HDPE 100 RC MULTILAYER PIPE SYSTEMS
High quality material for cost eﬀecve installaon
1. Product descripon
Cost and me pressure also force providers to rethink convenonal methods and use modern materials. For example, the previously required embedding of PE pipes in sand or ﬁne gravel is no longer necessary using pipes made of the latest PE 100-RC materials. Convenonal pipelines made of PE are exposed to higher stresses caused by stones, refuse glass and other compact materials present in the ground when no sand bedding is provided. In combinaon with the operang stresses (internal pressure, traﬃc and soil loads), the punctual or linear forces acng directly upon the pipe as a result will cause stress cracks (slow crack growth PE 100 RC mullayer pipes are co-extruded full-wall pipes with a dimensionally integrated coloured outer layer (drinking water = blue, gas = orange-yellow, waste water = brown). PE 100 RC mullayer is parcularly resistant to the consequences following from scratches caused when no sand bedding is provided and to point loads occurring over a longer period of me. The targeted ulisaon of further developed product characteriscs – resistance to slow crack growth – ensures the fulﬁlment of all requirements of modern and economic pipe laying. The manufacturing process ensures a service life of more than 100 years even with unconvenonal pipe laying (without sand bedding).
Comparison of PE 100 to PE 100-RC
All characteriscs of the raw material PE 100 proven over many years are also fulﬁlled by PE 100-RC, e.g. MRS 10. The only but signiﬁcant diﬀerence is the outstanding resistance of PE 100-RC to stress cracking. Processing, parcularly the joining technique, is subject to the same condions. Welding (e.g. heang element bu welding) is governed by guideline DVS 2207-1 for PE 100-RC as well and possible without any restricons.
The growing demand for faster and more economic pipe installaon with less environmental disturbance has led to new installaon techniques. The last several years has seen investors in the infrastructure system construcon industry searching for soluons for reducing investment costs with advanced technologies. The phenomenon encompasses both new pipelines and the renovaon of current ones.
These include sandless bedding, pipe bursng and horizontal direconal drilling. In order to apply such methods of pipe-laying and because of their aggressive impact on pipe, these new methods need new plasc pipe materials – a product that has its external surface durability several mes higher than normal and a higher point load resistance.
In terms of a common deﬁnion of the material PE 100-RC the PAS 1075 (Public Available Speciﬁcaon)tled мPipes made of polyethylene for alternave installaon technologiesо was published by DIN. This public available speciﬁcaon is considered a supplement to exisng standards and regulaons.
The scope of PAS 1075 is the increased resistance to slow crack growth of PE 100-RC pipes which are used for alternave installaon technologies, such as horizontal direconal drilling , burst-lining or installaon without sand embedding. The requirements, characteriscs and test procedures as well as the respecve quality assurance procedures are regulated and ensured via third party inspecon. Polyethylene pipes, which are described in the regulaon , do have a signiﬁcantly higher resistance to slow crack growth compared to regular PE 80 and PE 100 pipes.
Material requrements according to ISO 13479
Advantages of PE 100 RC MULTILAYER PIPES
PE 100 RC class materials and the most advanced plasc processing ensure the highest reliability of the product.
Π Good abrasion resistance
Π High stress crack resistance
Π Good resistance to point loads (e. g. stones, fragments) (Dr. Hessel нs test)
п High resistance to slow crack growth
п Opmal choice for pipe-laying without sand embedding and backﬁll
п Excavated soil to be used as backﬁll material
п Can be used for trenchless pipe-laying
п Can be bu-welded, ERW, poly fusion welded or connected mechanically
п Compable with classic PE pipes
What is that ensure protecon against occuriing points loads when no sand bedding is provided?
.The notch test acc. to PN EN ISO 13479 is a pressure test conducted on a secon of a pipe that has been notched on the surface, and then submerged in water at a given temperature and put under hydrostac pressure. The notch test allows to determine the resistance of pipes to the fast propagaon of cracks. The PE 100 RC pipe should withstand the hydrostac pressure given for 5 000 hours. (pe 100 RC MullayerЖ 10 000 h).
Moulded plate in order to test its resistance to environmental condions. The sample is notched and then stretched in an Arcopal soluon at a speciﬁc temperature. The RC material sample should withstand these condions for 3 300 hours without exhibing damage (acc. to ISO 16770) (pe 100 RC mullayer pipe withstand >8 760 h).
Dr. Hesselнs point load test is used to determine a materialнs resistance to slow propagaon of cracks. A sample of pipe secon is subjected to external point pressure in a given meframe and at a speciﬁc temperature. The RC sample should withstand these condions for 8 760 hours without exhibing damage (PE 100 RC mullayer = 10 000 h).
п Point load test: required result met, test interrupted aer 10 000 hours.
п FNCT: required result met.
п Notch test: required result met, test interrupted aer 10 000 hours.
Product Data Sheets
Pipe Clasiﬁcaon of PE 100-RC PIPE
There is several combinaon of material ,for pipe producon , what allow PE 100-RC material, and this combinaon exceed the minimum requirements applicable for PE 100
Type 1: Full wall pipes made of PE 100 сRC,
Single-wall full-wall pipes made of PE 100-RC as deﬁned in ISO 4065. This pipescan be made in full color, blue for water or orange for gas or brown for sewage, or black pipe and colour-strip according applicaon which are also made of PE 100 RC materials.
Type 2: Pipe with dimensionaly integrated protecve layer made of PE 100-RC
Double-layer pipes with dimensionally integrated protecve layers consist of PE 100 or PE 100-RC and have an internal co-extruded protecve layer made of PE 100-RC. Tripple-layer pipes with dimensionally integrated protecve layers consist of PE 100 or PE 100 -RC and have an internal and external coЁextruded protecve layer made of PE 100-RC. The co-extruded layers have been inseparably bonded with each other in a special tool that fuses the layers together. Made of PE 100-RC, the internal layer is integrated as a funconal layer in the wall structure. This producon based on two and three layers pipe are with diﬀerent external layer colour blue for water or orange for gas or brown for sewage.
Type 3: Pipes with dimensions according to ISO 4065 with dimensionally added outer protecve layer made of PE 100 сRC
Pipes of dimensions as speciﬁed in ISO 4065 with outer protecve jacket consist of a core pipe made of PE 100-RC and a protecve jacket made of polypropylene. The minimum thickness of the protecve jacket is 0.8 mm. The minimum thickness of the protecve jacket is dependent on the pipe dimension; large-sized pipes have a thicker jacket because of the heavier loads the pipes are designed for. The bonding strength between protecve jacket and core pipe must be such that the shearing forces occurring during pipe laying can be reliably transmied. This type is like opon, and on request, it is not present in regular producon yet.
PE 100 RCMULTILAYER PIPE water pipes have the same reference documents as classic PE 100 water pressure pipes. The pipes also have the Naonal Instute of Hygiene cerﬁcate . ThePE 100 RCMULTILAYER PIPE gas pipes have the same reference documents as classic PE 100 gas pipes.
PE 100-RC Mullayer Pipe- Producon Program
п PE 100 RC mullayer water pipe
п PE 100 RC mullayer gas pipe
п Opon -PE 100 RC mullayer sewage pipe
PE 100 RC MULTILAYER Water Pipe
PE 100 RC MULTILAYER Gas Pipe
Opon – PE 100 RC MULTILAYER Sewage Pipe
п Opon – PE 100 RC Mullayer Sewage Pipe –
on request can be produced RC mullayer pipe for disposal pipelynes(gravity pipelines)produced in light colored inner layer to allow and easier camera inspecon, for mining applicaon or disposal of other high abrasive media. Pipes can be supplied as 6 m and 12 m straight pipes or coil up to 125 mm in 100 m length. Further dimensions on request.
Pipe-laying and Assembly
PE 100 RC MULTILAYER pipes are laid and assembled just like typical PE100 pipes. Due to their high resistance to point loads and surface scratching eﬀects, the pipes can be laid in soil without backﬁll and sand embedding which is usually used as a protecve layer for the pipes. High resistance of
PE 100 RC MULTILAYER pipes to slow propagaon of cracks allows pipe-laying in diﬃcult nave soils with backﬁll and packing of crushed rocks and stones up to 60 mm of grain. Remember that the soil fragments must evenly support the pipeline around its circumference. Soil transport is expensive – applicaon of RC
PE 100 RC MULTILAYER can signiﬁcantly reduce the costs of supplying the construcon site with proper earthwork material and the removal of excess soil from the site.
Handling and Storage
Before the installaon of the pipes and components, check them for transport damage and other defects, and clean the joining faces and zones. Sort out damaged parts, and use a ﬁne-toothed saw or plasc pipe cuer if the pipe needs to be cut. Cuts at right angles to the longitudinal pipe axis can be achieved when the saw is guided, for example by a mitre gauge. Once cut, prepare the pipe ends as is required for the type of joining.
Unwinding pipes from bundle can be performed in various ways. In the case of pipes with outer diameter up to 63 mm, the pipe is usually unwound with th bundle held in vercal posion and the pipe start ﬁxed. An unwind device is recommended to be used for grater dimensions . The pipes must be unwound straight and must keep kinked;also pulling them oﬀ in a spiral form is not allowed.
Moreover, when unwinding a pipe, it should be taken into account that the ﬂexibility of PE pipes is inﬂuencedby the ambient temperature. At temperature nearthe frost point, pipes of an outer diameter greater then 75 mmshouldbe warmed up before unwinding whenever possible.
Note: When shortening and laying the pipeline, remember to take the temperature – dependent length change into account. A PE pipe 1 m long will elongate whenthe temperature rises and become shorter whenthe temperature decreases, by 0.2 mm per K.
Pipelaying in an open trench
Applicable standards are EN 805 (water pipe) , EN 1610 (waste water and sewer pipe) and EN 12207-2 Gas pipe.
Bedding and backﬁlling
Based on the proof of resistance to slow crack growth (tested by an independent, Mullayer PE 100-RC pipes made of PE 100-RC are suitable for laying without a sand bedding. Thus, addional work in order to replace the excavated mateЁrial with a sand bed in accordance with EN 805 (transport, disposal) is not necessary. The pipe properes are such that no restricon of the grain size of the bedding and backﬁlling materials is necessary.
Trenchless laying of pipes
MullayrPE 100 RC pipes suitable for alternave – trenchless laying
Alternave installaon methods are chosen because they are me and cost-saving . In the last few years various installaon technologies become the state-of-the-art due to their economic advantages:
п Minimal adverse eﬀect on developed and paved surfaces.
п Use of exisng pipeline routes.
п Minor inconvenience for residents.
п Shorter construcon me.
п Lower civil engineering and reculvaon costs.
п Installaon possible under rivers, lakes or traﬃc routes.
п Reducon in CO2 emissions, as no vehicles are needed for transport of road surface materials, excavaon work, etc.
п Avoidance of traﬃc reroung and congeson.
Ploughing (ﬁg. 1)
Ploughing is the fast and possibly most cost-eﬀecve method of laying new plasc pipes. The technique used has a minimal impact on the subsoil and is therefore considered to be environmentally friendly. A winch is used to pull a plough blade and pipe-laying unit through the ground. Once the pipe has been installed, the furrow (trench) is automacally closed as the plough blade advances. This method is also suitable for the parallel installaon of several pipelines. As the soil inially displaced by the plough is reused without any further processing, the pipes deployed have to be highly resistant to point, i.e. concentrated, loads. Owing to their high stress crack resistance, PE 100 RC pipes are parcularly durable.
This laying method are usually applied in rural areas and outside of traﬃc zones. With the milling technique, a suitable machine is used to cut a pipe trench into the soil, and the PE 100 RC pipes is simultaneously placed on the trench boom by means of a so-called installaon box. As the trench is in most cases not walkable, this box serves as a trench support in the installaon of the pipeline. Once the pipe has been laid, the trench is mechanically backﬁlled and compacted with the previously milled-out material, i.e. no sand bed is needed.
Trenchless pipe replacement
п Horizontal direconal drilling – HDD
Horizontal Direconal Drilling (HDD) is a method of installing underground pipelines, through trenchless methods. It involves the use of a direconal drilling machine, and associated aachments. Soil is loosened and ﬂushed out in various stages using a drilling ﬂuid. The ﬁrst step is to create a pipe duct by means of a pilot bore. Then, in further steps the ﬁnal pipe duct is widened and the pipe is introduced with the help of an inseron device.
This means very minimal surface disturbance and low reinstatement costs. We can drill under buildings, rivers, roads, through hills and rock.
Relining of an old waterpipe
Relining with pipe is a trench-free procedure, by which PE 100 RC is pulled into the exisng carriage from the manhole. The individual pipes are connected with an electrical or butwelding technique.
Burstlining, a trenchless pipe – bursng method, is used for repairing damaged pipelines by retaining or enlarging the hydraulic cross-secon. Together with the in-situ soil, the broken material compacted into the groundforms an annular space, into which the new pipeline aached to the bursng unit is introduced.
Bedding and backﬁlling
Based on the proof of resistance to slow crack growth, pipes made of PE 100-RC are suitable for laying without a sand bedding. Thus, addional work in order to replace the excavated material with a sand bed in accordance with EN 805 (transport, disposal) is not necessary. The pipe properes are such that no restricon of the grain size of the bedding and backﬁlling materials is necessary.
The standardized dimensioning for internal pressure load of PE 100 pipes is also valid for alternavely installed pipes. PE 100 RC MULTILAYER PIPE can be joined with technics as standard PE 100 pipe, but welding and electrofusion, as PE 100 RC is inseparable part of the pipe wall. The ﬁng using in this system are made from same material as PE 100 RC
PE 100 RC MULTILAYER PIPES provides project-related supplies and a number of special ﬁngs upon request. For laying without a sand bedding, the laer are made of PE 100-RC. A selecon is shown below – manufacturing in accordance with the customer speciﬁcaons possible: