Sewage Pipe- Brochure

www.wps-gmbh.comRAIN AND WASTE WATER INFRASTRUCTURE MADE OF POLYPROPYLEN (PP)Sewage drainageThe Gigapipe SystemCorrugated plastic pipe system SN8 DN/ID 200 – DN/ID 1.000 mm2WPS – Gigapipe SystemPipe technology for convincing solutionsCorrugated Pipe Solutions, in established composite construction offered by WPS, are a contri-bution to solve the water problems caused by the world’s rapidly increasing population and the consequences of global warming.In result of the long-year experience of our employees in the fields of Developing, Production and Sales of intelligent pipe systems, today we can offer our customers tailor-made services in the pipe business.Today this know-how of your employees builds the foundation of successful cooperation with customers across the European continent.The consequences of global warming, further industrialization and the increasing heavy rainfalls are challenges of our time, which require immediate efforts.“Think of tomorrow and invest in the growth markets of today…WPS – Water Pipe System GmbH - Your partner for multifarious solutions in corrugated pipe business3General information 4GIGAPIPE system 5SAFECONNEC 7Fitting range 10Bedding and installation guidelines 12General guidelines and standards for pipe laying 13Shaft range and installation guidelines 14INDEXRESIStaNt - flEXIblE - RESIlIENt4WPS – Gigapipe SystemLeading competence in corrugated pipesFor many decades, profiled plastic pipes have been considered among experts as being particularly well-suited for the installation and development of underground depressurised waste infrastructure. Their market share grows constantly not only in the larger pipe range with an inside diameter (ID) of up to 1,500 mm, but also in the medium and smaller diameter range between 200 and 600 mm ID. This type of product is characterised by long life cycles, low maintenance efforts, low installation costs, excellent hydraulic properties and high resistance to loads, abrasion and chemical degradation. Therefore, these flexible corrugated pipes are not only suited for networks for municipal disposal, but also, in particular, for estate drainage systems.From the point of view of sustainability, corrugated pipes offer further advantages in comparison with all the other types of pipes. The efficient use of raw material saves the resources consumed: compared to the production of a solid-wall plastic pipe, you save up to 60% of material while maintaining all the static properties (such as ring stiff-ness, ring flexibility). Thanks to their innovative design and their maximum production standard, the pipe systems remain tight towards the inside and the outside for up to 100 years and beyond. On the one hand, they thus protect the environment from emissions that are detrimental to health, and, on the other, they protect the infrastructure from hydraulic overloads due to infiltration water.The unique corrugated pipe system GIGAPIPE excels by the following five components:S Complete pipe range with nominal diameters ranging from DN/ID 200 to DN/ID 1,000S Shaft range in monolith constructionS Inline bell and custom-built compression sealS Extensive, high-quality fitting rangeS SAFECONNEC: reliable protection of the pipe-to-pipe connection for long-term tightness of the systemThese components are further described in the following.5WPS – Gigapipe SystemPipe technology in its best formThe complete GIGAPIPE system meets all of the strict standards of the Deutsches Institut für Normung (German Institute for Standardization) and is in line with the relevant technical rules and standards for water management, waste water and waste (DWA). External control and/or technical approval guarantee the compliance with these quality standards.FIElds oF APPlIcATIon:S Gravity lines of any kindS Waste water networks, rain water systemsS Combined sewersS Drainage systems for premisesS Special solutions for industry and communitiesS Open-construction exchange and renewal proceduresS Extension of existing networksS Special constructions for the management of rain and storm water and for industrial applications upon requestsTAndArdIsATIon:S The PP material guarantees a high modulus of elasticity and, combined with the especially developed profile geometry of the pipe, a high ring stiffness of = SN 8 in accordance with DIN ISO EN 9969.S Approval on the basis of DIN EN 13476 and DIN 16961S Profile pipe series 5 according to DIN 16961 =31.5 kN/m²S Appropriate for all bedding materials according to DIN EN 1610S Appropriate for all pressure tests according to DIN EN 1610S High-pressure cleaning methods according to CEN/TR 14920S Water tightness and root resistance are proven by tests according to DIN 19537-2/DIN EN 681.S Ring flexibility according to DIN EN ISO 19368, 30% deformation without failure behaviorMATErIAl:S Pipes, shaft constructions and fittings are uniformly made of low-temperature impact resistant polypropylene (PP-B).StaNDaRDISatIoNS aND tESt CERtIfICatIoNSIt is fully in line with WPS’ commitment to quality to guarantee the customer-oriented performance of all our products not only through our own quality management, but also by means of external quality control and third party certifica-tion.6WPS – Gigapipe SystemQualIty REQuIREmENtSS German Übereinstimmungszertifikat (ÜZ) (certificate of conformity) according to DIN EN 13476PhySICal PRoPERtIESS Optimum abrasion behavior according to the material comparison test using the Darmstadt method (cf. page 09)S The very smooth, pore-free surface of the material prevents the formation of deposits and incrustationS Average surface roughness values during service of k = 0.25 in combination with excellent hydraulic behavior of the pipe surfaceS Well-balanced ring stiffness and ring flexibility: WPS tests the GIGAPIPE successfully with a deformation of up to 50% and a ring stiffness of up to SN 8.S Upon request, GIGAPIPE can also be manufactured for a ring stiffness of > SN 16.ChEmICal RESIStaNCES DIN 8078, supplementary sheet 1S The durability of pipes, fittings and sealing elements with pH values ranging between pH 2 (acidic) and pH 12 (alkaline) is guaranteed without any restriction.S The resistance against waste water and soil substances according to DIN 1986 is proven.thERmal tolERaNCESS All pipes sections and fittings are designed for a temperature range between -25°C and +90°C, while adhering to the regulations with regard to thermal stress as defined in DIN EN 13476.IDENtIfICatIoN maRkING aCCoRDING to DIN EN 13476S Black outer profileS Inner surface in RAL turquoise blue – optimally suited for in-pipe camera inspections.S Two coextruded line marks for subsequent identification in the excavation: red – waste water or combined sewers, blue – storm water sewer.RECyClINGS At the end of their lifecycle, all pipes and fittings of the GIGAPIPE system can be recycled unrestrictedly.7NomINal WIDthS (DN) aND lENGthSS The GIGAPIPE system is available in the following nominal diameters: 200, 250, 300, 400, 500, 600, 800 and 1,000 (values in mm inner diameter (ID)/nominal diameter)S Standard length without inline bell: 6,000 mm.S Special lengths available upon requestS During installation, the pipes are cut off individually without special accessories.The complete, reliable drainage of settlement water and precipitation serves to ensure man’s health, to protect the environment and to maintain the infrastructure developed by man. For a waste water network, this is both an important criterion and justifies its right to exist. One of the most important criteria, however, is that the pipe remains tight as long as possible.SafECoNNEC - thE SECREt of RElIablE loNG-tERm tIGhtNESSThe GIGAPIPE system is connected by means of bells which are shaped out of the extremities of the relevant pipe during production (“in-line bell”). On the construction site, the pipe ends are just inserted into each other using a simple set of tools so that they fit accurately. A profile seal made of highly-developed caoutchouc (EDPM) guarantees the required tightness and a longitudinal force-looked connection.SAFECONNEC is a development which optimizes the interaction between bell and sealing ring and further improves the positive properties of flexible pipe systems. On the bell’s outside, a high-strength reinforcement tape is welded directly to that point where the sealing ring will press later against the plastic from inside. The tape durably prevents material creeping even under extreme stress and thus ensures tightness of the pipe connection for more than 100 years. The same process is used for all individual customized and manufactured products by WPS manufactory (e.g. special fittings, shafts and other components).S User-friendly handling, easy to installS Conforming to standards such as DIN 13476S The weld-on high-strength tape allows highly efficient material and energy input for environmental’s sake.WPS – Gigapipe System8WPS – Gigapipe SystemWatERtIGht uNDER PRESSuREAll the pipes and fittings of the GIGAPIPE system comply with the standards and are thus permanently tight up to an inside pressure of 0.5 bars. They even resist a short-time overpressure of 2.5 bars. This is true for pipes under laboratory conditions, in practical applications and for angular or deformed elements. High-pressure cleaning at up to 180 bars is admissible.Thanks to SAFECONNEC, the GIGAPIPE system as is satisfies the guidelines of the DWA worksheet no. 142 (33) without further requirements and can thus be used without restrictions in water protection areas and zones.The pictures show one of the major advantages of flexible corrugated plastic pipes when compared to rigid pipe systems of the traditional type: GIGAPIPE adapts highly tolerantly and without any problems to ground movements and thus balances, for example, increased loads, mass relocations, ground settlements or even bedding mistakes. The system remains intact and reliably tight. In some of the world’s areas that are prone to earthquakes, corrugated plastic pipes offering GIGAPIPE quality are used exclusively.RESIStaNt aND flEXIblEPEak valuES foR haRD WoRkDaySPIPE StatICThe special design of the pipe’s wall and material used, namely polypropylene (PP), ensure a balanced ratio of ring stiffness on the one hand and ring flexibility on the other.Regular static calculations prove its suitability for common traffic loads in installation depths ranging from 0.5 to 6.0 meters. In addition to that, WPS has numerous references for special applications, such as heavy-load traffic (traffic load range SLW 60), loads from airplanes, in the field of groundwater or due to rail tracks. For example, the GIGAPIPE is the ideal solution for high dynamic loads and thin covers of only 1.0 m (e.g. airstrip of an airport). More-over, it also proves its suitability with thick covers of more than 6 m. Upon request, WPS works out your individual, project-related static calculations.fIElDS of aPPlICatIoNS Gravity lines of any kindS Waste water networks, rain water systemsS Combined sewersS Drainage systems for premisesS Special solutions for industry and communitiesS Special constructions9WPS – Gigapipe SystemSchachtvarianten:flEXIbIlItyThe flexibility of the GIGAPIPE system ensures that the pipes remain flexible under variable loads and soil movements and transmit the load stress in the longitudinal and cross-section to the surrounding soil by deformation. The relaxation behavior of the applied polymer guarantees that the tension resulting from long-lasting system deformation is almost fully reversed. Short-term deformations are completely reversible anyhow.abRaSIoN RESIStaNCEIn order to test the resistance of pipes to mechanical wear, the so-called Darmstadt method is used in accordance with the valid standard (DIN 19565/EN 295). Comparative tests show that plastic pipes, in particular pipes made of polypropylene, offer the best abrasion resistance of all pipes. The layout of the GIGAPIPE’s double-wall structure allows to achieve maximum material efficiency and weight reductions while keeping longevity in mind.hyDRaulIC SyStEmSThe drainage behavior in gravity lines is mainly determined by the pipe’s decline and the surface quality of the pipe bottom. Thanks to the optimum processing of the raw material, the GIGAPIPE offers a non-porous, very smooth inner pipe with an absolute roughness of the pipe wall of 0.005 to 0.05 mm. Such a surface prevents the formation of deposits, incrustations and thus the biochemical processes related to them. In addition to that, it transports the effluent even at minimal sewer declines. Due to the low coefficients from the field of fluid engineering, the influence of pipe connections, branches, shafts, etc. has to be taken into consideration when calculation the mathematical service roughness (kb) (please find more detailed information in specification sheet ATV-DVWK-A 110 “Hydraulic Dimensioning and Performance Verification of Sewers and Drains”). The diagram shows the GIGAPIPE throughputs for a roughness value of kb = 0.25 mm.Results of a simulated installation with a 92% and 99% soil compression (Proctor standard), calculated by means of the „finite element method“: with increasing soil compression due to dynamic loads, the maximum soil tension is not in the pipe’s soffit area, but at the impost. Here, GIGAPIPE pipes absorb the load stress, supported by highly compressed soil.10WPS – Gigapipe SystemFitting RangeWPS’s GIGAPIPE system offers a com-plete waste and rainwater system with an extensive fitting range for all avail-able diameters ranging between ID 200 and ID 1.000 mm.Due to the comfortable and quick instal-lation of all system elements, the costs and the required installation times can be minimized.Measures without tolerance range have informel character.11Apart from the standard components listed here, WPS produces all required special components upon request, for example for rain water management or geothermal heat collectors, in its own manufactory facilities.12WPS – Gigapipe SystemBedding and installation guidelinesFor optimum pipe laying, a systematic bedding structure is required in the pipe trench, as shown in the adja-cent scheme corresponding to DIN EN 1610. The lower bedding [a] and the top bedding [b] both carry the pipe. Therefore, carful completion and sealing according to the load calculations are required. The height of the top bedding results from the bedding or support angle. This term is still widely used and characterizes in an easily comprehensible manner the carrying capacity of the bedding. The table below shows the ratio between the easy-to-measure height of the top bedding [b] and the bedding angle required for the GIGAPIPE system. The main compression directly above the pipe should be realized by a 20 to 30 cm cover layer [c] on top of the pipe soffit. The GIGAPIPE system must be laterally protected to a high degree by soil compression.thE folloWING baSIC valuES aRE takEN aS a baSIS foR thE CalCulatIoN of ThE sAMPlE sTATIcs:S Traffic load : SLW 60 with asphalt or concrete surfaceS Additional area loadS Embedment E 20S Laterally applied soil E3S Cover E1S Lower trench E4S Slope angle or embankmentS Ground water level13GEnErAl GuIdElInEs And sTAndArds For PIPE lAyInG:Please contact WPS’s technician staff or www.wps-gmbh.com in order to get technical support for the realization of the installation guidelines.IndIvIduAl PIPE lEnGTh:The pipes can be cut off individually by means of commercially available tools before laying. A clean cut in the corrugation valley has to be guaranteed. Finally, just apply the sealing ring again.The GIGAPIPE system is assembled manually, easily and quickly. You just need one simple lever tool which WPS keeps on stock for its customers.The first step is to clean the in-line bell. Second, an industrial lubricant is applied inside. The spigot of the following pipe segment is provided in the factory with a compression seal. This end is positioned in front of the above-mentioned bell, making sure that the correct identification mark (red = waste water / combined sewerage system, blue = rain water) is positioned on top that the protective film is removed.One half shell of WPS’s assembly tool is positioned in the second pipe valley after the in-line bell, while the second half shell is put on between the corrugations of the spigot to such an extent that the pins latch laterally into the first opening.Now the lever arms are applied at the first half shell. Due to the lever-like movements, the spigot is pushed into the bell. The pipes are properly connected as soon as the inner pipe of the spigot is inserted into the bell until stip. This way, a longitudinally force-locked connection is realized without welding.14WPS – Gigapipe SystemShaft range and installation guidelinesThe shaft range matching the GIGAPIPE system offers high-value manholes with a diameter ID of 1,000 mm in monolith construction; smaller diameters are used as inspection shafts for revisions and cleaning; furthermore, when used with individually formed lower parts, they may serve as inflow and passage channels.Base and cone (top part) of the GIGAPIPE manhole is produced in a rotational molding process, while the shaft body is made from an appropriate piece of GIGAPIPE pipe. The individual components are joined by means of extru-sion welding according to work sheet DVS 2207 and loaded as complete customized unit (monolith construction). Manhole covers made of PP for use of to 600 kg/m² are also available.Manhole covers (630Ø, class D according to EN 124) made of cast iron concrete can be used without restrictions.15Shaft INStallatIoNFor the installation of the GIGAPIPE system shafts, the technical regulations regarding the installation of sewer pipes and channels as per DIN EN 1610 are valid.Already when installing the shaft, the excellent product properties are apparent: its comparatively low weight and monolith construction facilitate component handling on the construction site and ensure a quick progress. Among others it is the structure, design and the selected material which guarantee the excellent resistance even with high traffic loads and a very good resistance against rupture even at low temperatures.CoNDItIoN foR thE CovERING PRoCESS a1Trench filling compressed by layers against pure soil; without proof of the degree of compression; applicable for hori-zontal Berlin type pit lining or insulation embankment (fill).bEDDING CoNDItIoN b1Bedding compressed by layers against pure soil or by layers against the embankment dam; without proof of the degree of compression; applicable for horizontal Berlin type pit lining. Must not be applied onto concrete.INStallatIoNAfter the preparation of the bedding described before, the insertion of the shaft in the pipe trench and the connection to the pipe system, the trench is filled. Class I or II material is filled in with the same care applied to pipe bedding. The filling material should be filled in by 30 cm layers, making sure that all cavities at the outer shaft shall are filled completely.For applying and compression of the bedding, methods have to be used that neither stress nor damage the shaft body. Shaft deformation has to be avoided at this stage by compressing the filling material either manually or by means of mechanical compression means with little self-weight. Below planted areas, the filling material has to be compressed to at least 95% according to the Proctor standard, below traffic areas, complete compression (98 – 100%) is required.For final filling, the excavated material dug out before is used; however, all sharp-edged objects which might damage the shaft have to be removed before. Final filling should depend not only on the shaft, but also on the later purpose of the surface (paving, road-works, etc.)WPs delivery programmeS Drainage – Agrosil 2500S Percolation – Sicadukt / DrossduktS Sewage - GigapipeS Rainwater – Agro-RainS Cable protection - KabuplastS Prestressing technology – Metal-, duct-, anchorpipes / injection-, venting-tubesS Special-purpose solutionsMittelstetter Straße 22aD-86641 Rain am LechTelephone: +49 (0)9090 / 923 99 - 0Telefax: +49 (0)9090 / 923 99 - 39E-mail: info@wps-gmbh.comInternet: www.wps-gmbh.comWPS - Water Pipe System GmbhTechnische Abweichungen und Druckfehler vorbehalten. www.M-RAW.de ®