Product Catalog

Line pipe for water and wastewater 2 Salzgitter Mannesmann Line Pipe has a long tradition in the pro- duction of longitudinally HFI-welded steel pipe and a wealth of experience in the correct coordination of all the de- cisive quality dimensions. Our customers find seven core competencies that they can depend on. They converge in the one objective: perfect pipe for every application. Wide product range Expertise and experience Quality products Quality deliveries Customer proximity Quality advice Flexibility Delivering Perfection Wide product range A comprehensive manufacturing programme for gas, oil, water, construction, heat transport, and mechanical engineering - and all of it in steel grades to German and worldwide international standards, with various different joining techniques. Rounded off with a broad range of accessories. Expertise and experience Modern manufacturing processes based on a century of experi- ence in pipe production, valuable investments in research and development, close cooperation with research institutes and professional bodies, national and international projects. Quality deliveries Short delivery times through optimised production programmes, extensive stock on hand for all kinds of replacement pipes and small orders, schedule reliability for optimum project time per- formance. Quality products The entire production chain in our own hands, strictest quality management at all stages of manufacture, from the hot wide strip to shipment of the finished products, all embedded in a state-of-the-art inspection and testing regime. Customer proximity A worldwide marketing network, a can-do approach to special application requirements, and an ongoing exchange of insights and experience with customers around the globe. Quality advice Specialists for pipeline planning, pipe specification, transport, storage and laying, experience gained in numerous challenging projects, from planning through to implementation. Flexibility Two locations for the parallel production of orders of all sizes and degrees of specialisation, production control geared to cus- tomer needs. With water, quality counts Naturally perfect Page 3 Product overview Page 4 Manufacturing programme Page 5 Coatings linings Page 6 Linings Page 7 Joining technology Page 8 MAPEC®- 3-layer coating Page 9 Fittings and accessories Page 10 Competence in practice Page 11 Quality management Page 12 Testing methods Page 13 Transport and storage Page 14 Partner from A to Z Page 15 3 Naturally perfect Pipelines are the arteries of our modern industrial society. They transport water, are indispensable in producing and moving energy in many forms over enormous distances, and sustain in countless other ways both life and the economy. The significance of pipeline networks is so fundamental that even a small error can cause major problems in a very short time. Similar to interference with the eco-system, disorders can lead to a chain reaction. First a single pipe fails - in the end, a whole community grinds to a halt. That's why we compare ourselves and our work to Nature and the processes in an eco-system. Just like Nature, we produce within a system, where the one process leads smoothly and pre- cisely into the next. This approach brings us closest to our ideal: pipes our customers can rely on, absolutely. Unlike Nature, though, we tolerate no nonconformities in our products. From the base material, steel, through to the finished pipe, everything at Salzgitter Mannesmann Line Pipe must adhe- re to our fixed ”genetic code“, which ensures that each indivi- dual pipe is a model of perfection. This brochure will tell you more about the pipes we produce for water and wastewater systems. For all their diversity, there is one decisive feature that the products in our range have in com- mon: top quality. Contents Line pipe for water and wastewater 4 Fibrous cement mortar coating (FCM) MAPEC® plastic coating Adhesive agent Epoxy resin Steel pipe Cement mortar Standardized diversity With Salzgitter Mannesmann Line Pipe by your side you can be sure of completing your water pipeline project cost-effectively and on schedule. Our wide range of steel grades, pipe lengths and wall thicknesses, coatings and linings and, above all, the many different connection types let you choose the optimum design for every application profile. Water pipe structure While the required hygienic properties and corrosion protection for the pipe inside surface are ensured by our cement mortar lining, the pipe outside must additionally be protected against mechanical damage. That's why our CSP (cement mortar-steel- plastic) pipe features not just one coating but is also available with an additional top coat of fibrous cement mortar as required. Product overview All standards met MaterialsStandards of applicationTechnical delivery conditions DIN EN 10224 DIN 2460 L235 - L355 Former standards: DIN 1626 DIN 2460 St 37.0 - St 52.0 DIN 1628 DIN 2460 St.37.4 - St 52.4 Further specifications on request 5 Line pipe with butt-weld joint for drinking water and similar media We keep an extensive stock of pipes to various standards at our warehouse. This enables us to react flexibly to customer requirements, whether it's delivery at short notice in an emer- gency, or small to medium-scale construction projects. Salzgitter Mannesmann Line Pipe manufactures flange pipe or pipe grooved for clamped joints and other special designs to order at both production sites. Your requirements, including spe- cial coatings for unburied pipelines or thermal insulation can all be served at short notice. Manufacturing programme Outside diameter Nominal width Wall thickness* Length Weight Operating pressure in mm in mm Inches in mm in m in kg/m PFA in bar 114.3 100 4 1/2 3.6 6-14 14.6 89 139.7 125 5 1/2 4.0 6-14 19.5 81 168.3 150 6 5/8 4.0 6-14 23.3 67 219.1 200 8 5/8 4.5 6-16 34.9 58 273.0 250 10 3/4 5.0 6-16 46.9 52 323.9 300 12 3/4 5.6 6-16 60.9 49 355.6 350 14 5.6 6-16 69.4 44 406.4 400 16 6.3 6-16 86.4 44 457.2 450 18 6.3 6-16 90.5 39 508.0 500 20 6.3 6-16 100.7 35 530.0 530 20 7/8 6.3 6-16 113.0 34 610.0 600 24 6.3 8-16 130.0 29 Line pipe with slip-weld joint for wastewater and other aggressive media Line pipe with Tyton® **, Tyton® **-Sit or DKM® socket connection for drinking water or wastewater Outside diameter Nominal width Wall thickness* Length Weight Operating pressure in mm in mm Inches in mm in m in kg/m PFA in bar 114.3 100 4 1/2 3.6 6-14 17.8 89 139.7 125 5 1/2 4.0 6-14 23.4 81 168.3 150 6 5/8 4.0 6-14 28.5 67 219.1 200 8 5/8 4.5 6-16 40.3 58 273.0 250 10 3/4 5.0 6-16 53.7 52 323.9 300 12 3/4 5.6 6-16 68.9 49 355.6 350 14 5.6 6-16 75.8 44 406.4 400 16 6.3 6-16 93.8 44 457.2 450 18 6.3 6-16 90.5 39 508.0 500 20 6.3 6-16 100.7 35 530.0 530 20 7/8 6.3 6-16 113.0 34 610.0 600 24 6.3 8-16 130.0 29 Outside diameter Nominal width Wall thickness Length Operating pressure PFA Operating pressure Tyton® / Tyton®-Sit PFA for DKM® in mm in mm Inches in mm in m in bar in bar 117.5 100 4 1/2 3.6 6. 12 and 14 40/16 40 144.0 125 5 1/2 4.0 6. 12 and 14 40/16 40 168.3 150 6 5/8 4.0 6. 12 and 14 40/16 40 219.1 200 8 5/8 4.5 6. 12 and 14 40/16 40 273.0 250 10 3/4 5.0 6. 12 and 14 40/10 40 323.9 300 12 3/4 5.6 (6.3) 6. 12 and 14 40/10 25 (40) * or to customer specifications ** Registered trademark of United States Pipe and Foundry Company 6 Coatings Type Description Properties Application example MAPEC® polyethylene (PE) coating N (LD-PE), maximum operating temperature Tmax 60°C, S (MD-PE) for Tmax 80°C or S (HD-PE) for Tmax 85°C 3-layer coating to DIN 30670: 1) Epoxy resin primer, 2) Adhesive and 3) Polyethylene Standard corrosion protection for line pipe Pipelines buried in rock-free soils Type Description Properties Application example MAPEC® PE/PP coating with longitudinal ribbing 3-layer coating to DIN 30670 (PE) or DIN 30678 (PP), consisting of 1) Epoxy resin primer, 2) Adhesive layer and 3) Special MAPEC® layer with longitudinal ribbing. Pipe coating with increased resistance to mechanical impact and abrasion For example, pipe relining projects, due to the increased abrasion protection provided by the coating Type Description Properties Application example MAPEC® PE/PP coating with rough coat surface 3 layer coating to DIN 30670 (PE) or to DIN 30678 (PP) consisting of 1) Epoxy resin primer, 2) Adhesive layer and 3) Specially roughened PE/PP layer Pipe coating with high friction resistance Pipeline projects in sloping terrrain, offshore regions, or in humid environments etc. Type Description Properties Application example MAPEC® polypropylene (PP) coating operating temperatures from 0°C to 110°C (other temperatures on request) 3-layer coating to DIN 30678: 1) Epoxy resin primer, 2) Adhesive, 3) Polypropylene Corrosion protection coating for operating temperatures up to 110°C, coatings for higher temperatures on request. Increased thermal loads on the pipe coating Type Description Properties Application example MAPEC® PE/PP coating with FCM-N fibrous cement mortar top coat 3 layer coating to DIN 30670 (PE) or to DIN 30678 (PP) consisting of 1) Epoxy resin primer, 2) Adhesive layer and 3) PE/PP layer, but with additional FCM coating (stan- dard type) to DVGW Worksheet GW 340 Increased mechanical protection for pipe and PE/PP coating Pipe-laying in rocky terrain Greater thicknesses as heavy coat against buoyancy Type Description Properties Application example MAPEC® PE/PP coating with FCM-S fibrous cement mortar top coat 3 layer coating to DIN 30670 (PE) or to DIN 30678 (PP) consisting of 1) Epoxy resin primer, 2) Adhesive layer and 3) PE/PP layer with integrated T-profile, additional rough coating and FCM-S top coat to DVGW Worksheet GW 340 The interlocking effect between the 3-layer coating with integrated T-profile and additional rough coating on the one hand and the FCM top coat on the other generates extremely strong adhesive bond The combination of mechanical protection and shear force transmission makes this coating type specially suited to trenchless pipe-laying, for example HDD longitudinal ribbing Polypropylene Rough Coating Fibrous cement mortar coating T-profile MAPEC® with longitudinal ribbing MAPEC® Rough Coating MAPEC® Polypropylene MAPEC® with FCM-N MAPEC® with T-profile and FCM-S MAPEC® Cement mortar 1) Epoxy resin primer 3) Polyethylene Steel pipe 2) Adhesive 7 Type Description Properties Application example Cement mortar lining CM-S Lining according to DIN 2614/DIN 2880, EN 10298 Based on CEM I (Portland cement) Excellent hygienic characteristics, optimally suited to drinking water through the use of CEM I High resistance to sulfate (variety S) Standard lining for drinking water pipe Type Description Properties Application example Cement mortar lining CM-S Lining according to DIN 2614/DIN 2880, EN 10298 Based on CEM III (blast furnace cement) Increased resistance to chemical attack E.g. pressurized wastewater Type Description Properties Application example Cement mortar lining CM-R Lining according to DIN 2614/DIN 2880, EN 10298 Based on CEM III (blast furnace cement) High resistance to chemical attack E.g. sewers (open channels) The right protection for every application profile Steel line pipe for the transportation of aqueous media is a com- posite product made from various materials. Each of these mate- rials plays its specific role in the design, contributing to the pipe's outstanding service behaviour. Our MAPEC® plastic coatings are extremely resistant to chemical attack, which means the steel pipe they protect can be laid in all classes of soil without any res- triction. For mechanical protection, a cement mortar coating can be used. Optimum corrosion protection on the pipe inside surface is provided by cement mortar linings matched to the intended medium. Linings 8 We also supply non-permanent connections such as flanges or couplings. These types are predominantly used in unburied pipelines. Type Description Properties Butt-weld joint Standard end design for welded joints: Variant B Optimally suited for drinking water pipelines, force-locking, with axial conductivity for cathodic corrosion protection, suitable for open-cut pipeline method. Nondestructive testing possible. Type Description Properties Socket joint Standard end design for mechanical pipe connections Axially force-locking with Tyton® connection or non-permanent connection withTyton®-Sit, for unburied pipelines Type Description Properties Slip welding joint Special design for aggressive media Optimally suited for wastewater pipes, force-locking, with axial conductivity for cat- hodic corrosion protection, suitable for open-cut pipeline method. Nondestructive testing possible, during welding, the joint area can be protected with suitable sealing materials. Type Description Properties Socket joint Standard end design for mechanical pipe connections Axially force-locking with DKM® connection, for increased operating pressures Type Description Properties Flange connection Threaded connection with various designs, such as fixed and loose flanges Non-permanent connection for unburied pipelines Type Description Properties Couplings Threaded coupling elements for grooved pipes Non-permanent connection for unburied pipelines Connections for all applications Steel line pipe for water and wastewater systems is available with a full range of connections to suit the intended application. The requirements and designs are standardized in DIN 2460 and DIN EN 10311. Design A Design B Joining technology 9 MAPEC®-3-layer coating MAPEC®-3-layer coating To prepare the steel pipe for the coating process, it is externally shot blasted to at least SA 2.5 requirements. This treatment not Corrosion protection When assessing the reliability and service life of buried metal pipelines, the type of corrosion protection applied – especially on the pipe outside surface – is an essential factor. Decisive Extra-strong PE coating*: Salzgitter Mannesmann Line Pipe also offers an extra-strong variant of the MAPEC® 3-layer coating with a top layer of 3,200 µm (= 3.2 mm). Here, the total coating thickness is 3,500 µm (= 3.5 mm). * special thicknesses on request 3. The third layer Standard PE coating*: The third layer completes the MAPEC®-3-layer coating and usually consists of polyethylene (or optionally polypropylene). As a specially safe top layer, it is applied to a thickness of 2000 µm (= 2.0 mm). This brings the total thickness of standard coating for steel water line pipe up to 2,300 µm (= 2.3 mm). points in this context include the methods used to produce and apply the protective coating, as well as the number and thick- ness of the individual layers. 1. The first layer of the steel pipe coating is an epoxy resin primer which is applied to a thickness of 100 µm (= 0.1 mm). A direct comparison of coatings for metal pipes shows that steel pipes are protected with a MAPEC® 3-layer coating, while ductile iron pipes are still provided with a conventional 2 layer coating. only removes any dust or dirt particles but also roughens the surface so that the primer can adhere better. 2. The second layer is a special adhesive agent, which acts as a bond between the primer and the top layer (PE or PP). In addition, it functions as a corrosion protection layer with a thickness of 200 µm (= 0.2 mm). 10 Fittings for socket pipes The fittings for our socket pipes are made from ductile iron according to DIN EN 545 and feature an advanced epoxy resin plastic coating suitable for all applications, including ex-tremely aggressive environments. Standard-fitted with a DKM® connecti- on, our cast fittings are compatible with all socket types (Tyton®, Tyton®-Sit, DKM®). Designation Description EU Flanged socket Designation Description F Flanged spigot Designation Description U Collar Designation Description MMK/MMQ Double socket bend Designation Description EN Hydrant duckfoot bend Designation Description MMB All-socket tee Designation Description MMR Double socket taper Designation Description FFK/FFQ Double flanged bend Designation Description N Double flanged duckfoot bend Designation Description T All flanged tee Examples from our manufacturing programme for fittings for socket pipes Fittings and accessories Weld-on fittings Steel fittings for welded connections, couplings and flange con- nections are usually supplied without external corrosion protec- tion but with a factory-applied cement mortar lining. These fit- tings are manufactured in accordance with DIN 2605 and DIN 2615 on the basis of the delivery conditions laid down in DIN 2616. Definition of dimensions for weld-on fittings Accessories for pipe laying Salzgitter Mannesmann Line Pipe sees itself as a systems sup- plier. Our pipe delivery to your construction site arrives complete with all the material and accessories you need for your pipe-lay- ing project. Our supply programme includes field coating materi- als as well as tools, devices and materials for pipe-laying. Fitting type Technical delivery conditions Design Bend DIN 2605 With cement mortar lining Tee DIN 2615 With cement mortar lining Reducer DIN 2616 With cement mortar lining Other designs and fitting types on request Pipe-laying accessories Shrink-on tubes, Corrosion protection tapes Casting mortar, Cement wrappers Lubricants, Sealing material (slip-welding joint) Pipe-laying tools Angled grinder with an attachment for cutting the cement mortar lining 11 Tried and tested Salzgitter Mannesmann Line Pipe can draw on a century of experience in the use of steel pipe for the transport and distribu- tion of drinking water. And we're happy to pass on our knowled- ge. In fact, outstanding expert advice is part of our supply programme. It is also a central element of our quality philosophy. Talking with the customer is important to us. We listen attentive- ly, because we know that many of the product designs estab- lished in the market today were inspired by our customer's sug- gestions. The steel socket pipe and the fibrous cement mortar coating are just two of the many successful examples of such cooperation. Technical advice The main pillars of our competence and success include: • direct exchange of experience with our customers • our own research and development activities • cooperation with external research institutes • participation in professional engineering bodies and standards committees The service life of our products is determined by the customer. We help with the selection of the type of pipe required for the application in question and can supply pipes for every conceiv- able safety level. Our customers in the water industry have such strict standards to comply with, they need a partner who will advise them well, from the definition of the appropriate pipe and the necessary corrosion protection and joining technology right through to pipeline construction and startup. Competence in practice 12 Why you always get the quality you expect from us The water industry needs a partner who has been constantly out in front, for decades now, when it comes to innovation, producti- on and service. Uncompromising quality in every aspect of our work The first precondition for pipe longevity is continuous high qual- ity in the manufacture, right through to the point of application. That's why the quality philosophy at Salzgitter Mannesmann Line Pipe covers the entire process - from the production of the hot wide strip as the starting material for our pipes through all the various stages of production right up to the technical sup- port we provide in the completion of pipeline projects. Technology leader We are experts in all the technologies used in steel pipe pro- duction. Back in the 1950s we introduced plastic coating for steel pipe. And we know that ongoing improvement of the ma- terials and processes we use is essential if we are to maintain and expand our leading position in the industry. Comprehensive quality management Each pipe is manufactured with the same care and passes through the same quality management from the starting material to the final inspection. Our quality assurance is an integral part of all aspects of the process flow, governing our daily work to an extent far beyond the requirements laid down in the applicable standards. We spend millions on getting everything right Our ultra-efficient pipe mills in Siegen and Hamm leave nothing to chance. Meticulous inspection of the incoming starting ma- terial and of the entire pipe production process ensure that only products of perfect quality reach our customers. Tested safety Both our locations are fully equipped with state-of-the-art meas- uring and testing facilities. It's almost like in a modern diagnosis clinic, the way the pipes are subjected to a thorough-going ”check-up“: they're measured, weighed, and subjected to ultra- sonic testing and visual inspection, followed by microscopic and macroscopic evaluation of the results. They also undergo destructive testing, so nothing at all is left to chance. In very complex diagnosis cases, we have the full backing of our Group's own research institute with its specialists in every area of pipe science and technology. Quality management 1313 Heat analysis The steel we work with is extremely homogeneous and is made with the utmost exactness to meet particular requirements. Each heat is subjected to analysis DIN EN ISO 14284 to check whether its chemical composition is in keeping with the applicable tolerances. This is re-checked at our mill in the form of one product analysis per heat. Cement mortar testing In the course of its long service life, the lining of a CSP pipe is exposed to many stresses, including corrosion, temperature variations, pressure and vibration. Com- pression and tensile bending tests in compliance with DIN 1164 are carried out regularly to check the resistance of the lining material to such loads. In addition, the materials we use have been analysed and approved by external testing labor- atories to verify their suitability for drinking water applications. Monitoring fosters confidence Tests and checks at Salzgitter Mannesmann Line Pipe are not restricted to those prescribed by the various standards. We carry out a large number of additional internal in-process checks and tests in order to ensure the compliance of the processes with our own much higher standards. We inspect and check just about everything that's checkable. Such start-to-finish monitoring guarantees to our customers that each individual pipe complies with the applicable specifications and maintains its outstanding properties for a long service life. Each pipe is given its unique Q-ID-number as a ”quality seal“. This means the entire manufacturing process can be traced back, right through to the steelworks. With the pipe Q-ID, the digitally stored test data can be called up for each pipe and the precise status before and after each production step can be ascertained. Just in case any doubts should ever arise. Peel resistance of plastics Plastic coatings have to protect the steel body in particular against corrosion, so they must be very tough in their resistance to external influences (pressure, impact, etc.). They must adhere firmly to the steel structure and not peel off or come loose at all. This is verified by testing according to DIN 30670/DIN 30678. In addition, all the MAPEC® coatings must be approved for the given application by external laboratories. In-process checks At every stage of the production process, checks are performed to verify a pipe's compliance ”in all its essential characteristics“ with the applicable specifications. This includes dimensional checks (length, diameter, wall thickness), mechanical- technological tests, hydrostatic testing for leaks, and measuring the layer thicknes- ses both of the MAPEC® PE coating and the cement mortar lining. Statistical evaluation of the results forms the basis for any necessary preventive measures to ensure the continuous high quality of the processes. Testing methods 14 The safe way to the site Our work doesn't stop once the pipe passes its final works inspection. Storage and logistics are part of our service, too. The pipes are shipped, stored and stacked according to strict regulations. Safe transport, without damage to the valuable cargo, is also a quality feature of Salzgitter Mannesmann Line Pipe. We regularly stock a comprehensive range of different standard pipes for water applications. This stock is designed for quick delivery in emergencies as well as for medium-sized construction projects. So we can ease the load on your own storage capa- cities while you continue to maintain and expand your supply system safely and flexibly. Our logistics experts can take over all your inventory manage- ment and the subsequent on-time delivery of the pipes to the construction site. Our service package is rounded off by express and emergency deliveries, overhead unloading, trucks - even for long lengths -, stacking, transferring to storage, routing and aggregated shipments. Ship, rail or truck - we find the best form of transport for you, so you can rely on having your pipes delivered safely and punctually, to the furthest corner of the world. Transport and storage 15 Questions are best discussed directly with us We can advise you in every aspect, from the definition of the pipe you need and joining techniques through detailed project planning and right on to the pipe-laying operations and startup of the pipeline. Partnering the water industry We have proved our all-round competence for infrastructure pro- jects of every size in countless projects in the water sector. With Salzgitter Mannesmann Line Pipe, you have a pipe producer by your side whose role is a partnering one. Our aim is to do everything in our power to ensure the success of your undertaking. We look forward to contact with you You can best turn our competencies and experience to account if you contact us at the early stages of projects. If you wish, we'll be happy to let you have detailed particulars of our technical capabilities, our quality assurance and our references. Get in touch with us. You'll find your contact for water line pipe in the Internet at www.smlp.eu Partner from A to Z M LP /L W A /e ng /p rin t ru n 8_ 50 0/ 03 .1 0/ © w w w .b au er -m ed ia -c on ce p t. d e Salzgitter Mannesmann Line Pipe GmbH Head Office Siegen Works In der Steinwiese 31 57074 Siegen Germany Phone: +49 271 691-0 Fax: +49 271 691-299 Postal address: Postfach 12 01 52 57022 Siegen Germany Hamm Works Kissinger Weg 59067 Hamm Germany Phone: +49 2381 420-455 Fax: +49 2381 420-718 Postal address: Postfach 17 13 59061 Hamm Germany info@smlp.eu www.smlp.eu