor open spaces
11 application field GEONFLEX These are the ideal conduits for protecting underground networks for infrastructure works such as buildings, RES (renewable energy source) electric power stations (photovoltaic & wind parks), street lighting works, telecommunications, etc. Difficult points of the ground which can obstruct passage are very easily circumvented thanks to the conduits exceptional flexibility. GEONDUR The ideal solution for underground networks in areas where the ground is subjected to great and constant stresses from external loads (e.g. roads). They are specially designed to achieve high levels of resistance to compression of over 750Νt.
12 10 1 2 3 4 5 6 7 8 Description of filling trench zones 1. Main backfill 2. Initial backfill 3. Sidefill 4. Upper bedding 5. Lower bedding 6. Depth of bedding 7. Depth of embedment 8. Trench depth 9. Trench width 10. Bottom of road construction, if any 9 installation g ide Installation of conduits in underground networks requires a series of works that need to be carried out as specified in the design so as to ensure the safety of the works and the installation itself. Some details on best practice for safe installation in accordance with the specification of Standard ΕΝ 1610 are given below: Basic information on trenches When digging a trench for conduit installation care must be taken in order to ensure a smooth, even underlying surface. It is best that trenching is performed as late as possible before the laying of the conduits and for backfilling to take place as soon as possible after their laying. Some basic accuracy checking criteria for the trench works are:» Slope and level of the bottom of the trench in accordance with the differences in height provided for.»»»» Dimensions of the excavated sections. Evenness of the trench surfaces, bottom and walls. Removal of surface and ground water. Selection, reuse and temporary storage of the excavated materials and removal of those which are unsuitable.
13 Trench dimensions The trenches should have the width and depth specified in the design. This should be the minimum required for a workmanlike installation of the underground network and compaction of the backfilling materials in accordance with the diameter of the conduit and its depth of installation. It is recommended that the minimum width of the trench be the greater than the values shown in the 2 tables below: Minimum recommended width of trench in relation to outside diameter of conduit OD + 400mm irrespective of whether there is support in the tunnel Irrespective of the angle of inclination of the trench walls conduits with outside diameter OD up to 200 mm Minimum recommended width of trench in relation to trench depth Trench depth (m) Minimum trench width (m) < 1 No minimum width required 1 1,75 0,80 > 1,75 4,00 0,90 > 4,00 1,00 conduits with outside diameter OD up to 200 mm Differences may occur in the above minimum recommended widths in the case of works which do not require a person to be inside the trench or in other special circumstances. A very important factor that needs to be taken into account at the time of selecting from the above sizes is the installation of more than one conduit in the trench. Trench materials The suitability of the ground materials for backfilling the trenches for underground networks depends on their geotechnical properties and their capacity for compaction. The backfill materials can be taken from the excavated materials. When these materials do not meet the requirements, are non existent or unavailable then suitable materials must be chosen as specified in the design. It is best to preclude the presence of backfill materials that are larger than 22 mm in diameter. It is also necessary that the backfill materials are free from organic substances (such as leaves, roots, grass etc.), snow and ice since their water content affects compaction. The trenches must be protected from surface water. It would be good to use pumps to remove and drain off any water towards nearby natural receptacles or other suitable receptacles. Installation Reception and transportation to the installation point The conduits and their fittings must be inspected upon delivery, to see that they bear the correct labels and markings and meet all the necessary specifications laid down in the design. Prior to installation they must be carefully checked for any signs of damage. Storage The conduits must be stored in such a way as to ensure that they remain incorruptible. They must not be placed next to open trenches and their storage area must be clean and free from any foreign bodies such as sharp stones that could cause damage. Laying In the case of interruption of the installation process, or due to a temporary break in the works, or in view of connection at a later date, the ends of the conduits must be sealed with protective caps. The caps must not be removed before the connection process. The area of the conduit that will come into contact with the connection fitting (coupler) must be clean and show no signs of damage. BEST PRACTICE: It is recommended that external caps be used to protect the inside of the conduits from wet and dry particles. Connection During the connection process (coupler, trench, etc.) it must be ensured that no foreign bodies can get inside the conduits. In order to achieve this,
14 particular care must be taken when cutting and assembling the conduit. Trenching After completion of the works for digging, shaping and inspecting the bottom of the trench, the next step is the laying of the conduit and backfilling with the material provided for in the design. It is recommended that the conduit be laid over a substrate (underlying layer) of 100 mm in the case of soil and 150 mm for stony or hard ground, and covered respectively to a height of 300 mm above the highest point of the outside diameter of the conduit (see diagram). It is recommended that the filling and compaction of the trench be carried out simultaneously on both sides of the conduit. It is suggested that the compaction, the degree of which must be provided for in the design, be carried out from the wall of the trench towards the conduit in uniform layers using manual equipment. Compaction using mechanical means must not be performed in an area above the zone of the pipe that is less than 300 mm deep. When choosing the mechanical means of compaction, the number of drillings and the thickness of the layers of compaction, it is necessary to take into account the type of compaction material and the type of conduit that will be laid in the trench. Compliance of the above with the specifications provided for in the design must be a priority. Inspection During the installation, in addition to visual checks, the following checks must also be performed: checks for any deformation of the conduits, change in degree of compaction and the adequacy and effectiveness of the laying. Checks on degree of compaction must be carried out throughout the works. The surface on which the conduits are laid must be thoroughly inspected and meet the requirements of the design regarding its degree of slope and evenness. ATTENTION: The above information comprises an informative guide for the safe digging of trenches and installation of conduits for cable protection as defined by European standard ΕΝ 1610. In NO way must it be used as a specification or be confused with the specifications laid down in each individual design. Impact test (acc. to European standard ΕΝ 61386-24) Light (L) Normal (Ν) Nominal conduit dimension (mm) Hammer mass (kg) +1% - 0% Height of fall (mm) 1% Force of mass (Joule) Hammer mass (kg) +1% - 0% Height of fall (mm) 1% Force of mass (Joule) 60 3 100 3 5 300 15 61 έως 90 3 200 6 5 400 20 91 έως 140 3 400 12 5 570 28 >140 3 500 15 5 800 40 Compression test (acc. to European standard ΕΝ 61386-24) Resistance to compression Classification Type 250 Type 450 Type 750 Compression Strength (Νt) 250 450 750
Product is made of halogen free raw materials - absence of fluorine, iodine, bromine, chlorine, etc - (EN 50267.02.02) The product and its production process are controlled and inspected by the German Institute VDE. Compliance with Construction Products European Directive 89/106/EEC (CPD). Compliance with REACH Regulation EC/1907/2006 about chemicals. The product does not attract rodents. Ingress protection against solid objects and water (EN 60529) Minimum impact strength Low smoke during combustion (EN 61034). UV stability Minimum - Maximum permanent applicationinstallation temperature. Minimum compression strength The product does not contain hazardous substances acc. to 2002/95/EC Directive (RoHS). Friction reduction in the inside of conduit due to slippery additional material. Certification Quality Management System EN ISO 9001:2008 Certification Environmental Management System EN ISO 14001:2004 Certification Occupational Health and Safety System OHSAS 18001:1999 Product Conformity to all requirements of relative European Directives.
March 2012 DEEPBLUE creative design 2810 344214 for more information... www.kouvidis.gr EMM. KOUVIDIS S.A. Integrated Conduits Systems for Cable Protection VIOPA Tylissos, GR 71500 Heraklion, Crete, Greece T: +30 2810 831 500, F: +30 2810 831 502 E: info@kouvidis.gr www.kouvidis.gr European Certification of Entrepreneurial Excellence - Quality