Brandenburger GFRP-Inliner Brochure (PDF 958 KB)

Brandenburgerwww.brandenburger.deBrandenburgerGFRP Pipe LiningExpertisein High Technology MaterialsGlass-fibrereinforced plastic(GFRP) –The perfect materialfor durable sewerrehabilitationBrandenburger Liner GmbH & Co. KGTaubensuhlstraße 6D - 76829 Landau/PfalzTel. +49 63 41 / 51 04-0Fax +49 63 41 / 51 04-155info@brandenburger.deBrandenburgerwww.brandenburger.deThe Brandenburger systemBrandenburger has developed a sewer reha-bilitation system in which all elements harmonizeperfectly, from the production of GFRP pipeliner made of light-curing resins and otherhigh-grade materials, the development andproduction of the required UV light equipmentto service for the expert liner installation.This closed system from one single manufactureris prerequisite for safe and durable renovationof damaged sewers.Brandenburger utilises high qualityThe company has a quality managementsystem and is DIN EN ISO 9001:2000 certified.RAL quality seal: RAL quality seal for sewerconstruction S27.18 - Brandenburger linerS14.05 - Brandenburger light-curing hat profileGFRP pipe liner productionUV light curing equipmentService/Application technologyInternational approvalsGermany:No. Z-42.3-330 DIBt, Deutsches Institut fürBautechnik (German Institute for ConstructionTechnology)Switzerland:QuiK, No. 2004-12-4422-01, Qualitätssiche-rung bei Instandsetzungs- und Sanierungsar-beiten an nichtbegehbaren Kanalisationen(Quality Assurance for Restoration and Reha-bilitation Work in Non-accessible Sewers)France:Avis Technique Nr. 17/06-182; CSTB, Wissenschaft-liches und technisches Zentrum für Bauwesen(Scientific and technical centre for the constructionindustry), www.cstb.frDenmark:NO DIG Kontrolordning for Ledningsrenovering(Inspection regulation on pipe line rehabilitation)No. B 1308Glass-fibre reinforced plastics (GFRP) find employment where highest stability, excellent chemical durability,and extreme longevity are demanded of industrial materials.BrandenburgerWith the patented seamless construction andthe high glass-fibre share the BrandenburgerGFRP pipe liner offers durability and best-possible mechanical strength. This even allowsfor applications in such cases where the old pipeis so damaged that the hardened Brandenburgerpipe liner needs to take over the completesupport function.Conventional pipe liners consist otherwise ofsynthetic fibres, such as a polyester needled felt.This serves as a base material for the resin, butdoes not feature any re-enforcing characteristics.Thus GFRP pipe liners feature significantlybetter material characteristics based on theirconstruction principle than pipe liners basedon synthetic fibres (e.g. polyester fibre).rW:H =2:2H=2rW=2rH=1,5rr/2W=2rrr2r5/8r3rH=3r3/2rrr/2W=2rrCircular profile: DN 150 - DN 1000 Arch profile Inverted egg-shaped profile: 200/300 - 800/1200 The rehabilitation of all common sewer diameters is possible with Brandenburger GFRP pipe liners (three typical examples shown here).The glass fibres are usually used as rovings(bundles of glass fibres), non-woven fabrics,clutches, mats, or as gauze. The tensile andpressure resistance of the glass fibre ensuresa stiffening of the plastic while at the sametime sustaining a certain flexibility.Materials made of glass-fibre reinforcedplastics (GFRP) play an important part in theaerospace industry, in the automotiveindustry, in pipeline construction, etc. Theyare usually employed as fibre compositematerials. A composite material is a materialthat is made up of two or more combinedmaterials that features other characteristicsthan its individual components. In GFRP pipeliners the glass fibres reinforce the resincomponent (matrix) in which they areimbedded. Contrary to that synthetic fibres(e.g. needled felt) are simply base materialfor the resin used.“Brandenburgerpipe liner with glass-fibrereinforcement –high-grade material formany applications”Expertise in High Technology MaterialWhere highest stability, excellent chemicaldurability, and extreme longevity are demandedof industrial materials, glass-fibre reinforcedplastics (GFRP) find employment. Brandenburgeris specialised in the processing of high-qualitymaterial for around 70 years and has successfullyput GFRP composite materials to use in moderntrenchless sewer rehabilitation since the early1990s.GFRP is a “programmable” material. The glassfibres can be precisely aligned for the loadsencountered in the sewer. Pipe liners made ofGFRP can withstand extreme loads at very thinwall thicknesses and feature a low weight at thesame time. With GFRP pipe liners all commonsewer diameters, from round and oval profilesto special profiles, can be rehabilitated in smallerand even large diameters.During the production of the BrandenburgerGFRP pipe liner, the glass fibre is imbedded ina special vinyl or polyester resin therebystrengthening the mechanical properties of theplastic. Crucial for the longevity of the finishedproduct is that the resin mixture and the glassquality used are perfectly tuned to one anotherin order to withstand the chemical andmechanical loads. That is why only high-graderesins (polyester resin pursuant DIN 18820group 3, type 1140 or EN 13121 group 4 orvinylester resins pursuant DIN 18820 group 5,type 1310 or EN 13121 group 7A) and corrosion-resistant glass fibres, so-called E-CR glass fibres,are used for Brandenburger GFRP pipe liners.Definition “glass fibre“:Glass fibres are long thin fibres madeof glass. During production they aredrawn out of molten glass. Glassfibres are for instance used for glass-fibre reinforced plastics (GFRP). Todaythey are considered to be one of them o s t i m p o r t a n t c o n s t r u c t i o nmaterials because they are durable,weather and chemical resistant, andinflammable. They feature a highresilience module, which improvesthe mechanical characteristics ofplastics.Type Glass transition temperature Bending strength1100 to 50 °C -........1110 above 70 °C 70 N/mm21120 above 70 °C 110 N/mm21130 above 120 °C 70 N/mm21140 above 120 °C 110 N/mm2E-glass:(E=electric) counts as standard fibre; approx. 90% market shareS-glass:(S=strength) fibre with increased chemical resistanceR-glass:(R=resistant) fibre with increased strength and durabilityC-glass:(C=corrosion) fibre with especially high corrosion resistanceE-CR glass: (E-glass corrosion resistant) fibre with esp. high acid resistanceand othersUnsaturated polyester resins(Excerpt from the DIN 16946)Glass fibre categories(Types of strengthening fibres)BrandenburgerHighest load and stabilityShort-time modulus of elasticityThe most important basic mechanical featuresfor application in the sewer rehabilitation arethe bending modulus of elasticity (bendingYoung modulus) as well as the bending strength.The bending Young modulus of a pipe liner isdetermined by the apex pressure trial. For thetrial a stress deformation behaviour is simulatedas it frequently occurs also under operationalconditions in the sewer. The bending Youngmodulus states with how much resistance amaterial counters a load. The higher the bendingYoung modulus is the stiffer the material is.With both short-time bending Young modulesof at least 7,500 N/mm2 and 10,800 N/mm2,Brandenburger GFRP pipe liners feature out-standing mechanical characteristics that ensurehigh load stability and durability.The strongest GFRP pipe liner:In November 2005 the thickest GFRP pipeliners in the world so far were installedby Brandenburger for the Hamburgwater works to rehabilitate oval profilesewers. At segment lengths of 80 to 100 mthe pipeliners had a weight of 8,000 kgto 10,000 kg. The curing speeds were atabout 40–50 cm/minute. For testpurposes the thickest yet manufacturedGFRP pipe liner that was cured by UVlight was accomplished by Brandenburgerat a diameter of 1000 mm and a wallthickness of 28 mm.Long-time Young modulusInformation on the long-time bending modulusof elasticity is provided by the reduction factorfor enduring loads. This value, determinedduring a 10,000-hour-long durability trial, takesnote of the flow properties of the various materialsand allows for a prediction of the behaviourafter 50 years of permanent load.GFRP pipe liners have a significantly lowerreduction factor and therefore a higher long-time modulus of elasticity than synthetic fibrepipe liners (acc. ATV M 127 part 2) and cantherefore be designed with significantly thinnerwall thicknesses. The pipe diameter is reducedonly slightly even at highest static requirements.Brandenburger pipe liner wall thicknesses“BrandenburgerGFRP Pipe Lining –outstanding materialcharacteristics”Sewers rehabilitated with Brandenburger GFRPpipe liners fulfil their tasks reliably at lesserwall thickness and can be written off as a long-term investment for municipal infrastructurefor at least 50 years.(1): PE-HD 1,000 N/mm2(2): PVC 2,500 N/mm2(3): Brandenburger GFRP pipe liner 7,500 N/mm2(4): Brandenburger GFRP pipe liner 10,800 N/mm2(5): Synthetic fibre pipe liner 3,500 N/mm2(6): Polyester 3,500 N/mm210,000Young modulusin N/mm28,0006,0004,0002,000(1) (2) (3) (4) (5) (6)Wall thickness in mm1816141210864201,000200300400450500600800Standard-Liner(Polyester needled felt with polyester resin;E = 3,000 N/mm2)Seamless light-curing Brandenburger liner(GFRP inliner with polyester resin;E = 10,800 N/mm2)Diameter in mmOld pipe condition IIaccording ATV-M 127,Part 2 (01/2000),Groundwater level above(liner) invert = 3.0 mLongest GFRP pipe liner:In the Fall of 2004, at a length of 295metres the currently longest pipe linerwas installed and cured with UV light. Thepipe liner DN 250, wall thickness 5 mm,weighed 2,300 kg total and was drawn inwith a draw-in force of max. 700 kg.Controlled stretch behaviourBrandenburger GFRP pipe liner are light, stable,and yet superbly radial flexible. A speciallydeveloped glass fibre composite provides anextraordinary even stretching along the circum-ference. Thus it form-fits itself to the old pipewalls. Stretching in the longitudinal directionis prevented on the other hand by the specialalignment of the glass fibre. Every BrandenburgerGFRP pipe liner is produced undersized in thefactory. This minimises the risk of creasesforming at various old pipe deformations.Brief construction t imes –quick return to operation ofthe sewerDuring rehabilitation with Brandenburger GFRPpipe liners the subsequent work can be carriedout right after the curing; as opposed to syntheticfibre pipe liners. This includes the pipe linerconnections in the two shafts as well as theiropening and connection to the lateral inlets (e.g.with hat profile or compression technology).This is not possible with synthetic fibre pipeliner, because the shrinkage may take severaldays or weeks.Since this subsequent work can be done imme-diately following the installation of the liner, theconstruction time is shortened and the sewercan be put back into operation quickly. Thismeans significantly less interference for thelocal residents and less costs.BrandenburgerDrawing in with ease:A new record has been established inmid-2008 by the production and in-stallation of a pressure line liner DN791: With a wall thickness of 11.2 mmand a length of 241 m, this liner weighedover 15 tonnes and was thereby thehitherto heaviest BrandenburgerGFRP pipe liner that ever left the plant.“Brandenburger linerinstallation in practicalapplication – withconsistent high qualityaround the world”GFRP pipe liner – Sound practical applicationThe GFRP material is impressive even duringpipe liner installation. As it is drawn into theold pipe the longitudinal re-enforcement madeof glass fibre, whose tensile strength lies wayabove that of the liner's weight, takes up thelongitudinal pull. This makes an overstretchingor tearing of the GFRP pipe liner impossible.Brandenburger GFRP pipe liners are expandedby pressurised air. Any water existing in theconduit or even in holes is displaced by the evenexpansion pressure. The new “pipe-in-a-pipe”attaches itself seamlessly to the old pipe wall.Durably sealedAccording to DIN EN 1610 even the rehabilitatedsewer section has to be sealed. In order forthis requirement to be applied, the pipe linerhas to be saturated in resin evenly and withoutmany air pockets. This is ensured as best aspossible by the preparation at the factory.The internal foil that is needed for the pipe linersserves solely as an installation aid for GFRP pipeliners and is removed promptly after the curing.This makes it possible to carry out the leakagetest right after the curing, which is the prerequi-site for a durable and long-term rehabilitation.Conversely to that, practically no leakage-proofof the actual pipe liner laminate can be made forsome pipe liner systems with laminated internalfoil. In a meanwhile applicable procedure (APS-Arbeitskreis Prüfinstitute Schlauchliner) the imper-meability is first tested in a laboratory. It is onlypossible here to remove some sections, cut intothe foil, and then to test these small material sectionsfor impermeability. This equals the systematicsof a sample test. A test of the entire liner on theother hand presents a 100% test and thus alsocarries much more significance. The test in thesewer itself has no significance for the aformen-tioned systems, because the test only can checkthe foil, but not the impermeability of the underlyingpipe liner. In addition the internal foil can be damagedby the roughening by the cutting robot before thelateral branch connection, high-pressure rinsing,aging, as well as abrasion by sediments.Current tests by independent inspection institu-tions on construction site samples have shownthat Brandenburger GFRP pipe liners have excel-lent results not only in the leakage tests, but alsofor the achieved material characteristics (refer to:IKT-Liner Report 2003/2004, 2004/2005, 2006and 2007: “Prüfergebnisse von der Baustelle”(Test results from the construction site), www.ikt.de).1601208040Max. draw-in force pipe liner weightForce/weight [kN]200 400 600 800 1.000 1.200DN GFRP-pipe linerMaximum draw-in force for example on a GFRP pipeliner with 5 mm wall thickness and 100 m lengthExpertise in High Technology Material